CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

OVERHEAD CONSOLE
REMOVAL (FIG. 33)
(1) Remove screws holding overhead console to re-
inforcement bracket. (2) Slide overhead console rearward to separate re-
inforcement bracket retainer tab from console. (3) Lower console from roof and disconnect wire
connectors.
INSTALLATION
Reverse The preceding operation.
HEAD LINING
REMOVAL
(1) Disconnect battery negative cable.
(2) Pull dome lamp downward to disengage from
retaining ring in head lining. Separate lens from
lamp body and remove bulb. Separate bulb holder
from lamp body. Remove attaching screw holding re-
taining ring to roof bow, if equipped. (3) Remove screws holding coat hooks to roof above
quarter panels. (4) Remove roof rail and A-pillar mouldings.
(5) Remove screws holding sun visors to roof
header and disconnect wire connector, if equipped.
Remove inboard sun visor hangers. (6) Remove overhead console, if equipped.
(7) Pull front reading lamp downward to disengage
from retaining ring in head lining and disconnect
wire connector. Remove screws holding retaining
ring to roof header, if equipped. (8) Remove pinch welt holding headlining to sun
roof opening, if equipped. (9) Remove screws holding lift gate opening header
moulding to rear roof header. Separate moulding
from header. (10) Remove one quarter trim panel as necessary
to clear head lining removal path. (11) Remove head lining from vehicle.
INSTALLATION
Reverse the preceding operation.
SUNROOF LIFT CONTROL
REMOVAL (FIG. 34)
(1) Remove sunroof glass panel. Refer to Owners
manual for proper procedures. (2) Remove pinch welt holding head lining to edge
of sunroof opening. (3) Remove trim ring from tilt control handle.
(4) Remove screws holding tilt control handle to
tilt control. Separate handle from control. (5) Remove nuts holding lift control to roof panel.
Separate lift control from roof.
INSTALLATION
Reverse the preceding operation.
REAR WINDOW GLASS
The rear window moulding often cannot be sal-
vaged after removal operation is completed. Verify
moulding availability from the parts supplier before
removing moulding.
REMOVAL (FIG. 35)
(1) Remove rear window moulding.
(2) Remove lift gate trim as necessary to gain ac-
cess to rear window defogger wire connector and
ground screw, if equipped.
WARNING: WEAR EYE AND HAND PROTECTION
WHEN HANDLING SAFETY GLASS. PERSONAL IN-
JURY CAN RESULT.
CAUTION: Do not damage body or trim finish when
cutting out glass or applying fence primer.
(3) Cut the urethane around the perimeter of the
back window glass. Refer to Windshield section of
this group for proper procedures. (4) Separate the rear window from the vehicle.
INSTALLATION
(1) Prepare the work area, window fence, and glass
the same way as described in the Windshield section
of this group. (2) Place the fence spacers at the locations shown
(Fig. 35). (3) Apply a 10 mm (0.4 in.) bead of urethane
around the perimeter of the glass. (4) Install the glass in the same manner described
in the Windshield section of this group. (5) Install the rear window moulding. Apply 50
mm (2 in.) masking tape over moulding to assure
alignment. (6) Connect rear window defogger wiring and in-
stall lift gate trim.
Fig. 33 Overhead ConsoleÐTypical
Ä AG-BODY 23 - 65

(7) After urethane has cured remove masking tape
and water test to verify repair. Verify rear window
defogger operation, refer to Group 8N, Rear Window
Defogger.QUARTER GLASS MODULE
REMOVAL (FIG. 36)
(1) Remove quarter trim panel as necessary to
gain access to quarter glass module. (2) Remove nuts holding quarter glass module to
quarter glass opening. (3) Cut urethane bonding around perimeter of
quarter glass opening fence. (4) Push quarter glass module from quarter glass
opening. (5) Separate module from vehicle.
INSTALLATION
(1) Clean hardened urethane from quarter glass
opening fence and glass module, if module replace-
ment is not required. (2) Prepare fence and module using method de-
scribed in the Windshield section of this group. (3) Reverse the removal operation.
ROOF SEAM MOLDING
REMOVAL (FIG. 37)
(1) Remove upper quarter trim panel.
(2) Remove head lining as necessary to gain access
to inside roof panel. (3) Remove seal nut holding seam molding to roof
panel.
Fig. 34 Sunroof
Fig. 35 Lift Gate Window Glass
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(4) Separate molding from roof panel.
INSTALLATION
Reverse the preceding operation.
QUARTER PANEL SPOILER
REMOVAL (FIG. 38)
(1) Remove access cover from lift gate opening end
of quarter panel spoiler. (2) Remove bolt holding spoiler to tail lamp closure
panel. (3) Remove quarter trim panel.
(4) Remove nuts holding spoiler to quarter panel
from behind quarter panel above rear wheelhouse
(Fig. 38). (5) Separate spoiler from vehicle.
INSTALLATION
Reverse the preceding operation.
LIFT GATE SPOILER
REMOVAL (FIG. 39)
(1) Raise lift gate to the up position.
(2) Remove nuts holding spoiler to outboard pinch
flanges of lift gate. (3) Separate spoiler from lift gate.
INSTALLATION
Reverse the preceding operation.
LIFT GATE PROP CYLINDER
REMOVAL (FIG. 40)
(1) raise lift gate to the full open position.
(2) Support lift gate on a suitable lifting device.
(3) Remove bolt holding bottom of lift gate prop
cylinder to c-pillar. (4) Remove bolt holding top of lift gate prop cylin-
der to lift gate. (5) Separate prop cylinder from vehicle.
INSTALLATION
Reverse the preceding operation.
LIFT GATE
REMOVAL (FIG. 41)
(1) Raise lift gate to the full open position.
(2) Remove rear roof header molding.
Fig. 36 Quarter Glass Module
Fig. 37 Roof Seam Molding
Fig. 38 Quarter Panel Spoiler
Fig. 39 Lift Gate Spoiler
Ä AG-BODY 23 - 67

