CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

PAINT AND TRIM CODE DESCRIPTIONS
Ä BODY 23 - 5

POWER SUNROOF INDEX
page page
Adjustment Bracket ........................ 7
Drain Channel ............................ 7
Drive Cable Locators ....................... 7
Drive Cables ............................. 8
General Information ........................ 6
Glass Panel ............................. 7 Glass Vertical Height Adjustment
.............. 6
Guide Assembly .......................... 8
Motor and Drive Gears ..................... 7
Sunshade ............................... 8
Wind Deflector ........................... 6
GENERAL INFORMATION
All sunroofs are equipped with drain tubes that are
located in the A, B or C-pillars. The drain tubes
must be kept open to prevent water from entering
the passenger compartment.
LUBRICATION
(1) Lubricate cables with Lubriplate or equivalent
when cables are replaced. (2) Periodically clean dirt from guide rail covers.
DRAIN TUBES
² Inspect the drain holes, located in the trough
around the sunroof opening to verify they are clear.
Inspection should be performed at least once a year
or when problems are suspected. If drain hose or
tubes are plugged, use compressed air or blunt flexi-
ble wire to clear them. If tubes cannot be cleared,
they must be repaired.
² The lower ends of the rear drain tubes are located
in the rear quarter panel drop wells. To clear rear
drain tubes, use compressed air or blunt flexible wire
from the lower ends of the tubes.
GLASS VERTICAL HEIGHT ADJUSTMENT
GLASS VERTICAL ADJUSTMENT (FIG. 1)
(1) Open glass to vent position.
(2) Slide upper half of mechanism covers rearward
until clips disengage and separate covers from vehi-
cle. (3) Close glass panel, separately loosen adjusting
bolts and individually adjust the corners of glass. (4) Adjust front of glass panel to 1.0 mm (0.040 in.)
below top surface of roof panel. (5) Adjust rear of glass to 1.0 mm (0.040 in.) above
top surface of roof panel. (6) Secure adjustment bolts and install cover.
WIND DEFLECTOR
WIND DEFLECTOR REMOVAL (FIG. 2)
(1) Open sun roof glass panel.
(2) Remove screws holding wind deflector to sun
roof unit side rail. (3) Separate wind deflector from vehicle.
WIND DEFLECTOR INSTALLATION
Reverse the preceding operation.
WIND DEFLECTOR ADJUSTMENT (FIG. 2)
(1) Open sunroof.
Fig. 1 Glass Adjustment
Fig. 2 Deflector Assembly
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(2) position wind deflector so 19 mm (0.75 in.)
above top surface of roof panel and 1 mm (0.040 in.)
rearward of roof panel forward edge. (3) Secure wind deflector to sunroof unit.
GLASS PANEL
GLASS PANEL REMOVAL
(1) Remove wind deflector mechanism covers (Fig.
1). (2) Position glass to vent position.
(3) Position sunshade full rearward.
(4) Loosen nuts holding glass panel to side adjust-
ment brackets. (5) Slide glass panel rearward 12 mm (0.5 in.) and
separate glass from sunroof unit.
GLASS PANEL INSTALLATION
(1) Position glass panel in opening with logo rear-
ward and slide panel forward 12 mm (0.5 in.). (2) Verify that attaching nuts are below top sur-
face of glass adjustment brackets. (3) Close sunroof to center glass panel in roof open-
ing. (4) Tighten center screws to hold adjustment.
(5) Open glass to vent position and tighten nuts to
8N Im (70.8 in-lbs.).
(6) Close glass and check alignment.
(7) Install the mechanism covers.
(8) Adjust wind deflector, if necessary.
ADJUSTMENT BRACKET
ADJUSTMENT BRACKET REMOVAL (FIG. 3)
(1) Remove wind deflector, mechanism covers and
glass panel. (2) Move glass carriage to vent position and re-
move rearward adjustment bolt from adjustment
bracket. (3) Lift rear of adjustment bracket to highest ver-
tical position and disengage front of bracket from
unit.
