CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

DOOR TRIM PANEL WITH POWER WINDOWS INSTALLATION
Reverse the preceding operation.
DOOR TRIM PANEL WITH MANUAL WINDOWSREMOVAL (FIG. 11)
(1) Open door glass to full down position.
(2) Disconnect battery negative cable.
(3) Remove window crank cap, attaching screw,
and handle. (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 retain-
ers at top of panel. Separate trim from door.
DOOR TRIM PANEL WITH MANUAL WINDOWS INSTALLATION
Reverse the preceding operation.
FRONT DOOR SILENCER AND WATER SHIELD
REMOVAL (FIG. 12)
(1) Remove front door trim panel.
(2) Remove push-in fasteners holding silencer pad
to door inner panel and separate silencer from door. (3) Pull water shield from adhesive around perim-
eter of door inner panel.
INSTALLATION
Reverse the preceding operation.
FRONT DOOR AND HINGE
The front door hinge is welded to the door and
bolted to the hinge pillar. The door half of the hinge
pivots on a removable hinge pin. The hinge pin is
driven in from the bottom on the top hinge and from
the top on the bottom hinge. All adjustments to the
hinge are performed on the hinge pillar half of the
hinge. If the welded half of the hinge must be bent to
align door, consult an authorized body repair facility.
FRONT DOOR REMOVAL (FIG. 13)
(1) Remove door trim panel, silencer pad, and wa-
ter shield. (2) Disconnect all wire connectors and wire har-
ness hold downs inside door and push wire harness
through access hole in front of door into hinge pillar
opening. (3) Open door and support door on a suitable lift-
ing device. (4) Drive bottom hinge pin upward and remove pin
from hinge. (5) Drive top hinge pin downward and remove pin
from hinge.
Fig. 10 Front Door Trim Panel with Power Windows
Fig. 11 Front Door Trim Panel with Manual Windows
Fig. 12 Front Door Silencer and Water Shield
Ä AA-BODY 23 - 15

(6) Separate door from vehicle.
FRONT DOOR INSTALLATION
Reverse the preceding operation. The door should
not require re-alignment. If door does need align-
ment, refer to Front Door Hinge Installation para-
graph in this section.
FRONT DOOR HINGE REMOVAL (FIG. 14)
(1) Remove front fender wheelhouse splash shield.
Refer to Front Wheelhouse Splash Shield Removal
paragraph in this section. (2) Support door on a suitable lifting device.
(3) Drive out hinge pin on the effected hinge.
(4) Remove bolts holding hinge to hinge pillar and
separate hinge form vehicle.
FRONT DOOR HINGE INSTALLATION
Reverse the preceding operation. Align door to
achieve 6 mm (0.240 in.) gap to all surrounding pan-
els and flush across gaps.
OUTSIDE FRONT DOOR LATCH RELEASE HANDLE
OUTSIDE FRONT DOOR LATCH RELEASE HANDLE REMOVAL (FIG. 14)
(1) Remove front door trim panel, silencer pad, and
water shield. (2) Raise door glass to full up position.
(3) Disconnect security alarm switch and illumi-
nated entry switch from back of outside front door
latch release handle, if equipped. For additional in-
formation refer to Group 8Q, Vehicle Theft Security
System (4) Disconnect lock rod and latch release rod from
door latch assembly. (5) Remove nuts holding outside door latch handle
to retainer bracket and separate bracket from door. (6) Swing lock rod upward, parallel to back of
latch handle, and separate latch handle from door
panel.
OUTSIDE FRONT DOOR LATCH RELEASE
HANDLE INSTALLATION
Reverse the preceding operation.
FRONT DOOR LATCH
REMOVAL (FIG. 15)
(1) Remove front door trim panel, silencer pad and
water shield. (2) Raise door glass to full up position.
(3) Disconnect all actuator rods from door latch as-
sembly. (4) Remove screws holding door latch assembly to
inner door rear panel and separate latch from door.
INSTALLATION
Reverse the preceding operation.
Fig. 13 Front Door Assembly
Fig. 14 Outside Front Door Latch Release Handle
Fig. 15 Front Door Latch Assembly
23 - 16 AA-BODY Ä

