CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

REAR WINDOW DEFOGGER
CONTENTS
page page
CONTROL SWITCH/TIMER RELAY MODULE . . 1
GENERAL INFORMATION .................. 1REPAIR GRID LINES, TERMINALS AND PIGTAILS.3
SERVICE PROCEDURES ................... 1
GENERAL INFORMATION
For proper operation of the Rear Window Defogger
system refer to the Owner's Manual. Vehicles equipped with an electrically heated rear
window defogger also have a 40/90 amp generator. The system consists of a rear glass with two verti-
cal bus bars and a series of electrically connected
grid lines fired on the inside surface. A control
switch and a timer relay combined into a single as-
sembly is used on all models (Fig.1).
Circuit protection is provided by a fusible link, lo-
cated in the charging circuit, for the heated grid cir-
cuit and by a fuse for the relay control circuit. When the switch is turned to the ON position, cur-
rent is directed to the rear defogger grid lines. The
heated grid lines heat the rear glass to clear the sur-
face of fog or frost.
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments, care should be taken in
cleaning glass or removing foreign materials, de-
cals or stickers. Normal glass cleaning solvents or
hot water used with rags or toweling is recom-
mended.
CONTROL SWITCH/TIMER RELAY MODULE
The control switch and timer relay are integrated
into a single panel or console mounted assembly. Ac-
tuating the switch energizes the circuit which allows
current to flow through the grid lines. Upon initial
actuation for approximately ten minutes, or until ei-
ther the switch or ignition is turned off. An indicat-
ing lamp illuminates a lens inlaid in the control
switch.
SERVICE PROCEDURES
Electrically heated rear window defogger operation
can be checked in vehicle in the following manner: (1) Turn ignition ON.
(2) Turn rear window defogger control switch ON.
(3) Using a ammeter on the battery. Turn the De-
fogger control switch ON, a distinct increase in am-
perage draw should be noted. (4) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between the grid lines and adjacent
clear glass can be detected in three to four minutes
of operation. (5) Using a DC voltmeter (Fig. 2) contact terminal
B with the negative lead, and terminal A with the
positive lead. The voltmeter should read 10-14 volts.
Fig. 1 Rear Window DefoggerÐTypical
Fig. 2 Rear Glass Grid Line TestÐTypical
Ä REAR WINDOW DEFOGGER 8N - 1

(6) Steps (3, 4 or 5) above will confirm system op-
eration. Indicator light illumination means that
there is power available at the output of the relay
only, and does not necessarily verify system opera-
tion. (7) If turning the switch ON produced no distinct
current draw on the ammeter the problem should be
isolated in the following manner: (a) Confirm the ignition switch is ON.
(b) Ensure that the heated rear glass feed wire is
connected to the terminal or pigtail and that the
ground wire is in fact grounded. (c) Ensure that the fusible link and control cir-
cuit fuse is operational and all electrical connec-
tions are secure.
(8) When the above steps have been completed and
the system is still inoperative, one or more of the fol-
lowing is defective: (a) Control switch/timer relay module.
(b) All rear window grid lines would have to be
broken or one of the feed wires are not connected
for the system to be inoperative.
(9) If turning the switch ON produces severe volt-
meter deflection, the circuit should be closely
checked for a shorting condition. (10) If the system operation has been verified but
indicator lamp does not light, replace the switch. (11) For detailed wiring information, refer to group
8W, Wiring Diagrams.
GRID TEST
The horizontal grid lines and vertical bus bar lines
printed and fired on inside surface of rear window
glass (Fig. 2) comprise an electrical parallel circuit.
The electrically conductive lines are composed of a
silver-ceramic material which when fired on glass be-
comes bonded to the glass and is highly resistant to
abrasion. It is possible, however, that a break may
occur in an individual grid line resulting in no cur-
rent flow through the line. To detect breaks in grid
lines the following procedure is required: (1) Turn ignition ON and turn control switch to
ON. The indicator light should come on. (2) Using a DC voltmeter with 0-15 volt range,
contact terminal B with negative lead of voltmeter.