ADJUSTMENT BRACKET INSTALLATION
Reverse the preceding operation. Adjust glass, and
wind deflector as necessary.
DRAIN CHANNEL
DRAIN CHANNEL REMOVAL
(1) Remove wind deflector mechanism covers and
glass panel. (2) Locate glass carriage to vent position and drain
channel in full forward position. (3) Remove screws holding drain channel to sup-
port frame.
DRAIN CHANNEL INSTALLATION
Reverse the preceding operation.
DRIVE CABLE LOCATORS
DRIVE CABLE LOCATORS REMOVAL (FIG. 4)
(1) Position glass 19 mm (0.75 in.) until rearward
until cable locator is visible. (2) Remove screws holding drive cable locator to
unit. (3) Remove travel limiting micro switch grommet
and disconnect wire connector. (4) Insert a small screwdriver under rear edge of
locator and pry locator from track.
DRIVE CABLE LOCATORS INSTALLATION
Reverse the preceding operation. The small out-
board lip underneath cable locator slips under bottom
slot on guide track. After locator is seated install
screws.
MOTOR AND DRIVE GEARS
MOTOR AND DRIVE GEAR REMOVAL (FIG. 5)
(1) Open sunroof to vent position.
(2) Remove head lining.
Fig. 3 Glass Height Vertical Adjustment
Fig. 4 Removing Cable Drive Locator
Ä BODY 23 - 7

(3) Remove bolts holding sunroof motor to motor
bracket. (4) Disconnect wire connector.
(5) Separate motor and drive gear from drive ca-
bles.
MOTOR AND DRIVE GEAR INSTALLATION
(1) Verify that sunroof is in vent position. Push
mechanism forward on both sides to align drive ca-
bles. (2) Engage drive gears onto drive cables.
(3) Install motor and drive gear screws and tighten
to5N Im (44 in-lbs.).
(4) Install head lining.
DRIVE CABLES
DRIVE CABLES REMOVAL (FIG. 6)
(1) Open sunroof to vent position.
(2) Remove head lining, wind deflector, mechanism
covers, glass panel, side glass adjustment brackets,
motor and drive cable locators. (3) Lift cable out of cable retainer and pull for-
ward. Separate cable from assembly.
DRIVE CABLES INSTALLATION
Verify sunroof is in vent position. Push mechanism
forward on both sides to align drive cables. Reverse
the preceding operation.
SUNSHADE
SUNSHADE REMOVAL (FIG. 7)
(1) Remove wind deflector, mechanism covers and
glass panel. (2) Position system to full rearward position.
(3) Slide sunshade panel full forward and release
the front tabs from track assembly. (4) Pull rear retaining clip inboard and lift sun
shade out.
SUNSHADE INSTALLATION
Reverse the preceding operation.
GUIDE ASSEMBLY
GUIDE ASSEMBLY REMOVAL (FIG. 8)
(1) Remove wind deflector, mechanism covers, glass
panel, drain channel, sunshade and drive cable locator
as necessary. (2) Move glass carriage to vent position.
(3) Remove front slide from guide assembly.
(4) Remove screws holding front and center guide
track to unit. (5) Pull cable out of groove for cable end.
(6) Pull guide outward to release from housing.
Separate rear end of guide from clips. Slide guide out of
unit.
Fig. 5 Sunroof Motor and Drive Gear
Fig. 6 Drive Cables
Fig. 7 Sunshade Assembly
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GUIDE ASSEMBLY INSTALLATION
(1) Install guide cable into rear of guide assembly.
(2) Install guide assembly at an angle so the rear
portion slips under finger clips at rear of module
housing. (3) Place cable in groove of cable holder.
(4) Install screws in track assembly.
(5) Install locators.
(6) Reverse removal operation.