FRONT DOOR SIDE VIEW MIRROR
REMOVAL (FIG. 16)
(1) Remove front door trim panel.
(2) Remove side view mirror remote adjusting
knob cover, if equipped. (3) Remove screws holding mirror bezel to door
frame and separate bezel from door. Loosen set-screw
holding bezel to mirror adjuster cable, if equipped. (4) Remove silencer seal from door frame behind
mirror bezel. (5) Disconnect power mirror wire connector, if
equipped. (6) Remove access hole cover.
(7) Remove nuts holding mirror to door frame and
separate mirror from door.
INSTALLATION
Reverse the preceding operation.
FRONT DOOR GLASS
REMOVAL (FIG. 17)
(1) Remove door trim panel, silencer pad, and wa-
ter shield. (2) Position door glass half way up in door glass
opening. (3) Insert door glass removal tool C-4867 between
the glass slide and channel retaining lip at approxi-
mately 50 mm (2 in.) down from top rearward corner
of glass. Push handle of tool toward glass to open
channel. Push downward at the front of the glass to
separate the slide from the channel. (4) Insert door glass removal tool C-4867 between
the glass slide and channel retaining lip at approxi-
mately 50 mm (2 in.) up from bottom rearward cor-
ner of glass through opening in inner door panel.
Push handle of tool toward glass to open channel.
Pull upward at front of glass to separate the slide
from the channel. Do not allow upper slide to snap
bank into channel. (5) Rotate front of glass downward and slide glass
forward to separate glass lift channel from regulator
lift arm roller. (6) Remove door glass through opening at top of
door.
INSTALLATION
(1) Lower door glass into opening at top of door.
(2) Tip rear of glass downward and insert window
regulator lift arm roller into glass lift channel. (3) Guide door glass into glass run weatherstrip at
front of door. (4) Push top of glass rearward to snap top slide
into glass run channel. (5) Push downward at front of glass to snap bottom
slide into glass run channel. (6) Install water shield, silencer pad and trim
panel.
FRONT DOOR BELT MOULDING AND
WEATHERSTRIP
BELT MOULDING AND WEATHERSTRIP REMOVAL (FIG. 18)
(1) Remove trim panel, silencer pad, and water
shield as necessary to gain access to belt moulding
attaching screws. (2) Remove door glass.
(3) Remove screws holding belt moulding and
weatherstrip to outer door panel and separate moul-
ding from door.
BELT MOULDING AND WEATHERSTRIP INSTALLATION
Reverse the preceding operation.
Fig. 16 Front Door Side View Mirror
Fig. 17 Front Door Glass
Ä AA-BODY 23 - 17

FRONT DOOR GLASS CHANNEL AND RUN
WEATHERSTRIP
GLASS CHANNEL AND RUN WEATHERSTRIP
REMOVAL (FIG. 19)
(1) Remove door belt moulding and weatherstrip
assembly. (2) Remove front and rear door glass opening cor-
ner seals (Fig. 18) (3) Pull door glass run weatherstrip from forward
lower channel and upper door frame back to rear up-
per corner of door frame. (4) Separate weatherstrip from top of rear door
frame down to first clip. Using a suitable hook tool,
disengage clip barb from door frame channel. Pull
weatherstrip outward to disengage clip. Repeat this
procedure at each clip down the rear channel. (5) Separate glass channel and run weatherstrip
from door.
GLASS CHANNEL AND RUN WEATHERSTRIP INSTALLATION
(1) Insert glass run weatherstrip into top of glass
opening upper channel. Align molded corners of
weatherstrip to corners of glass opening. (2) Push weatherstrip and glass run channel into
upper rear glass opening channel. Seat the top re-
taining clip by placing a fiber trim stick (C-4755)
over the clip attaching rivet inside the glass run
channel and push or tap firmly inward until clip
seats. Verify the alignment of the weatherstrip in
the top rear corner. Repeat this procedure on each
clip going down the run. (3) Install glass opening corner seals.
(4) Install door belt moulding and weatherstrip as-
sembly.
FRONT DOOR GLASS RUN LOWER CHANNEL
FRONT OR REAR LOWER CHANNEL REMOVAL (FIG. 20)
(1) Remove door glass channel and run weather-
strip as necessary to gain access to lower channels
and attaching rivets. (2) Drift punch rivet center expansion pins from
each pop-rivet fastener holding channel to door panel
or mirror support frame. (3) Drill pop-rivet fasteners out of door panel or
mirror support frame and separate front or rear
channel from door.
FRONT OR REAR LOWER CHANNEL INSTALLATION
(1) Install lower channel into at design location.
(2) Install pop-rivets using a suitable pop-rivet
gun. (3) Install Glass channel and run weatherstrip.
(4) Install belt moulding and weatherstrip assem-
bly. (5) Install door glass.
(6) Install window opening lower corner seals.
(7) Install door water shield silencer pad and trim
panel.
FRONT DOOR WINDOW REGULATOR/MANUAL
MANUAL WINDOW REGULATOR REMOVAL (FIG. 21)
(1) Remove trim panel, silencer pad, and water
shield.
Fig. 18 Front Door Belt Moulding and Weatherstrip
Fig. 19 Front Door Glass Channel and Run Weatherstrip
23 - 18 AA-BODY Ä

