CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

(4) Separate wheelhouse splash shield from vehi-
cle.
INSTALLATION
Reverse the preceding operation.
TRANSAXLE SPLASH SHIELD REMOVAL (FIG. 9)
(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. 10)
(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 SHIELD
INSTALLATION
Reverse the preceding operation.
FRONT FENDER
REMOVAL (FIG. 11)
(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 side applique as necessary to clear
front fender. Refer to Body Side Applique Removal
paragraph in this section. (5) Remove bolts holding bottom of front fender at
rear of wheel opening. (6) Remove bolt holding front fender to hinge pil-
lar at rear of wheelhouse. (7) Remove bolt holding front fender to cowl at top
of front door opening. (8) Remove bolts holding front fender to underside
of 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
Fig. 8 Cowl Cover Assembly
Fig. 9 Front Wheelhouse and Transaxle Splash
ShieldsÐTypical
Fig. 10 Engine Drive Belt Splash ShieldÐTypical
Ä AG-BODY 23 - 55

mm (0.240 in) gap to front door edge. All surfaces
across gaps should be flush.
DOOR TRIM PANEL
REMOVAL (FIG. 12)
(1) Lower door glass to down position. Disconnect
battery negative cable, if equipped with power win-
dows. (2) Remove window crank screw cover. Remove
screw holding window crank to regulator and sepa-
rate crank from door, if equipped with manual win-
dows. (3) Remove screw holding inside latch release han-
dle bezel to door. Slide bezel forward and remove
from door panel. Disconnect power door lock switch
wire connector, if equipped. (4) Pull power mirror switch outward to disengage
clips holding switch to door panel. Disconnect mirror
switch wire connector, if equipped. (5) Lift upward at rear edge of power window/seat
switch bezel to disengage clips holding bezel to door
panel. Disconnect wire connectors from power win-
dow and power seat switches, if equipped. (6) Remove screw holding trim panel to door from
inside power window switch bezel opening. (7) Pry outward on reflector lens to disengage
clips. Remove screw holding trim panel to door from
behind reflector. (8) Remove hidden screws holding trim panel to
door from carpet area on trim panel. (9) Disengage push-in fasteners holding trim panel
to door at ends and bottom center of trim panel. (10) Lift trim panel from door.
INSTALLATION
Reverse the preceding operation.
FRONT DOOR SILENCER AND WATER SHIELD
REMOVAL (FIG. 13)
(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.
Fig. 11 Front Fender
Fig. 12 Door Trim Panel
Fig. 13 Front Door Silencer and Water ShieldÐTypical
23 - 56 AG-BODY Ä

FRONT DOOR REMOVAL (FIG. 14)
(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.
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.
DOOR LATCH
REMOVAL
(1) Remove door trim panel.
(2) Remove silencer and water shield, as necessary.
(3) Raise door glass to up position. (4) Disconnect linkage rods from door latch assem-
bly. (5) Remove screws holding latch top door end
frame. (6) Separate latch from door.
INSTALLATION
Reverse the preceding operation.
MANUAL WINDOW REGULATOR
REMOVAL
(1) Remove door trim panel.
(2) Remove silencer and water shield as necessary.
(3) Raise glass to 25 mm (1 in.) below full up posi-
tion and support glass lift plate to keep the glass
from falling. (4) Remove bolts holding regulator to inner door
panel. (5) Slide regulator lift arm roller from lift plate
channel. (6) Remove regulator assembly through access hole
in door.
INSTALLATION
Reverse the preceding operation.
POWER WINDOW REGULATOR
REMOVAL (FIG. 15)
(1) Remove door trim panel.
(2) Remove silencer and water shield as necessary.
(3) Raise glass to 25 mm (1 in.) below full up posi-
tion and support glass to keep the glass from falling.
Disconnect battery negative cable. (4) Remove bolts holding regulator to inner door
panel. (5) Remove nuts holding lift plate to glass.
(6) Remove regulator assembly through access hole
in door.
INSTALLATION
Reverse the preceding operation.
Fig. 14 Front Door Assembly
Fig. 15 Power Window Regulator
Ä AG-BODY 23 - 57