WINDSHIELD
SAFETY PRECAUTIONS AND WARNINGS
WARNING: DO NOT OPERATE VEHICLE FOR AT
LEAST 24 HOURS AFTER WINDSHIELD INSTALLA-
TION. WINDSHIELD MAY NOT PERFORM PROPERLY
IN THE EVENT OF A COLLISION IF URETHANE AD-
HESIVE IS NOT SUFFICIENTLY CURED. REFER TO
MANUFACTURER OF URETHANE BEING USED FOR
CURING TIME SPECIFICATIONS. WHEN INSTALLING GLASS, DO NOT USE URE-
THANE ADHESIVE AFTER DATE ON PRODUCT HAS
EXPIRED. SAFETY AND QUALITY OF REPAIR
WOULD BE QUESTIONABLE. DO NOT USE URETHANE ADHESIVE OR PRIMER IN
CLOSED WORK AREA, PERSONAL INJURY CAN RE-
SULT. PROTECT SKIN FROM COMING IN CONTACT WITH
URETHANE, PERSONAL INJURY CAN RESULT. WEAR EYE AND HAND PROTECTION WHEN
WORKING WITH GLASS, PERSONAL INJURY CAN
RESULT.
CAUTION: Protect all painted or trimmed surfaces
from coming in contact with urethane or primers,
damage will result. Do not damage painted surfaces when removing
mouldings or cutting urethane around windshield.
It is difficult to salvage a windshield during the
removal operation. The windshield is part of the struc-
tural support for the roof. The urethane bonding used
to secure the windshield to the fence is difficult to cut
or clean from any surface. If the mouldings are set in
urethane, it would also be unlikely they could be
salvaged. Before removing the windshield, check the
availability of the windshield and mouldings from the
parts supplier.
WINDSHIELD REMOVAL
(1) Remove inside rear view mirror.
(2) Remove cowl cover.
(3) Remove windshield mouldings using a suitable
hook tool and trim stick (Fig. 1). (4) Cut urethane bonding from around windshield
using a suitable sharp cold knife. A pneumatic cutting
device can be used if available (Fig. 2). (5) Separate windshield from vehicle.
WINDSHIELD INSTALLATION
CAUTION: Open the left front door glass before
installing windshield to avoid pressurizing the pas-
senger compartment if a door or the trunk lid is
slammed before urethane bonding is cured. Water
leaks can result.
Fig. 8 Guide Assembly
Fig. 1 Windshield Mouldings
Fig. 2 Cut Urethane Around Windshield
Ä BODY 23 - 9

Allow the urethane at least 24 hours to cure before
returning the vehicle to use. The windshield fence should be cleaned of old ure-
thane bonding material. Support spacers should be
cleaned and properly installed on weld studs or re-
pair screws at bottom of windshield opening. (1) Place replacement windshield into windshield
opening and position glass in the center of the open-
ing against the support spacers. Mark the glass at
the support spacers with a grease pencil or pieces of
masking tape and ink pen to use as a reference for
installation. Remove replacement windshield from
windshield opening (Fig. 3). (2) Position the windshield inside up on a suitable
work surface with two padded, wood 10 cm by 10 cm
by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed par-
allel 75 cm (2.5 ft.) apart (Fig. 4). (3) Clean inside of windshield with Mopar Glass
Cleaner and lint-free cloth. (4) Apply clear glass primer 25 mm (1 in.) wide
around perimeter of windshield and wipe with clean/
dry lint-free cloth. (5) Install mouldings on windshield (Fig. 4).