(2) Raise glass to 25 mm (1 in.) from full up posi-
tion. Using suitable tape, secure door glass to upper
window frame. (3) Remove bolts holding window regulator to in-
ner door panel. (4) Slide roller from window lift channel. Rotate
regulator to bring lift arm through access hole first.
(5) Remove regulator assembly from door.
MANUAL WINDOW REGULATOR INSTALLATION
Reverse the preceding operation.
FRONT DOOR WINDOW REGULATOR/POWER
POWER WINDOW REGULATOR REMOVAL(FIG. 22)
(1) Remove trim panel and water shield and con-
nect window switch to wire connector. (2) Raise glass to 25 mm (1 in.) from full up posi-
tion. Using suitable tape, secure door glass to upper
window frame. (3) Disconnect battery negative cable. (4) Remove bolts holding window regulator to in-
ner door panel. (5) Slide roller from window lift channel. Rotate
regulator to bring lift arm through access hole first.
(6) Remove regulator assembly from door.
POWER WINDOW REGULATOR INSTALLATION
Reverse the preceding operation.
FRONT POWER DOOR LOCK ACTUATOR
REMOVAL (FIG. 23)
(1) Remove trim panel, silencer pad, and water
shield. (2) Disconnect link rod from door latch.
(3) Remove bolts holding power door lock actuator
to inner door panel and separate actuator from door.
INSTALLATION
Reverse the preceding operation.
Fig. 20 Front Door Lower Channels
Fig. 21 Front Door Window RegulatorÐManual
Fig. 22 Front Door Window RegulatorÐPower
Fig. 23 Front Power Door Lock Actuator
Ä AA-BODY 23 - 19

REAR DOOR TRIM PANEL
DOOR TRIM PANEL WITH POWER WINDOWS REMOVAL (FIG. 24)
(1) Move glass to down position.
(2) Disconnect battery negative cable.
(3) Remove screw holding latch release handle be-
zel to door. Slide bezel forward and separate from
door trim. (4) Remove ash tray. Remove screw holding trim
panel to door from ash tray opening. (5) Pry power window switch from retainer in door
trim and disconnect wire connector. (6) 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.
DOOR TRIM PANEL WITH POWER WINDOWS INSTALLATION
Reverse the preceding operation.
DOOR TRIM PANEL WITH MANUAL WINDOWSREMOVAL (FIG. 25)
(1) Move glass to down position.
(2) Remove screw holding latch release handle be-
zel to door. Slide bezel forward and separate from
door trim. (3) Remove ash tray. Remove screw holding trim
panel to door from ash tray opening. (4) Pry window crank cap from crank. Remove
screw holding crane to regulator and separate from
door (6) 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.
DOOR TRIM PANEL WITH MANUAL WINDOWS INSTALLATION
Reverse the preceding operation.
REAR DOOR SILENCER AND WATER SHIELD
REMOVAL (FIG. 26)
(1) Remove door trim panel.
(2) Remove push-in fasteners holding silencer pad
to door inner panel and separate silencer from door. (3) Pull water shield from adhesive around perim-
eter of door inner panel.
INSTALLATION
Reverse the preceding operation.
REAR DOOR AND HINGE
The rear door hinge is welded to the door and
bolted to the B-pillar. The door half of the hinge piv-
ots on a removable hinge pin. The hinge pin is
driven in from the bottom on the top hinge and from
the top on the bottom hinge. All adjustments to the
hinge are performed on the hinge pillar half of the
Fig. 24 Rear Door Trim Panel with Power Windows
Fig. 25 Rear Door Trim Panel with Manual Window
Fig. 26 Rear Door Silencer and Water Shield
23 - 20 AA-BODY Ä

