CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

TORQUE SPECIFICATION
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 25

FRAME AND BUMPERS
CONTENTS
page page
BUMPER AND FASCIA .................... 1 FRAME................................ 9
BUMPER AND FASCIA INDEX
page page
AA-Vehicle Front Bumper ................... 1
AA-Vehicle Rear Bumper ................... 5
AC-Vehicle Front Bumper ................... 2
AC-Vehicle Rear Bumper ................... 6
AG-Vehicle Front Bumper ................... 3
AG-Vehicle Rear Bumper ................... 7
AJ-Vehicle Front Bumper and Fascia .......... 4 AJ-Vehicle Rear Bumper
.................... 7
AP-Vehicle Front Bumper ................... 4
AP-Vehicle Rear Bumper ................... 7
AY-Vehicle Front Bumper ................... 5
AY-Vehicle Rear Bumper ................... 8
Safety Precautions and Warnings ............. 1
SAFETY PRECAUTIONS AND WARNINGS
WARNING: BUMPER ENERGY ABSORBER UNITS
CONTAIN PRESSURIZE GAS. DO NOT PUNCTURE
OR HEAT ABSORBER UNIT FOR ANY REASON.
PERSONAL INJURY CAN RESULT.
DO NOT VENTURE UNDER A HOISTED VEHICLE
THAT IS NOT SUPPORTED ON SAFETY STANDS.
PERSONAL INJURY CAN RESULT.
CAUTION: To avoid damaging a bright metal or
painted finish bumper or fascia, use a padded work
surface.
AA-VEHICLE FRONT BUMPER
REMOVAL (FIG. 1)
(1) Remove socket and bulb from park and turn
lamp. (2) Disconnect horn and fog lamp connectors (if
equipped). (3) Remove push-in fasteners holding sight shield
to vertical support in front of radiator. (4) Remove nuts holding fascia to fender, from be-
hind forward flange of fender. (5) Support front bumper assembly on suitable lift-
ing device and remove bolts holding bumper rein-
forcement to energy absorber units.
INSTALLATION
Reverse the preceding operation. Align bumper
height to approximately 3 mm (1/8 in.) gap to bottom
of head lamp assemblies and flush to front fenders
below the side marker lamps.
Fig. 1 Standard Front BumperÐAA-Vehicle
Ä FRAME AND BUMPERS 13 - 1

BUMPER AND WRAP-AROUND FASCIA REMOVAL (FIG. 2)
(1) Remove socket and bulb from park and turn
lamp. (2) Disconnect horn and fog lamp connectors (if
equipped). (3) Remove push-in plastic fasteners at forward
edge of front wheel opening. (4) Remove pal-nut fasteners from behind front
fenders rearward of the side marker lamp. (5) Remove push-in, fasteners holding sight shield
to vertical support in front of radiator. (6) Remove nuts holding fascia to fender, from be-
hind forward flange of fender. (7) Support front bumper on suitable lifting device
and remove bolts holding bumper reinforcement to
energy absorber units.
INSTALLATION
Reverse the preceding operation. Align bumper
height to approximately 3 mm (1/8 in.) gap to bottom
of head lamp assemblies and flush to front fenders
below the side marker lamps.
BUMPER OVERHAUL (FIG. 3)
(1) Position bumper assembly on a suitable padded
work surface to avoid damage to painted fascia. (2) Remove sight shield push-in, fasteners and sep-
arate shield from assembly. (3) Remove air dam screws and push-in fasteners
and lift dam out of retaining channels at ends of fas-
cia. Remove dam retaining channels and reinforce-
ments from fascia (if equipped). (4) Remove park and turn signal lamp assemblies,
see Group 8L, Lamps (5) Remove fog lamp bracket from bottom of
bumper reinforcement (if equipped). (6) Remove horns from back of bumper reinforce-
ment. (7) Remove lower air intake louver screws and
push-in fastener and separate louver from fascia. (8) Remove upper reinforcement to fascia attaching
bolts and separate reinforcement from fascia. (9) Straighten toy-tab fasteners holding horizontal
moulding to fascia and separate moulding from two
sided adhesive tape behind moulding. Remove moul-
ding from fascia.
BUMPER ASSEMBLY
Reverse the preceding operation.
AC-VEHICLE FRONT BUMPER
FRONT BUMPER AND STANDARD FASCIA REMOVALÐAC/D OR AC/C-H- BODY (FIG. 4)
(1) Remove nuts holding fascia to fender, from be-
hind forward flange of fender. (2) Support front bumper assembly on suitable lift-
ing device and remove bolts holding bumper rein-
forcement to energy absorber units. (3) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation. Align bumper
height to fit flush to bottom of head lamp assemblies
and grille.
FRONT BUMPER OVERHAULÐAC\ OR AC/C-H- BODY (FIG. 4)
(1) Position bumper assembly on a suitable padded
work surface to avoid damage to painted fascia. (2) Remove push-in fasteners holding fascia to re-
inforcement. (3) Remove upper reinforcement to fascia attaching
bolts and separate reinforcement from fascia.
Fig. 2 Wrap-around Front BumperÐAA-Vehicle
Fig. 3 Front Bumper OverhaulÐAA-Vehicle
13 - 2 FRAME AND BUMPERS Ä