With positive lead of voltmeter, contact terminal A
(Fig. 2). The voltmeter should read 10-14 volts. A
lower voltage reading indicates a poor ground con-
nection. (3) With negative lead of voltmeter, contact a good
body ground point. The voltage reading should not
change. (4) Connect negative lead of voltmeter to terminal
B and touch each grid line at Mid-Point with Posi-
tive lead. A reading of approximately 6 volts indi-
cates a line is good. A reading of 0 volts indicates a
break in line between Mid-Point C and terminal A.
A reading of 10-14 volts indicates a break between Mid-Point C and terminal B. Move toward break and
voltage will change as soon as break is crossed (Figs.
2 and 3).
CONTROL SWITCH/TIMER RELAY MODULE TEST
Control switch/timer relay module may be tested
in-vehicle or bench tested. In vehicle testing is ac-
complished in the following manner: (1) Remove the switch, relay assembly from the in-
strument panel or console, see Group 8E, Instrument
Panel and leave the switch connector plugged in. (2) Turn ignition ON.
(3) Using a DC voltmeter, with 0-15 range, check
voltage at terminals B, I and L. (Figs. 3 and 4). Ter-
minals B and I should confirm a voltage of 10 to 14
volts to ground when the ON switch is pressed. Ter-
minal L should confirm voltage to ground. When ter-
minals B and I show no voltage, trace circuit
upstream of switch/relay module for problem (wiring
cut, fusible link or circuit breaker inoperative, bulk-
head connector not operative, etc.) If terminal L in-
dicates voltage, place switch in Off position. If
voltage at L is still indicated or indicator lamp re-
mains on, the switch/relay module should be re-
placed. (4) If the relay checks out to this point, momen-
tarily operate switch to ON position. The indicator
lamp should come on and remain on for approxi-
mately 10 minutes. Terminal L should confirm volt-
age. If the indicator lamp fails to light or voltage at
terminal L is not confirmed the switch/relay module
should be replaced.
Fig. 3 Systems Electrical Circuit
8N - 2 REAR WINDOW DEFOGGER Ä

Bench checking of the relay may be accomplished
in the following manner. By following the in-vehicle
procedure except Step 2: With a DC power supply,
apply 12 volts to terminal B and I and ground termi-
nal G.
REPAIR GRID LINES, TERMINALS AND PIGTAILS
The repair of the grid lines or the terminal is pos-
sible using the Mopar Repair Package or equivalent. (1) Mask repair area so conductive epoxy can be
extended onto the line or the bus bar (Fig. 5).
(2) Follow instructions in repair kit for preparing
damaged area. (3) Remove package separator clamp and mix plastic
conductive epoxy thoroughly. Fold in half and cut
center corner to dispense epoxy. (4) For grid line, mark off area to be repaired with
masking tape or a template (Fig. 5). (5) Apply conductive epoxy through slit in masking
tape. Overlap both ends of the break by 19mm (3/4
inch). (6) For a terminal or pigtail replacement, mask
adjacent areas so epoxy can be extended onto line as
well as bus bar. Apply a thin layer of epoxy to area
where terminal was fastened and to adjacent line. (7) Apply a thin layer of conductive epoxy on termi-
nal and place terminal on desired location. To prevent
terminal from moving while the epoxy is curing, it
must be wedged or clamped. (8) Carefully remove masking tape from grid line.
CAUTION: Do not allow the glass surface to exceed
204ÉC (400ÉF), glass may fracture. (9) Allow epoxy to cure 24 hours at room tempera-
ture or use heat gun with a 260É-371ÉC (500É-700ÉF)
range for 15 minutes. Hold gun approximately 254 mm
(10 inches) from repaired area. (10) After conductive epoxy is properly cured remove
wedge from terminal and check out operation of rear
window defogger. Do not attach connectors until curing
is complete.
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE
IRRITATION. CONTAINS EPOXY RESIN AND AMINE TYPE HARD-
ENER, HARMFUL IF SWALLOWED. AVOID CONTACT
WITH SKIN AND EYES. FOR SKIN, WASH AFFECTED
AREAS WITH SOAP AND WATER. DO NOT TAKE
INTERNALLY. IF TAKEN INTERNALLY, INDUCE VOM-
ITING; CALL A PHYSICIAN IMMEDIATELY. IF IN CON-
TACT WITH EYES, FLUSH WITH PLENTY OF WATER-
.USE WITH ADEQUATE VENTILATION. DO NOT USE
NEAR FIRE OR FLAME. CONTENTS CONTAIN 3 PER-
CENT FLAMMABLE SOLVENTS.