(3) Disconnect lift gate wire connectors and rear
window washer hose, if equipped. (4) Remove upper lift gate trim molding.
(5) Support lift gate on a suitable lifting device.
(6) Disconnect top of prop cylinders from lift gate.
(7) Mark lift gate hinge locations to assist instal-
lation an alignment of lift gate. (8) With assistance of a helper, remove bolts hold-
ing lift gate to hinge. (9) Separate lift gate from vehicle.
INSTALLATION
Reverse the preceding operation.
LIFT GATE LATCH AND STRIKER
LIFT GATE LATCH REMOVAL (FIG. 42)
(1) Raise lift gate to the full open position.
(2) Remove luggage compartment tail trim panel.
(3) Disconnect lock linkage rod from lift gate latch
arm. (4) Remove nuts holding lift gate latch to tail
panel. (5) Separate latch from tail panel and disconnect
lift gate remote release cable.
LIFT GATE LATCH INSTALLATION
LIFT GATE STRIKER REMOVAL (FIG. 42)
(1) Raise lift gate to the full open position.
(2) Remove lower lift gate trim panel.
(3) Mark lift gate striker location to assist instal-
lation. (4) Remove bolts holding lift gate striker to lift
gate. (5) Separate striker from lift gate.
LIFT GATE STRIKER INSTALLATION
Reverse the preceding operation.
LIFT GATE LOCK CYLINDER
REMOVAL (FIG. 43)
(1) Raise lift gate to the full open position.
(2) Remove luggage compartment tail trim panel.
(3) Disconnect linkage return spring (Fig. 42).
(4) Disconnect linkage rod from lift gate lock arm.
(5) Remove bolts holding lift gate lock to tail
panel. (6) Separate lock from tail panel.
INSTALLATION
Reverse the preceding operation.
FUEL FILL DOOR
REMOVAL (FIG. 44)
(1) Remove right lower quarter trim panel.
(2) Open fuel fill door.
(3) Remove nuts holding fuel fill door to quarter
panel from in luggage compartment. (4) Separate fuel fill door from vehicle.
INSTALLATION
Reverse the preceding operation
Fig. 40 Lift Gate Prop Cylinder
Fig. 41 Lift Gate
Fig. 42 Lift Gate Latch and Striker
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LIFT GATE AND FUEL FILL DOOR RELEASE
CABLES
LIFT GATE AND FUEL FILL DOOR CABLES
REMOVAL (FIG. 45)
(1) Remove interior trim as necessary to gain ac-
cess to release cables. (2) Remove left front door opening scuff plate.
(3) Remove screw holding trim cover to release ca-
ble handle and separate cover from handle. (4) Remove screw holding release handle to door
sill. (5) Pry open retainer tab holding cable core end in
handle pivot. Pry cable case end from handle. (6) On fuel fill door cable, remove nut holding ca-
ble latch to fuel fill opening. (7) On lift gate latch, remove lift gate latch cover
and disconnect cable end from latch. Route cable
back through trunk lid.
LIFT GATE AND FUEL FILL DOOR CABLES INSTALLATION
Reverse the preceding operation.
TAIL LAMP CLOSURE PANEL
REMOVAL
(1) Remove lift gate opening scuff plate.
(2) Remove lift gate opening sill cover.
(3) Remove luggage compartment tail panel trim.
(4) Remove lower quarter trim panels.
Fig. 45 Lift Gate and Fuel Fill Door Release Cables
Fig. 43 Lift Gate Lock CylinderFig. 44 Fuel Fill Door
Ä AG-BODY 23 - 69