FRONT BUMPER ASSEMBLY
Reverse the preceding operation.
FRONT BUMPER AND FASCIA REMOVALÐAC/ C-BODY (FIG. 5)
(1) Raise vehicle and support on safety stands.
(2) Remove push-in fasteners holding bumper fas-
cia to front wheel opening lip. (3) Support bumper on a suitable lifting device.
(4) Remove nuts holding bumper reinforcement to
energy absorbers. (5) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation.
BUMPER OVERHAULÐAC/C-BODY
(1) Position bumper assembly on a suitable padded
work surface to avoid damage to painted fascia. (2) Remove bolts holding bumper face bar to rein-
forcement. (3) Remove push-in fasteners holding fascia to re-
inforcement. (4) Separate reinforcement from fascia.
BUMPER ASSEMBLY
Reverse the preceding operation.
AG-VEHICLE FRONT BUMPER
FRONT BUMPER FASCIA REMOVAL (FIG. 6)
(1) Remove headlamp and fog lamp (if equipped)
assemblies, refer to Group 8L, Lamps. (2) Raise vehicle and support on safety stands.
(3) Remove radiator closure panel sight shield.
(4) Remove push-in fasteners holding fascia to
front fender wheel opening flange. (5) Remove nuts holding fascia to fender from
above side marker reflectors. Remove fender splash
shields if necessary. (6) Remove nuts holding front fascia headlamp
mounting panel to forward edge of fenders. (7) Remove bolts holding fascia headlamp mount-
ing panel to radiator closure panel brace. (8) Remove push-in fasteners holding fascia to bot-
tom of bumper reinforcement. (9) Separate front bumper fascia and headlamp
mounting panel from vehicle.
INSTALLATION
Reverse the preceding operation. If headlamps re-
quire aiming, refer to Group 8L, Lamps.
HEADLAMP MOUNTING PANEL REMOVALÐAG-VEHICLE (FIG. 7)
(1) Remove all lamp assemblies, refer to group 8L,
Lamps. (2) Remove front bumper fascia.
(3) Remove bolts holding fascia to headlamp
mounting panel ends. (4) Remove push-in fasteners holding fascia to
headlamp mounting panel. (5) Separate headlamp mounting panel from fascia.
INSTALLATION
Reverse the preceding operation
Fig. 4 Front BumperÐAC\ or AC/C-H-Body
Fig. 5 Front BumperÐAC/C-Body
Fig. 6 Front Bumper FasciaÐAG-Vehicle
Ä FRAME AND BUMPERS 13 - 3

FRONT BUMPER REINFORCEMENT REMOVALÐAG-VEHICLE (FIG. 8)
(1) Remove bumper fascia as necessary to gain
clearance to remove bumper reinforcement. (2) Remove nuts holding bumper reinforcement to
energy absorber units. (3) Separate bumper reinforcement from vehicle.
carriage
INSTALLATION
Reverse the preceding operation
FRONT BUMPER ENERGY ABSORBERREMOVALÐAG-VEHICLE (FIG. 8)
(1) Remove front fascia and bumper reinforcement
as necessary to remove absorber unit. (2) Remove bolts holding energy absorber unit to
front closure panel. (3) Separate energy absorber from vehicle.
FRONT BUMPER ENERGY ABSORBERINSTALLATION
Reverse the preceding operation.
AJ-VEHICLE FRONT BUMPER AND FASCIA
REMOVAL (FIG. 9)
(1) Remove socket and bulb from park and turn
lamp. (2) Remove nuts holding fascia to fender, from be-
hind forward flange of fender. (3) Support front bumper assembly on suitable lift-
ing device and remove bolts holding bumper rein-
forcement to energy absorber units.
INSTALLATION
Reverse the preceding operation. Align bumper
height to approximately 5 mm (0.200 in.) gap to bot-
tom of grille and flush to front fenders on the sides.
AP-VEHICLE FRONT BUMPER
REMOVAL (FIG. 10)
(1) Raise vehicle and support on safety stands.
(2) Disconnect front park and turn signal lamp
wire connector. (3) Remove front side marker lamp socket from
lamp assembly and position socket out of the way. (4) Remove bolt holding front bumper fascia to
wheelhouse splash shield. (5) Remove nuts holding fascia to front fender.
(6) Support front bumper on lifting device.
(7) Remove bolts holding front bumper reinforce-
ment to energy absorber units. (8) Separate front bumper from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 7 Headlamp Mounting PanelÐAG-Vehicle
Fig. 8 Front Bumper Reinforcement and Energy Absorber UnitÐ
Fig. 9 Front Bumper and FasciaÐAJ-Vehicle
13 - 4 FRAME AND BUMPERS Ä