hinge. If the welded half of the hinge must be bent to
align door, consult an authorized body repair facility.
REAR DOOR REMOVAL (FIG. 27)
(1) Remove B-pillar trim panel and disconnect all
wire connectors leading to door. Push wire harness
through access hole in B-pillar into hinge opening. (2) Support door on a suitable lifting device.
(3) Drive bottom hinge pin upward and remove pin
from hinge. (4) Drive top hinge pin downward and remove pin
from hinge. (5) Separate door from vehicle.
REAR DOOR INSTALLATION
Reverse the preceding operation. The door should
not require re-alignment. If door does need align-
ment, refer to Rear Door Hinge Installation para-
graph in this section.
REAR DOOR HINGE REMOVAL (FIG. 27)
(1) To remove upper hinge bolted half, remove
B-pillar trim panel. To remove lower hinge bolted
half it is not necessary to remove B-pillar trim. (2) Support rear door on a suitable lifting device.
(3) Drive out hinge pin on the effected hinge.
(4) Remove bolts holding hinge to B-pillar and sep-
arate hinge form vehicle.
REAR DOOR HINGE INSTALLATION
Reverse the preceding operation. Align door to
achieve 6 mm (0.240 in.) gap to all surrounding pan-
els and flush across gaps.
OUTSIDE REAR DOOR LATCH RELEASE HANDLE
REMOVAL (FIG. 28)
(1) Remove door trim panel, silencer pad, and wa-
ter shield. (2) Raise door glass to full up position.
(3) Remove rear door speaker, if equipped. (4) Disconnect latch release rod from door latch as-
sembly. (5) Remove nuts holding outside door latch handle
to retainer bracket and separate bracket from door. (6) Separate latch handle from door panel.
INSTALLATION
Reverse the preceding operation.
REAR DOOR LATCH
REMOVAL (FIG. 29)
(1) Remove door trim panel, silencer pad and wa-
ter shield. (2) Raise door glass to full up position.
(3) Remove door speaker, if equipped.
(4) Disconnect all actuator rods from door latch as-
sembly. (5) Remove screws holding door latch assembly to
inner door rear panel and separate from door.
INSTALLATION
Reverse the preceding operation.
Fig. 27 Rear Door Assembly
Fig. 28 Outside Rear Door Latch Release Handle
Fig. 29 Rear Door Latch Assembly
Ä AA-BODY 23 - 21

REAR POWER DOOR LOCK ACTUATOR
REMOVAL (FIG. 30)
(1) Remove door trim panel, silencer pad, and wa-
ter shield. (2) Raise door glass to full up position.
(3) Remove door speaker, if equipped.
(4) Disconnect actuator rod from door latch assem-
bly. (5) Remove screws holding power lock actuator to
inner door panel and separate from door.
INSTALLATION
Reverse the preceding operation.
REAR DOOR GLASS
REMOVAL (FIG. 31)
(1) Remove door trim panel, silencer pad, and wa-
ter shield. (2) Position door glass half way up in door glass
opening. (3) Pull upward firmly at the front upper corner of
glass to disengage lower glass guide from run chan-
nel. (4) Insert door glass removal tool C-4867 between
the glass slide and division run channel retaining lip
at approximately 50 mm (2 in.) down from top rear-
ward corner of glass. Push handle of tool toward
glass to open channel. Pull forward on the glass to
separate the slide from the channel. (5) Position glass inboard of the division channel.
Pivot top of glass rearward between division channel
and inner door panel. (6) Separate regulator lift arm roller from glass lift
channel. Hold regulator lift arm outward and lift
glass upward. (7) Remove door glass through opening at top of
door.
INSTALLATION
(1) Lower door glass into opening at top of door.
(2) Insert window regulator lift arm roller into
glass lift channel. (3) Push top of glass rearward to snap top slide
into division run channel. (4) Push downward at front of glass to snap bottom
slide into channel. (5) Install water shield, silencer pad and trim
panel.
REAR DOOR BELT MOULDING AND
WEATHERSTRIP
BELT MOULDING AND WEATHERSTRIP
REMOVAL (FIG. 32)
(1) Remove trim panel, silencer pad, and water
shield. (2) Remove door glass.
(3) Remove screws holding belt moulding and
weatherstrip to outer door panel and separate moul-
ding from door.
BELT MOULDING AND WEATHERSTRIP INSTALLATION
Reverse the preceding operation.
REAR DOOR GLASS RUN WEATHERSTRIP
REMOVAL (FIG. 33)
(1) Remove door belt moulding and weatherstrip
assembly. (2) Pull door glass run weatherstrip from forward
lower channel and upper door frame back to division
channel.
Fig. 30 Rear Power Lock Actuator
Fig. 31 Rear Door Glass
23 - 22 AA-BODY Ä