MANUAL WINDOW REGULATOR
REMOVAL (FIG. 16)
(1) Remove door trim panel.
(2) Remove silencer and water shield as necessary.
(3) Raise glass to 25 mm (1 in.) below full up posi-
tion and support glass to keep the glass from falling. (4) Remove bolts holding regulator to inner door
panel. (5) Remove nuts holding lift plate to glass.
(6) Remove regulator assembly through access hole
in door.
INSTALLATION
Reverse the preceding operation.
MANUAL WINDOW LIFT PLATE AND GUIDE
REMOVAL (FIG. 16)
(1) Remove door trim panel, silencer and water
shield. (2) Raise glass enough to align lift plate to large
access hole in inner door panel. (3) Remove nuts holding glass to lift plate.
(4) Separate glass from lift plate and allow glass to
rest on bottom of door. (5) Remove bolt holding guide bar to upper door
frame. (6) Remove bolts holding guide bar top inner door
panel. (7) Slide regulator lift arm roller from lift plate
channel. (8) Remove lift plate and guide bar through large
access hole in inner door panel.
INSTALLATION
Reverse the preceding operation.
DOOR GLASS
REMOVAL (FIG. 17)
(1) Remove door trim panel.
(2) Remove silencer and water shield.
(3) Raise door glass 100 mm (4 in.) from down po-
sition. (4) Disconnect battery negative cable if equipped
with power windows. (5) Loosen bolts holding glass stabilizers and guide
hook receiver to top of inner door frame. (6) Remove nuts holding door glass to lift plate.
(7) Separate glass from lift plate and lift glass up-
ward from opening at top of door.
INSTALLATION
Reverse the preceding operation.
GLASS RUN WEATHERSTRIP
REMOVAL
(1) Remove door trim panel.
(2) Remove silencer and water shield as necessary.
(3) Remove side view mirror cover.
(4) Pull glass run weatherstrip from door frame
channel.
INSTALLATION
Reverse the preceding operation.
OUTSIDE DOOR LATCH RELEASE HANDLE
REMOVAL (FIG. 18)
(1) Remove door trim panel, silencer pad, and wa-
ter 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.
Fig. 16 Manual Window RegulatorFig. 17 Door Glass
23 - 58 AG-BODY Ä

(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.
INSTALLATION
Reverse the preceding operation.
INSIDE LATCH RELEASE HANDLE
REMOVAL
(1) Remove door trim panel.
(2) Remove screw holding handle to inner door
panel. (3) Disconnect linkage rod from back of handle.
(4) Separate handle from door.
INSTALLATION
Reverse the preceding operation.
POWER DOOR LOCK ACTUATOR
REMOVAL (FIG. 19)
(1) Remove door trim panel. Remove silencer and
water shield as necessary. (2) Raise door glass to the up position.
(3) Disconnect battery negative cable.
(4) Disconnect lock actuator linkage rod from door
latch. (5) Remove bolts holding actuator to inner door
panel. (6) Separate power door lock actuator from door.
INSTALLATION
Reverse the preceding operation.
SIDE VIEW MIRROR
REMOVAL (FIG. 20)
(1) Remove door trim panel.
(2) Disconnect power mirror wire connector. (3) Remove covers to gain access to mirror attach-
ing nuts. (4) Remove nuts holding mirror to door frame.
(5) Separate mirror from door frame.
INSTALLATION
Reverse the preceding operation.
DOOR GLASS OPENING MOULDING
REMOVAL
(1) Remove door trim panel.
(2) Remove door glass.
(3) Remove side view mirror.
(4) Disengage clips holding door glass opening
moulding to the door frame (Fig. 21). (5) Remove screws holding door glass opening
moulding and belt weatherstrip to door belt flange
(Fig. 22). (6) Remove the belt weatherstrip.
(7) Remove window opening moulding.
INSTALLATION
Reverse the preceding operation.
Fig. 18 Outside Door Latch Release HandleÐTypical
Fig. 19 Power Door Lock Actuator
Fig. 20 Side View Mirror
Ä AG-BODY 23 - 59