WARNING: KEEP OUT OF REACH OF CHILDREN.
Fig. 4 Rear Window Defogger Switch, Timer, Relay, and Wire Connector
Fig. 5 Grid Line RepairÐTypical
Ä REAR WINDOW DEFOGGER 8N - 3

POWER LOCKS
CONTENTS
page page
CIRCUIT BREAKER TEST .................. 1
DECK LID OPERATION ................... 3
DECK LID PULL-DOWN SYSTEMÐAC and AY BODIES .............................. 3
DOOR LOCK INHIBIT ..................... 6
DOOR LOCK INHIBIT ..................... 1
DOOR LOCK MOTOR REPLACEMENT ........ 3
DOOR LOCK SYSTEM TEST ............... 3
ELECTRIC MOTOR TEST .................. 2 GENERAL INFORMATION
.................. 1
KEYLESS ENTRY SYSTEM ................ 1
LAMP OUTAGE MODULE REPLACEMENT .... 6
POWER DOOR LOCKS .................... 2
POWER PULL DOWN .................... 4
REMOTE KEYLESS ENTRY ................ 5
REMOTE KEYLESS MODULE REPLACEMENT . . 6
SWITCH TEST .......................... 1
WIRING VOLTAGE TEST .................. 1
GENERAL INFORMATION
All doors can be locked or unlocked electrically by
operating the switch on a front door panel or arm
rest. The rear doors can be locked or unlocked by actu-
ation of the front door switch, or can be locked or un-
locked mechanically and independently with their
respective locking knobs. The front doors can be locked or unlocked mechan-
ically with the locking knob regardless of electrical
locking and unlocking actuation with the front door
knobs. The right and left front door on all car lines can be
locked or unlocked mechanically from the outside
with the key or electrically as described above. The
left front can also be unlocked by actuation of the in-
side remote door handle. The right front door on AC,
AG, AJ and AY can be unlocked by actuation of the
inside remote door handle. The deck lid lock consists of a latch with internal
solenoid and push button switch. The solenoid is en-
ergized only when the push button is depressed.
DOOR LOCK INHIBIT
The power door lock inhibit system prevents the
doors from being locked using the power door locks
when either of two conditions occur: (1) The key is in the ignition switch and any of the
doors are open. The ignition switch does not have to
be ON. (2) The key is in the ignition switch and the head-
lamp are on.
KEYLESS ENTRY SYSTEM
The system allows locking and unlocking of vehicle
door(s) and Trunk lid by remote control using a hand
held radio transmitter. The ignition switch must be
OFF before the trunk lid can be unlocked with the
transmitter. The receiver may receive signals from two trans-
mitters. Each transmitter has its own code, and the
code has been stored in memory. If the transmitter is
replaced or a second transmitter is add, the code on
both units have to be placed in memory.
CIRCUIT BREAKER TEST
Find correct circuit breaker on fuse block. Pull out
slightly but be sure that circuit breaker terminals
still contact terminals in fuse block. Connect ground
wire of voltmeter to a good ground. With probe of
voltmeter positive wire, check both terminals of cir-
cuit breaker for 12 volts. If only one terminal checks
at 12 volts, circuit breaker is defective and must be
replaced. If neither terminal shows 12 volts, check
for open or shorted circuit to circuit breaker.
WIRING VOLTAGE TEST
The following wiring test sequence determines
whether or not voltage is continuous through the
body harness to switch. (1) Remove left side switch from trim panel.
(2) Carefully separate multiple terminal block on
wiring harness from switch body. (3) Connect one lead of test light to a ground ter-
minal:
² Black Wire AA and AC Bodies
² Gray wire AG and AJ Bodies
² Touch other test light lead to Red Wire terminal.
² If test light comes on, the wiring circuit between
the battery and switch is functional.
² If test light does not come on, check 30 amp circuit
breaker or for a open circuit.
SWITCH TEST
Remove the switch from its mounting location. Us-
ing an ohmmeter, refer to (Fig. 1) to determine if
continuity is correct in the Lock and Unlock switch
positions. If these results are not obtained, replace
the switch.