(5) Remove bolt holding quarter panel spoiler to
tail lamp closure panel, if equipped. (6) Remove tail lamps and license plate lamps, re-
fer to Group 8L, Lamps for proper procedures. (7) Remove nuts holding tail lamp closure panel to
tail panel. (8) Remove nuts holding tail lamp closure panel to
quarter panel ends. (9) Separate tail lamp closure panel from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 46 Tail Lamp Closure Panel
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AJ-VEHICLE BODY COMPONENT SERVICE INDEX
page page
A-Pillar and Roof Rail Mouldings ............. 77
Cowl Cover ............................. 73
Cowl Panel Trim and Scuff Plates ............ 77
Door Glass ............................. 76
Door Glass Lift Plate and Guide Post ......... 76
Door Latch ............................. 75
Door Trim Panel ......................... 74
Floor Carpet ............................ 80
Front Center Console ..................... 79
Front Door and Hinge ..................... 75
Front Door Silencer and Water Shield ......... 74
Front End Splash Shields .................. 73
Front Seat Belts ......................... 78
Front Seats ............................. 78
Fuel Fill Door ........................... 84
Glass Run WeatherstripÐAJ-21 Body ......... 76
Grille .................................. 71
Grille Header Molding ..................... 71
Grille Opening Panel ...................... 71
Head Lining ............................. 81
Hood and Hinges ........................ 72
Hood Latch and Release Cable .............. 72
Inside Latch Release Handle ................ 76 Lower Grille
............................. 71
Outside Door Latch Release Handle .......... 76
Overhead Console ........................ 80
Power Door Lock Actuator .................. 76
Quarter Extension Trim Panel ............... 77
Quarter Glass Module ..................... 85
Quarter Trim Panel ....................... 77
Rear Seat Belts .......................... 78
Rear Seats ............................. 79
Rear Shelf Trim Panel ..................... 78
Rear Window Glass ...................... 81
Sun Roof Air Deflector .................... 81
Sun Roof Drain Tubes .................... 81
Sun Roof Weatherstrip .................... 81
Trunk Lid .............................. 82
Trunk Lid and Fuel Fill Door Release Cables . . . 83
Trunk Lid Hinge ......................... 82
Trunk Lid Latch .......................... 83
Trunk Lid Lock .......................... 83
Trunk Lid Luggage Rack ................... 83
Trunk Lid Torsion Bar ..................... 83
Trunk Opening Weatherstrip ................ 83
Window Regulator ........................ 75
GRILLE
REMOVAL (FIG. 1)
(1) Remove screws holding grille to header mold-
ing at top of grille. (2) Push downward on top of bumper fascia to gain
clearance for grille removal. (3) Push grille downward and pull outward.
(4) Separate grille from vehicle.
INSTALLATION
Reverse the preceding operation.
GRILLE HEADER MOLDING
REMOVAL (FIG. 1)
(1) Remove grille.
(2) Remove nuts holding header molding to grille
opening panel. (3) Separate header molding from vehicle.
INSTALLATION
Reverse the preceding operation.
LOWER GRILLE
REMOVAL (FIG. 1)
(1) Remove screws holding lower grille to fascia.
(2) Separate lower grille from vehicle.
INSTALLATION
Reverse the preceding operation.
GRILLE OPENING PANEL
REMOVAL (FIG. 2)
(1) Remove front bumper and fascia.
(2) Remove grille.
(3) Remove headlamp modules.
(4) Remove bolt holding grille opening panel to
bracket forward of radiator. (5) Raise hood and remove push-in fasteners hold-
ing sight shields to closure panel. Separate sight
shields from vehicle.
Fig. 1 Grille Assembly
Ä AJ-BODY 23 - 71

(6) Remove nuts holding grille opening panel to
front fenders. (7) Remove bolts holding grille opening panel to
front fenders. (8) Separate grille opening panel form vehicle.
INSTALLATION
Reverse the preceding operation. Align grille open-
ing panel to fit flush across fender joining locations.
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. (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 to 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
(1) Raise hood to the full up position.
(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.
Fig. 2 Grille Opening Panel
Fig. 2 Hood Assembly Remove or InstallÐTypical
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(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. 5)
(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. 6)
(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.
Fig. 3 Hood Hinge AssemblyÐTypical
Fig. 4 Hood Latch AssemblyÐTypical
Fig. 5 Cowl Cover Assembly
Ä AJ-BODY 23 - 73

TRANSAXLE SPLASH SHIELD REMOVAL (FIG. 6)
(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. 7)
(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.
DOOR TRIM PANEL
REMOVAL (FIG. 8)
(1) Lower door glass and disconnect battery nega-
tive cable. (2) Remove courtesy lamp and remove socket.
(3) Remove screw holding trim panel to door from
courtesy lamp opening. (4) Disengage clips holding speaker grille to trim
panel and separate grille from door. (5) Remove screw holding trim panel to door from
speaker grille opening. (6) Remove screw holding inside latch handle bezel
to trim panel and separate bezel from door. Discon-
nect power door lock switch wire connector, if
equipped. (7) Remove window crank, if equipped.
(8) Remove screw holding trim panel to door from
arm rest pull cup opening. (9) Remove hidden screws holding trim panel to
door from carpet area at bottom of trim. (10) Lift trim panel upward and separate panel
from door. (11) Disconnect radio speaker, power window and
power mirror wire connectors, if equipped.
INSTALLATION
Reverse the preceding operation.
FRONT DOOR SILENCER AND WATER SHIELD
REMOVAL (FIG. 9)
(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.
Fig. 6 Front Wheelhouse and Transaxle Splash ShieldsÐTypical
Fig. 7 Engine Drive Belt Splash ShieldÐTypical
Fig. 8 Door Trim Panel
23 - 74 AJ-BODY Ä