DOOR OPENING WEATHERSTRIPS
REMOVAL
(1) Remove interior trim as necessary to gain ac-
cess to door opening weatherstrip. (2) Pull weatherstrip from pinch flange around
door opening.
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 MOULDINGS
STICK-ON BODY SIDE MOULDING REMOVAL AND INSTALLATION
(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, refer to step one. Firmly press moulding to
body surface to assure adhesion.
BODY SIDE APPLIQUE
REMOVAL (FIG. 23)
DOOR APPLIQUE
(1) Remove rivets holding bottom or door applique
to door pinch flange usin ga3mm(0.125 in.) drill.
(2) Lift door applique upward to disengage appli-
que from retainer channel. (3) Separate applique from door.
SILL APPLIQUE (1) Remove push-in fasteners holding sill applique
to bottom of rocker panel. (2) Remove push-in fasteners holding sill applique
to front and rear wheel lip openings. (3) Lift sill applique upward to disengage applique
from retainer channels. (4) Separate sill applique from vehicle.
INSTALLATION
Prime and touch-up bare metal surfaces before in-
stalling applique to avoid corrosion. Reverse the re-
moval operation.
Fig. 21 Window Opening Moulding
Fig. 22 Outer Belt Weatherstrip
Fig. 23 Body Side Applique
23 - 60 AG-BODY Ä

DOOR OPENING SCUFF PLATES
REMOVAL (FIG. 24)
(1) Open front door.
(2) Remove screws holding scuff plate to door sill.
(3) Separate scuff plate from vehicle.
INSTALLATION
Reverse the preceding operation.
A-PILLAR AND ROOF RAIL MOULDINGS
A-PILLAR MOULDING REMOVAL (FIG. 24)
(1) Open front door.
(2) Remove push-in fasteners holding A-pillar
moulding to roof rail above door opening. (3) Remove trim plug and screw holding A-pillar
molding to A-pillar (4) Slide A-pillar moulding upward and pull rear-
ward to separate moulding from A-pillar.
A-PILLAR MOULDING INSTALLATION
Reverse the preceding operation.
LOWER QUARTER TRIM PANEL
REMOVAL (FIG. 24)
(1) Remove tail panel trim cover and security
shade, if equipped (2) Remove rear seat cushion and backs.
(3) Remove seat back latch striker bezel.
(4) Remove screw covers. Remove screws holding
lower quarter trim panel to quarter. (5) Pull rearward end of trim panel away from
quarter panel and push trim forward to clear door
opening flange. (6) Separate lower quarter trim panel from vehicle.
INSTALLATION
Reverse the preceding operation.
UPPER QUARTER TRIM PANEL
REMOVAL (FIG. 24)
(1) Remove lower quarter trim panel.
(2) Remove rear seat shoulder harness turning
loop cover. (3) Remove bolt holding belt turning loop to C-pil-
lar. (4) Remove bolt holding front seat belt to floor at
door sill. (5) Remove screw holding coat hook to roof rail.
(6) Remove roof rail moulding as necessary to clear
quarter panel removal path. (7) Remove push-in fastener holding upper quarter
trim to roof rail. (8) Remove screw covers from trim panel to gain
access to screws. (9) Remove screws holding upper quarter trim to
quarter panel. (10) Raise and support lift gate in the up position.
Disconnect bottom of lift cylinder. (11) Swing rear of trim panel away from quarter
panel and pull trim forward to clear door opening
flange. (12) Separate upper quarter trim panel from vehi-
cle.
INSTALLATION
Reverse the preceding operation.
LOWER TAIL PANEL TRIM COVER
REMOVAL (FIG. 24)
(1) Raise lift gate to the up position.
(2) Remove hidden screws holding tail panel trim
cover to tail panel from carpeted area. (3) Remove push-in fasteners holding top tail panel
trim to opening sill. (4) Lift up floor cover and position cover out of the
way. (5) Separate cover from vehicle.
INSTALLATION
Reverse the preceding operation.
LIFT GATE TRIM
REMOVAL (FIG. 25)
(1) Raise the lift to the up position.
(2) Disengage clips holding side moldings to lift
gate. Separate moldings from lift gate. (3) Remove expanding push-in fasteners holding
upper trim panel to lift gate. (4) Remove screw plugs and screws holding upper
trim panel to lift gate. Separate upper trim panel
from lift gate. (5) Remove screw plug and screw holding lower
trim panel to rear window wiper motor, if equipped. (6) Remove screws holding lower trim panel to lift
gate. Separate lower trim panel from lift gate.
INSTALLATION
Reverse the preceding operation.
FRONT SEAT BELTS
OUTBOARD SHOULDER HARNESS/LAP BELT REMOVAL (FIG. 26)
(1) Adjust front seat to the forward position.
(2) Remove bolt holding outboard lap belt anchor
to floor below door sill. (3) Remove lower and upper quarter trim panels as
necessary to gain access to shoulder harness turning
loop and retractor. (4) Remove bolt holding shoulder turning loop to
B-pillar.
Ä AG-BODY 23 - 61