Ä POWER LOCKS 8P - 1

ELECTRIC MOTOR TEST
Make certain battery is in normal charged condi-
tion before circuits are tested. To determine which motor is faulty, check each in-
dividual door for electrical lock and unlock or discon-
nect the motor connectors one at a time, while
operating the door lock switch. In the event that
none of the motors work, the problem maybe caused
by a shorted motor, or a bad switch. Disconnecting
the defective motor will allow the others to work. The power lock motors are also equipped with a
thermal protection system which prevents the motors
from burning out. The motors may chatter if they are
continuously activated. To test an individual door lock motor, disconnect
the wire connector at the motor (Fig. 2 and 3). Test
at the connector for 12 volts while applying door lock
switch. If no voltage repair wire. Apply 12 volts to
the motor terminal, and a known good ground to the
other terminal to check motor operation. Should the motor defect be a result of a broken
wire, it should have no effect on the operation of the
other motors.
POWER DOOR LOCKS
When AC, AG, AJ or AY Body vehicles are
equipped with power door locks, the system includes
an automatic door locking feature which is actuated
through the vehicle's body controller. When this system is enabled the automatic door
locks will work automatically. When the system is
disabled the door locks will work by use of the door
lock switches only. The body controller controls the power locks when
the door lock switch is activated. If the door lock switch is pressed for longer than eight consecutive
seconds, the body controller will de-energize the door
lock relay. Also, the body controller will automati-
cally lock all doors when all of the conditions below
are met:
² All doors are closed
² The vehicle speed exceeds 15 61 MPH
² The throttle position sensor tip-in is greater than
10 62 degrees
The DRB II must be used to enable/disable the au-
tomatic door lock system. Refer to the Body Diagnos-
tic Procedures Manual for the procedure. The body controller will automatically re-lock all
doors if the above conditions are met and if any of
the doors become ajar. The body controller does not
control the door unlock function. The switch is wired
directly to the lock relay.
Fig. 1 Door Lock Switch Continuity
Fig. 2 Door Lock Motor
Fig. 3 Door Latch with Lock MotorÐAC and AY Bodies
8P - 2 POWER LOCKS Ä

DOOR LOCK SYSTEM TEST
For complete testing of the AC, AG, AJ and AY
body automatic door lock systems, refer to the Body
Diagnostic Procedures Manual.
DOOR LOCK MOTOR REPLACEMENT
(1) Remove inside door release handle, window
regulator handle, if equipped and door trim panel. (2) Roll door watershield away from lower rear cor-
ner of door to reveal inside panel access opening. (3) Disconnect link at the motor as required (Fig. 4
through 7).
(4) Disconnect motor lead wires.
(5) Remove motor or latch attaching screws and re-
move motor assembly. (6) For installation reverse above procedures.
DECK LID OPERATION
For vehicles equipped with electric deck lid release.
TEST
(1) Confirm solenoid lead wire is connected and 10
volts or more are available at solenoid. (2) Provide proper ground through latch mounting
screws. (3) Remove latch and examine plunger. Plunger
should spring back when pressed. (4) Insure that solenoid plunger travel is adequate
approximately 16 mm (5/8 inch).
ADJUSTMENT
Adjust deck lid latch and striker so that deck lid
latches with a moderate slam. With ignition switch
in On or Accessory position, push deck lid unlock switch. Should latch fail to lock or unlock replace
latch assembly.
DECK LID PULL-DOWN SYSTEMÐAC and AY
BODIES
C-body vehicles have, as an option, a deck lid
power pull-down mechanism which latches and pulls
the deck lid down the last 25 mm (1 in.) of travel.
The system incorporates a combination latch/deck lid
Fig. 4 Front Power Door Lock MotorsÐAA, AG, AJ and AP Bodies
Fig. 5 Rear Power Door Lock MotorsÐAA and AP Bodies
Fig. 6 Front Power Door Lock MotorsÐAC and AY Bodies
Ä POWER LOCKS 8P - 3

release mechanism and a power pull-down motor as-
sembly (Fig. 8 through 10). When the deck lid is closed, very light pressure is
required to cause the latch to grab the pull down bar.
The pull down motor will automatically take the
deck lid to its completely closed position.