(6) Apply black-out primer 15 mm (.75 in.) wide on
top and sides of windshield and 25 mm (1 in.) on bot-
tom of windshield. Allow at least three minutes dry-
ing time. (7) Position windshield bonding compression spac-
ers on lower fence above the support spacers at the
edge of the windshield opening (Fig. 5). (8) Apply a 10 mm (0.4 in.) bead of urethane
around perimeter of windshield along the inside of
the mouldings. (9) With the aid of a helper, position the wind-
shield over the windshield opening. Align the refer-
ence marks at the bottom of the windshield to the
support spacers. (10) Slowly lower windshield glass to windshield
opening fence. Guide the top moulding into proper
position if necessary. Push windshield inward to
fence spacers at bottom and until top moulding is
flush to roof line (Fig. 6). (11) Clean excess urethane from exterior with Mo- par, Super Clean or equivalent.
(12) Install cowl cover and wipers.
(13) Install inside rear view mirror.
(14) After urethane has cured, water test wind-
shield to verify repair.
Fig. 3 Center Windshield and Mark at Support
Spacers
Fig. 4 Work Surface Set-up and MouldingsInstallation
Fig. 5 Position Urethane Compression Spacers
Fig. 6 Lower Windshield Into Position
23 - 10 BODY Ä

AA-VEHICLE BODY COMPONENT SERVICE INDEX
page page
A-Pillar and Roof Rail Mouldings ............. 25
B-Pillar Trim Panel ....................... 25
Body Side Moulding and Applique ............ 24
Cowl Cover ............................. 13
Cowl Panel Trim and Scuff Plates ............ 25
Door Opening Weatherstrips ................ 24
Floor Carpet ............................ 30
Front Center Console ..................... 29
Front Door and Hinge ..................... 15
Front Door Belt Moulding and Weatherstrip ..... 17
Front Door Glass ........................ 17
Front Door Glass Channel and Run Weatherstrip . 18
Front Door Glass Run Lower Channel ......... 18
Front Door Latch ......................... 16
Front Door Side View Mirror ................ 17
Front Door Silencer and Water Shield ......... 15
Front Door Trim Panel .................... 14
Front Door Window Regulator/Manual ......... 18
Front Door Window Regulator/Power .......... 19
Front End Splash Shields .................. 13
Front Fender ............................ 14
Front Power Door Lock Actuator ............. 19
Front Seat Belts ......................... 27
Front Seats ............................. 28
Fuel Fill Door ........................... 36
Grille .................................. 11
Head Lining ............................. 30
Hood and Hinges ........................ 11
Hood Latch and Release Cable .............. 12
Outside Front Door Latch Release Handle ..... 16
Outside Rear Door Latch Release Handle ...... 21 Overhead Console
........................ 30
Quarter Extension Trim Panel ............... 27
Quarter Trim Panel ....................... 27
Rear Deck Filler Panel .................... 31
Rear Door and Hinge ..................... 20
Rear Door Belt Moulding and Weatherstrip ..... 22
Rear Door Glass ......................... 22
Rear Door Glass Run Weatherstrip ........... 22
Rear Door Glass Stationary Glass Module ..... 23
Rear Door Latch ......................... 21
Rear Door Silencer and Water Shield ......... 20
Rear Door Trim Panel ..................... 20
Rear Door Window Regulator/Manual ......... 23
Rear Door Window Regulator/Power .......... 23
Rear Power Door Lock Actuator ............. 22
Rear Seat Belts .......................... 28
Rear Seats ............................. 28
Rear Shelf Trim Panel ..................... 27
Rear Window Glass ...................... 32
Sun Roof Air Deflector .................... 31
Sun Roof Drain Tubes .................... 31
Sun Roof Weatherstrip .................... 31
Trunk Lid .............................. 33
Trunk Lid Hinge ......................... 34
Trunk Lid Latch .......................... 34
Trunk Lid Lock .......................... 34
Trunk Lid Luggage Rack ................... 35
Trunk Lid Torsion Bar ..................... 34
Trunk Lining ............................ 35
Trunk Opening Weatherstrip ................ 35
Vinyl Roof Bonnet ........................ 31
GRILLE
REMOVAL (FIG. 1)
(1) Raise hood to full up position.
(2) Remove hood safety catch release rod retainer
and separate rod from grille. (3) Remove grille end reinforcement attaching
bolts. (4) Remove nuts holding grille to hood.