(5) Remove bolt holding belt retractor to quarter
panel. (6) Separate belt from vehicle.
OUTBOARD SHOULDER HARNESS/LAP BELTINSTALLATION
Reverse the preceding operation.
INBOARD BUCKLE REMOVAL (FIG. 26)
(1) Remove bolt holding inboard buckle to floor. (2) Disconnect seat belt sensor wire connector, if
equipped. (3) Separate buckle assembly from vehicle.
INBOARD BUCKLE INSTALLATION
Reverse the preceding operation.
REAR SEAT BELTS
REAR OUTBOARD SHOULDER HARNESS/LAPBELT REMOVAL (FIG. 27)
(1) Remove lower and upper quarter trim panel.
(2) Remove bolt holding lap belt anchor to floor at
wheelhouse kickup. (3) Remove bolt holding seat belt retractor to quar-
ter panel.
REAR OUTBOARD SHOULDER HARNESS/LAP BELT INSTALLATION
Reverse the preceding operation.
REAR INBOARD BUCKLE REMOVAL (FIG. 27)
(1) Lift seat belt buckle anchor cover to expose
bolt. (2) Remove bolt holding inboard buckle/center oc-
cupant belt to seat frame. (3) Separate buckle from vehicle.
Fig. 24 Interior Mouldings, Panels, and Trim Covers
Fig. 25 Lift Gate Trim
23 - 62 AG-BODY Ä

REAR INBOARD BUCKLE INSTALLATION
Reverse the preceding operation.
FRONT SEATS
REMOVAL (FIG. 28 OR 29)
(1) Position seat full forward.
(2) Remove screws holding rear track riser covers
and separate covers from tracks. (3) On power seat track, remove outboard track
cover. (4) Remove nuts holding seat track to floor.
(5) Position seat full rearward.
(6) On power seat track, remove door sill scuff
plate and disconnect wire connector. (7) Remove bolts holding seat track to cross mem-
ber. (8) Remove seat from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR SEATS
REMOVAL (FIG. 30)
(1) Hinge seat backs forward.
(2) Remove bolts holding rear seat frame to floor
on sides of center floor hump near luggage compart-
ment kick-up. (3) Pull seat forward to disengage retaining hooks
from floor. (4) Separate seat from vehicle.
Fig. 26 Front Seat BeltsÐTypical
Fig. 27 Rear Seat Belts
Fig. 28 Manual Front Seat
Fig. 29 Power Front Seat
Ä AG-BODY 23 - 63

INSTALLATION
Reverse the preceding operation.
FRONT CENTER CONSOLE
REMOVAL (FIG. 31)
(1) Position front seats full forward.
(2) Remove rear ash tray.
(3) Remove rear lower carpeted end cover.
(4) Remove nuts holding console to floor bracket.
(5) Position front seats full rearward.
(6) Raise console storage bin cover and remove bot-
tom mat. (7) Remove screws holding bottom of storage bin to
floor bracket. (8) Remove screws holding console side panels to
instrument panel. Disengage hook and loop fasteners
and separate side panels from console. (9) Disconnect shift indicator cable and clips from
shift mechanism through right side panel opening, if
equipped with automatic transaxle. Refer to Group
8E, Instrument Panel and Gauges for proper proce-
dures. (10) Disengage clips holding parking brake lever
cover to console and separate cover from vehicle. (11) Remove center instrument panel bezel. Refer
to Group 8E, Instrument Panel. Remove screws hold-
ing console to instrument panel. (12) Remove screws holding console to lower in-
strument panel. (13) Remove bolts holding console to forward floor
mounting bracket. (14) Remove gear selector knob.
(15) Separate console from floor and remove from
vehicle.
INSTALLATION
Reverse the preceding operation.
FLOOR CARPET
REMOVAL (FIG. 32)
(1) Remove cowl trim panels and scuff plates.
(2) Remove front seats and inboard seat belts.
(3) Remove center arm rest and front console.
(4) Remove inboard and outboard seat belt lower
attaching bolts. (5) Remove left dash panel foot rest.
(6) Remove rear seat.
(7) Pull carpet from under quarter trim covers.
(8) Fold carpet and remove through door opening.
INSTALLATION
Reverse the preceding operation.
Fig. 30 Rear Seat Cushion and Back
Fig. 31 Center Console
Fig. 32 Floor Carpet and SilencersÐTypical
23 - 64 AG-BODY Ä