POWER PULL DOWN
(1) Latch testing: (a) With the deck lid open and the latch switch
released. There should be continuity between the
black with the red tracer (BK/RD*) and the black
(BK) wire (Fig. 10). (b) With the latch switch depressed (as if the
deck lid was closed), there should be continuity be-
tween the black (BK) and the black with white
tracer (BK/WT*) wire terminals. (c) If these results are not obtained, replace the
pull down latch.
(2) Pull down motor testing: (a) With the pull down motor connector wiring
removed, connect a 12 volt positive source to the
red (RD) wire terminal of the motor and ground
the tan (TN) wire terminal. This will cause the
pull down bar to retract. (b) With the positive source still connected to the
red (RD) wire terminal, ground the grey (GY) wire
terminal. This will cause the pull down bar to raise
Fig. 7 Rear Power Door Lock MotorsÐAC and AY Bodies
Fig. 8 Deck Lid Pull Down LatchÐAC and AYBodies
Fig. 9 Deck Lid Power Pull Down MotorÐAC and AY Bodies
Fig. 10 Deck Lid Power Pull Down AssemblyÐACand AY Bodies
8P - 4 POWER LOCKS Ä

to the deck lid open position. If the pull down limit
switch is depressed at this time, the motor should
stop.(c) If these results are not obtained, replace the
pull down motor assembly.
REMOTE KEYLESS ENTRY
OPERATION
The transmitter has three buttons for operation
(Fig. 11).
² UNLOCK driver's door, enable illuminated entry,
and disarm the Theft Security System. Pushing and
releasing the button once will unlock the driver's
door. Two times within five seconds all doors will un-
lock.
² LOCK all doors, set Theft Security System and
chirp horn. Chirp of horn is a short toot to notify
that the alarm system is set and the indicator lamp
on the instrument panel will flash for about 15 sec-
onds.
² Unlock Trunk Lid
² The receiver is capable of retaining VAC even
when power is removed.
² Each receiver must have at least one and no more
than two transmitters.
CONTROL RANGE
Operation range is within 7 meters (23 ft.) of the
receiver.
TRANSMITTER BATTERY
The battery can be removed without special tools
and are readily available at local retail stores. The
recommended battery is Duracell DL 2016 or equiv-
alent. Battery life is about one to two years.
PROGRAM REMOTE KEYLESS ENTRY
(1) Remove trim cover or floor console as needed
that may be covering the Air Bag System Diagnostic
Module (ASDM). (2) Pull floor carpeting back between the accelera-
tor peddle and ASDM. (3) Locate program line a dark green wire with a
insulator on the end. Located between the accelerator
and (ASDM). (4) Turn ignition switch to the ON position.
(5) Connect the program line from the Remote
Keyless Entry Module to ground. The door locks will
lock and unlock to indicate the receiver is ready to
receive transmitter code. Trunk solenoid will not cy-
cle. (6) Press any button on the transmitter to set code.
If there is a second transmitter it has to be set at
this time. The locks will cycle to confirm program-
ming. (7) Disconnect the program line from ground. This
returns the system to its normal operation mode. (8) Replace trim cover or floor console as neces-
sary.
HORN CHIRP CANCELLATION
During the programming operation the horn chirp
can be disabled using the following procedures: (1) Remove trim cover or floor console as needed
that may be covering the Air Bag System Diagnostic
Module (ASDM). (2) Pull floor carpeting back between the accelera-
tor peddle and ASDM. (3) Locate program line a dark green wire with a
insulator on the end. Located between the accelerator
and (ASDM). (4) Turn ignition switch ON.
(5) Connect the program line from the Remote
Keyless Entry Module to ground. The door locks will
lock and unlock to indicate the receiver is ready to
receive transmitter code. Trunk solenoid will not cy-
cle. (6) Press any button on the transmitter to set code.
If there is a second transmitter it has to be set at
this time. The locks will cycle to confirm program-
ming. (7) Press LOCK then UNLOCK transmitter but-
tons repeat three times. (8) Door locks and rear release will cycle three
times as feedback of Horn Chirp lockout. (9) Remove ground from program line to restore
normal system operation. (10) To reinstate the Horn Chirp feature refer to
Program Remote Keyless Entry.