AY-VEHICLE FRONT BUMPER
BUMPER AND FASCIA REMOVALÐAY/P-BODY (FIG. 11)
(1) Remove wheel house splash shields as neces-
sary to gain access to fascia attaching nuts. (2) Remove lower fascia bottom extension cover.
(3) Remove nuts holding fascia to fender, from be-
hind forward flange of fender. (4) Support front bumper assembly on suitable lift-
ing device. (5) Remove nuts holding bumper to energy ab-
sorber units. (6) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation. Align bumper
height to fit flush to bottom of filler panel.
FRONT BUMPER AND FASCIA REMOVALÐAY/ S-BODY (FIG. 12)
(1) Raise vehicle and support on safety stands.
(2) Remove push-in fasteners holding bumper fas-
cia to front wheel opening lip. (3) Support bumper on a suitable lifting device.
(4) Remove nuts holding bumper reinforcement to
energy absorbers. (5) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation.
BUMPER OVERHAULÐAY/S BODY
(1) Position bumper assembly on a suitable padded
work surface to avoid damage to painted fascia. (2) Remove bolts holding bumper face bar to rein-
forcement. (3) Remove push-in fasteners holding fascia to re-
inforcement. (4) Separate reinforcement from fascia.
BUMPER ASSEMBLY
Reverse the preceding operation.
AA-VEHICLE REAR BUMPER
REAR BUMPER AND STANDARD FASCIAREMOVAL (FIG. 13)
(1) Open trunk lid and separate quarter panel lin-
ers (if equipped) from tail panel area. (2) Remove rear fascia attaching nuts at rear of in-
ner quarter panel drop-down wells. (3) Remove lower fascia push-in fasteners holding
fascia to bottom of bumper reinforcement. (4) Remove fascia nuts holding fascia to trunk
opening panel. (5) Remove fascia bolts holding fascia to ends of
bumper reinforcement. (6) Separate fascia from reinforcement and sepa-
rate fascia from vehicle. (7) Support bumper reinforcement. Remove rein-
forcement attaching bolts and separate assembly
from energy absorbers.
INSTALLATION
Reverse the preceding operation.
Fig. 10 Front BumperÐAP-Vehicle
Fig. 11 Front Bumper and FasciaÐAY/P-Body
Fig. 12 Front BumperÐAY/S-Body
Ä FRAME AND BUMPERS 13 - 5

REAR BUMPER AND WRAP-AROUND FASCIA REMOVAL (FIG. 14)
(1) Remove push-in fasteners holding rear fascia to
rearward edge of wheel opening. (2) Open trunk lid and separate quarter panel
liner from tail panel area ,if equipped. (3) Remove pal-nut fasteners located behind quar-
ter panel, holding fascia to quarter panel. (4) Perform steps 2 through 7 of Rear Bumper and
Standard Fascia Removal/Installation procedure.
INSTALLATION
Reverse the preceding operation.
AC-VEHICLE REAR BUMPER
REAR BUMPER REMOVALÐAC/D-BODY (FIG. 15)
(1) Disconnect license plate lamps wire connectors.
(2) Remove nuts holding fascia to quarter panel
ends. (3) Support bumper assembly on suitable lifting
device and remove bolts holding bumper reinforce-
ment to energy absorber units. (4) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation. Align bumper
height to fit flush to bottom of tail lamp.
REAR BUMPER OVERHAULÐAC/D-BODY (FIG. 16)
(1) Position bumper assembly on a suitable padded
work surface to avoid damage to painted fascia. (3) Remove push-in fasteners holding fascia to bot-
tom of reinforcement. (4) Remove bolts holding fascia to reinforcement
and separate fascia from reinforcement. (5) Remove bolts holding bumper guards to fascia
and separate guards from fascia.
REAR BUMPER ASSEMBLY
Reverse the preceding operation.
REAR BUMPER REMOVAL AC/C-BODY (FIG. 17)
(1) In luggage compartment, separate liners from
quarter panels to gain access to fascia nuts.
Fig. 13 Standard Rear BumperÐAA-Vehicle
Fig. 14 Wrap-around Rear BumperÐAA-Vehicle
Fig. 15 Rear BumperÐAC/D-Body
Fig. 16 Rear Bumper OverhaulÐAC/D-Body
13 - 6 FRAME AND BUMPERS Ä