(5) Separate grille from hood.
INSTALLATION
Reverse the preceding operation.
HOOD AND HINGES
HOOD REMOVAL (FIG. 2)
(1) Raise hood to full up position.
(2) Lift front edge of cowl cover on the right side of
the windshield washer bottle and disconnect the un-
der hood lamp wire connector. (3) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation. When install- ing hood, align all marks and secure bolts. The hood
should be aligned to 4 mm (0.160 in.) gap to the front
fenders and flush across the top surfaces along fend-
ers. (4) Remove the top hood to hinge attaching bolts
and loosen the bottom bolts until they can be re-
moved by hand.
Fig. 1 Grille Assembly
Ä AA-BODY 23 - 11

(5) With assistance of a helper at the opposite side
of the vehicle to support the hood, remove the bottom
hood to hinge attaching bolts. Separate the hood
from the vehicle.
HOOD INSTALLATION
Reverse the preceding operation.
HOOD HINGE REMOVAL (FIG. 3)
(1) Support hood on the side that requires hinge
replacement. (2) Mark all bolt and hinge attachment locations
with a grease pencil or other suitable device to pro-
vide reference marks for installation. When install-
ing hood hinge, align all marks and secure bolts. The
hood should be aligned to 4 mm (0.160 in.) gap to the
front fenders and flush across the top surfaces along
fenders. Shims can be added or removed under hood
hinge to achieve proper hood height. (3) Remove hood to hinge attaching bolts.
(4) Remove hood hinge to front fender attaching
bolts and separate hinge from vehicle.
HOOD HINGE INSTALLATION
Reverse the preceding operation. If necessary, paint
new hinge before installation.
HOOD LATCH AND RELEASE CABLE
HOOD LATCH REMOVAL (FIG. 4)
(1) Raise hood top the full up position.
(2) Remove hood latch attaching bolts holding
latch to radiator closure panel and separate from ve-
hicle. (3) Pry release cable casing attachment from slot
receiver on latch, disengage cable end from latch arm
hook.
HOOD LATCH INSTALLATION
Reverse the preceding operation.
HOOD LATCH RELEASE CABLE REMOVAL (FIG. 5)
(1) Raise hood to the full up position.
Fig. 2 Hood Assembly
Fig. 3 Hood Hinge Assembly
Fig. 4 Hood Latch Assembly
23 - 12 AA-BODY Ä

(2) Remove push-in fasteners holding hood latch
cover to radiator closure panel and separate cover
from vehicle. (3) Disconnect hood release cable casing and cable
end from hood latch assembly. Refer to Hood Latch
Removal procedure in this section. (4) Remove hood latch release cable handle attach-
ing bolts from under left lower edge of instrument
panel. (5) Disengage release cable rubber grommet from
engine compartment dash panel behind instrument
panel. (6) Rout cable assembly through engine compart-
ment around battery, under fender lip, under relay
bank, and under wiring harnesses, toward dash
panel. Push cable through access hole in dash panel
under the brake master cylinder, into passenger com-
partment.
HOOD LATCH RELEASE CABLE INSTALLATION
Reverse the preceding operation.
COWL COVER
REMOVAL (FIG. 6)
(1) Raise hood to full up position.
(2) Disconnect windshield washer hoses from wiper
arms. (3) Remove windshield wiper arm assemblies. Re-
fer to Group 8K, Windshield Wiper and Washer Sys-
tems. (4) Remove plastic expanding type fasteners hold-
ing cowl cover to cowl, below windshield. (5) Lift back of cowl cover and slide cover rearward
from under dash panel to hood seal and separate
cover from vehicle.
INSTALLATION
Reverse the preceding operation.
FRONT END SPLASH SHIELDS
FRONT WHEELHOUSE SPLASH SHIELD REMOVAL (FIG. 7)
(1) Hoist vehicle and support on suitable safety
stands. (2) Remove front wheel assembly.