TESTING
CONDITION: When trying to program the receiver
module in the vehicle with a new transmitter and
there is no response from the module, Example: the
door locks do not cycle through a lock/unlock routine.
Refer to Fig. 12 for a block wiring diagram or to
Group 8W, Wiring Diagrams.
Fig. 11 Transmitter
Ä POWER LOCKS 8P - 5

(1) Be sure that the module has a battery feed
from the 20 Amp breaker in cavity 1 of the black
connector. Also affected would be the optical horn
and the stop lamps. (2) Be sure that the module has an ignition feed
from 5 Amp fuse in cavity 8 of the black connector.
Also affected would be the body computer, instru-
ment cluster and message center. (3) Be sure that the module has a ground from the
right side cowl behind the body computer to the cav-
ity 5 of the black connector. (4) Be sure that you are supplying a good ground
to the programming wire. (5) If the above circuits are good, replace the Re-
ceiver Module. CONDITION: Doors can be locked or unlocked with
the Keyless Entry transmitter. But the doors will not
lock. The Vehicle Theft Alarm system will not arm,
when using only the power door LOCK switch in the
driver's door. (1) Be sure you have not left key in the ignition
column lock cylinder. (2) If step 1 is OK, check the Key in Lock switch
circuit in the steering column for a short to ground. (3) In this problem the body computer controls the
LOCK function. Be sure that it is providing a battery
voltage output to the door lock relay. The door lock
relay controls the door lock motors. CONDITION: Doors will lock but Vehicle Theft
System will not arm when using the transmitter. (1) The Keyless Entry Receiver Module controls
the door lock signal to the door lock relay. The door
lock relay controls the door lock motors. Check for
battery voltage at cavity 10 of the Theft Alarm mod-
ule from the Receiver module. (2) If voltage is OK, replace Receiver module.
CONDITION: All doors except driver's door will
lock with the transmitter. (1) Test the driver's door output of the Receiver
Module for a ground. (2) If there is no ground at the pin, replace the Re-
ceiver module. (3) If there is a ground at the output, replace the
door lock motor. CONDITION: Only driver's door will lock with the
transmitter.
² Repair ground circuit to unlock relay
² Replace unlock relay
CONDITION: Doors do not lock with the transmit-
ter, but still get horn CHIRP that indicates that they
did lock. Replace Receiver module. CONDITION: Doors will lock with the transmitter
but there is no horn CHIRP. (1) Press horn button, listen horn sound.
(2) If the horn sounded, change horn relay. (3) Still no CHIRP, check continuity between the
horn relay and the receiver output pin. Repair as
necessary. (4) Still no horn CHIRP, replace the receiver mod-
ule. (5) If using a DRB II, refer to Body Diagnostic Pro-
cedures.
REMOTE KEYLESS MODULE REPLACEMENT
(1) Remove lower right instrument panel silencer.
(2) Remove glove box assembly.
(3) Remove three screws attaching the mounting
bracket to instrument panel. (4) Lower bracket and module assembly, to discon-
nect wire connector. (5) Remove two screws attaching the Remote Key-
less entry Module to bracket. (6) Remove two screws attaching the security mod-
ule to bracket. (7) To installation reverse above procedures.
LAMP OUTAGE MODULE REPLACEMENT
(1) Remove lower right instrument panel silencer.
(2) Remove glove box and ash receiver module.
(3) Remove three screws attaching the mounting
bracket to instrument panel. (4) Lower bracket and module assembly, to discon-
nect wire connectors. (5) Remove two screws attaching the Lamp Outage
Module to bracket. (6) Remove two screws attaching the security mod-
ule to bracket. (7) To installation reverse above procedures.
DOOR LOCK INHIBIT
The power door lock inhibit system prevents the
doors from being locked using the power door locks
when either of two conditions occur: (1) The key is in the ignition switch and any of the
doors are open. The ignition switch does not have to
be ON. (2) The key is in the ignition switch and the head-
lamp are on.
AC, AG, AJ AND AY BODIES
With the ignition switch in the ON or OFF position
and the driver's door open the Body Controller will
ignore the command to lock the power door locks.
Once the key is removed, or the driver's door is
closed, the Body Controller will allow the power door
locks to lock. Refer to Body Diagnostic Procedure
Manual for further testing procedures.
8P - 6 POWER LOCKS Ä