(2) Remove nuts holding bumper fascia to quarter
panels. (3) Remove fasteners holding bumper fascia to
wheel opening flange. (4) Disconnect license plate lamp wire connectors.
(5) Remove bolts holding bumper to rear closure
panel. (6) Remove nuts holding bumper to energy ab-
sorber units. (7) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation.
AG-VEHICLE REAR BUMPER
REMOVAL (FIG. 18)
(1) Raise vehicle and support on safety stands.
(2) Remove nuts holding rear fascia to luggage
compartment tail panel. (3) Remove nuts holding fascia ends to quarter
panel end flanges. (4) Remove pop-rivets holding bumper fascia to
wheel lip flanges. (5) Remove nuts holding bumper fascia to quarter
panel along belt line. (6) Support rear bumper assembly on lifting de-
vice. (7) Remove nuts holding rear bumper reinforce-
ment to energy absorbers. (8) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation.
AJ-VEHICLE REAR BUMPER
REMOVAL (FIG. 19)
(1) Remove nuts holding rear fascia to quarter
panel ends. (2) Remove push-in fasteners holding fascia to bot-
tom of bumper reinforcement. (3) Remove nuts holding fascia to trunk tail panel.
(4) Remove bolts holding fascia to ends of bumper
reinforcement. (5) Separate fascia from reinforcement and sepa-
rate fascia from vehicle. (6) Support bumper reinforcement on a lifting de-
vice. Remove bolts holding reinforcement to energy
absorbers. Separate reinforcement from energy ab-
sorbers.
INSTALLATION
Reverse the preceding operation.
AP-VEHICLE REAR BUMPER
REMOVAL (FIG. 20)
(1) Raise vehicle and support on safety stands.
(2) Support rear bumper on lifting device.
(3) Remove bolts holding rear bumper reinforce-
ment to energy absorber units. (4) Pull rear bumper assembly rearward to disen-
gage retainers from quarter panel. (5) Separate front bumper from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 17 Rear BumperÐAC/C-Body
Fig. 18 Rear Bumper Fascia and ReinforcementÐAG-Vehicle
Fig. 19 Rear Bumper and FasciaÐAJ-Vehicle
Ä FRAME AND BUMPERS 13 - 7

AY-VEHICLE REAR BUMPER
REAR BUMPER REMOVALÐAY/P-BODY (FIG. 21)
(1) Remove nuts holding fascia to quarter panel
ends. (2) Support bumper assembly on suitable lifting
device and remove bolts holding bumper reinforce-
ment to energy absorber units. (3) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation. Align bumper
height to fit flush to bottom of tail lamp.
REAR BUMPER OVERHAULÐAY/P-BODY
(1) Position bumper assembly on a suitable padded
work surface to avoid damage to painted fascia. (2) Remove bolts holding bumper face bar to rein-
forcement and separate face bar from assembly. (3) Remove push-in fasteners holding fascia to re-
inforcement. (4) Remove upper reinforcement to fascia attaching
bolts and separate reinforcement from fascia.
REAR BUMPER ASSEMBLY
Reverse the preceding operation.
REAR BUMPER REMOVALÐAY/S-BODY (FIG. 22)
(1) In luggage compartment, separate liners from
quarter panels to gain access to fascia nuts. (2) Remove nuts holding bumper fascia to quarter
panels. (3) Remove fasteners holding bumper fascia to
wheel opening flange. (4) Disconnect license plate lamp wire connectors.
(5) Remove bolts holding bumper to rear closure
panel. (6) Remove nuts holding bumper to energy ab-
sorber units. (7) Separate bumper from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 20 Rear BumperÐAP-Vehicle
Fig. 21 Rear BumperÐAY/P-Body
Fig. 22 Rear BumperÐAY/S-Body
13 - 8 FRAME AND BUMPERS Ä