(3) Remove push-in fasteners holding front wheel-
house splash shield to fender opening lip and inner
wheelhouse area. (4) Separate wheelhouse splash shield from vehi-
cle.
FRONT WHEELHOUSE SPLASH SHIELD INSTALLATION
Reverse the preceding operation.
TRANSAXLE SPLASH SHIELD REMOVAL (FIG.7)
(1) Remove one front wheelhouse splash shield
push-in fastener and separate wheelhouse splash
shield from transaxle splash shield. (2) Remove transaxle splash shield attaching bolts
and separate transaxle splash shield from vehicle.
TRANSAXLE SPLASH SHIELD INSTALLATION
Reverse the preceding operation.
ENGINE DRIVE BELT SPLASH SHIELD REMOVAL (FIG. 8)
(1) Hoist vehicle and support on suitable safety
stands. (2) Remove bolts holding engine drive belt splash
shield to right frame rail. (3) Separate drive belt splash shield from vehicle.
ENGINE DRIVE BELT SPLASH SHIELDINSTALLATION
Reverse the preceding operation.
Fig. 5 Hood Latch Release Cable Assembly
Fig. 6 Cowl Cover Assembly
Ä AA-BODY 23 - 13

FRONT FENDER
REMOVAL (FIG. 9)
(1) Remove front side marker lamp assembly. Re-
fer to Group 8L, Lamps for instructions. (2) Remove front bumper as necessary to gain
clearance to remove front fender. Refer to Front
Bumper Removal paragraph in this section. (3) Remove front wheelhouse splash shield. Refer
to Front Wheelhouse Splash Shield Removal para-
graph of this section. (4) Remove rocker panel moulding as necessary to
clear front fender. Refer to Body Side Moulding and
Applique Removal paragraph in this section. (5) Remove bolts holding bottom front fender at
rear of wheel opening. (6) Remove bolt holding front fender at rear of
wheelhouse. (7) Remove bolt holding front fender at top of front
door opening. (8) Remove bolts holding front fender to front
lower brace and under radiator closure panel. (9) Remove bolts holding front fender to front of
radiator closure panel. (10) Raise hood and support hood on a suitable
holding device. Mark hinge for installation indexing.
Remove lower hood hinge attaching bolts and sepa-
rate hinge from front fender. Refer to Hood Hinge
Removal paragraph in this section. (11) Remove bolts holding front fender to inner
wheelhouse along hood opening. (12) Separate front fender from vehicle.
INSTALLATION
Reverse the preceding operation. Align front fender
to achiev ea4mm (0.160 in) gap to hood edge and 6
mm (0.240 in) gap to front door edge. All surfaces
across gaps should be flush.
FRONT DOOR TRIM PANEL
DOOR TRIM PANEL WITH POWER WINDOWS REMOVAL (FIG. 10)
(1) Move glass to down position.
(2) Disconnect battery negative cable.
(3) Using a suitable prying tool, lift upward at
front of power window switch bezel and disengage be-
zel from clip in door panel. Disconnect wire connector
from back of switch. (4) Remove door latch handle bezel insert. Discon-
nect power door lock switch wire connector, if
equipped. Remove screws holding handle bezel to
trim panel and separate bezel from door. (5) Remove screw holding armrest pull handle to
door through door latch handle bezel opening. (6) Remove hidden screw from in carpet at rear
lower corner of trim panel. (7) Using a suitable trim clip tool, disengage frog
leg clips at the ends and bottom of trim panel. After
all trim clips are loose, push inward at the top of the
trim panel and lift upward to disengage barb fasten-
ers at top of panel. Separate trim from door.
Fig. 7 Front Wheelhouse and Transaxle Splash Shields
Fig. 8 Engine Drive Belt Splash Shield
Fig. 9 Front Fender Assembly
23 - 14 AA-BODY Ä