(3) Separate glass run weatherstrip from door.
INSTALLATION
(1) Insert glass run weatherstrip into top of glass
opening upper channel. Align molded corner of
weatherstrip to upper front corner of glass opening. (2) Push weatherstrip into upper rear corner of
door frame above division channel. (3) Install door belt moulding and weatherstrip as-
sembly.
REAR DOOR GLASS STATIONARY GLASS MODULE
STATIONARY GLASS MODULE REMOVAL (FIG. 34)
(1) Remove belt moulding and weatherstrip assem-
bly. (2) Remove upper window opening moulding.
(3) Remove bolts and screws holding division chan-
nel and glass module to door assembly and separate
module from door frame. (4) Remove module through opening at top of door.
STATIONARY GLASS MODULE INSTALLATION
Reverse the preceding operation. Use two sided ad-
hesive tape to secure module weatherstrip to inside
of door frame.
REAR DOOR WINDOW REGULATOR/MANUAL
MANUAL WINDOW REGULATOR REMOVAL (FIG. 35)
(1) Remove trim panel, silencer pad, and water
shield. (2) Position door glass 150 mm (6 in.) up into glass
opening. Pull upward firmly at front edge of glass to
disengage lower glass run guide from division chan-
nel. (3) Remove bolts holding window regulator to in-
ner door panel. (4) Slide roller from window lift channel.
(5) By hand, pull glass upward to 25 mm (1 in.)
from full up position. Using suitable tape, secure
door glass to upper window frame. (6) Remove regulator assembly from door.
MANUAL WINDOW REGULATORINSTALLATION
Reverse the preceding operation.
REAR DOOR WINDOW REGULATOR/POWER
POWER WINDOW REGULATOR REMOVAL(FIG. 36)
(1) Remove trim panel, silencer pad, and water
shield.
Fig. 32 Rear Door Belt Moulding and Weatherstrip
Fig. 33 Rear Door Glass Run Weatherstrip
Fig. 34 Rear Door Stationary Glass Module
Ä AA-BODY 23 - 23

(2) Position door glass 150 mm (6 in.) up into glass
opening. Firmly pull upward at front edge of glass to
disengage lower glass run guide from division chan-
nel. (3) Remove bolts holding window regulator to in-
ner door panel. (4) Slide roller from window lift channel.
(5) By hand, pull glass upward to 25 mm (1 in.)
from full up position. Using suitable tape, secure
door glass to upper window frame. (6) Remove regulator assembly from door.
POWER WINDOW REGULATOR INSTALLATION
Reverse the preceding operation.
DOOR OPENING WEATHERSTRIPS
FRONT OR REAR DOOR OPENINGWEATHERSTRIP REMOVAL (FIG. 37)
(1) Remove interior trim as necessary to gain ac-
cess to door opening weatherstrip. (2) Pull weatherstrip from pinch flange around
door opening.
FRONT OR REAR DOOR OPENING
WEATHERSTRIP INSTALLATION
(1) Locate the middle to the weatherstrip at the
center of the upper pinch flange. Push weatherstrip
onto pinch flange at the top corner near the B-pillar. (2) When the weatherstrip has been installed down
the door opening to the sill pinch flange, mate the
ends of the weatherstrip together and finish install-
ing.
BODY SIDE MOULDING AND APPLIQUE
STICK-ON BODY SIDE MOULDING REMOVAL AND INSTALLATION (FIG. 38)
(1) Warm the effected stick-on moulding and body
metal to approximately 38ÉC (100ÉF) using a suitable
heat lamp or heat gun. (2) Pull stick-on moulding from painted surface.
(3) Remove adhesive tape residue from painted
surface of vehicle. (4) If moulding is to be reused, Remove tape resi-
due from moulding. Clean back of moulding with Mo-
par, Super Kleen solvent or equivalent. Wipe
moulding dry with lint free cloth. Apply new body
side moulding (two sided adhesive) tape to back of
moulding. (5) Clean body surface with Mopar, Super Kleen
solvent or equivalent. Wipe surface dry with lint free
cloth. (6) Apply a length of masking tape on the body,
parallel to the top edge of the moulding to use as a
guide, if necessary. (7) Remove protective cover from tape on back of
moulding. Apply moulding to body below the mask-
ing tape guide. (8) Remove masking tape guide and heat body and
moulding, see step one. Firmly press moulding to
body surface to assure adhesion.
Fig. 35 Rear Door Window RegulatorÐManual
Fig. 36 Rear Door Window RegulatorÐPower
Fig. 37 Door Opening Weatherstrips
23 - 24 AA-BODY Ä