CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

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. 10)
(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. 10)
(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.
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) Disconnect power window motor wire connec-
tor, if equipped. (5) Remove rivets holding regulator to inner door
panel usin ga6mm (0.250 in) drill.
(6) Slide regulator lift arm roller from lift plate
channel. (7) Remove regulator assembly through access hole
in door.
INSTALLATION
Reverse the preceding operation.
Fig. 9 Front Door Silencer and Water ShieldÐTypicalFig. 10 Front Door Assembly
Ä AJ-BODY 23 - 75

DOOR GLASS
REMOVAL
(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.
DOOR GLASS LIFT PLATE AND GUIDE POST
REMOVAL
(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) Remove nuts holding door glass to lift plate
and separate glass from lift plate. Allow glass to
slide downward to the bottom of door. (6) Remove bolts (nuts on AJ-27 body) holding
guide post to inner door panel. (7) Separate lift plate channel from regulator lift
roller. (8) Remove lift plate and guide assemble from door
through access hole in inner door panel.
INSTALLATION
Reverse the preceding operation.
GLASS RUN WEATHERSTRIPÐAJ-21 BODY
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. 11)
(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. (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
(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.
Fig. 11 Outside Door Latch Release HandleÐTypical
23 - 76 AJ-BODY Ä

INSTALLATION
Reverse the preceding operation.
COWL PANEL TRIM AND SCUFF PLATES
COWL PANEL AND DOOR OPENING SCUFF PLATE REMOVAL (FIG. 12)
(1) Open front door.
(2) Remove screw holding trim panel to cowl for-
ward of the front door opening. (3) Remove screws holding scuff plate to door sill.
(4) Separate cowl panel trim and scuff plate from
vehicle.
COWL PANEL AND DOOR OPENING SCUFF PLATE INSTALLATION
Reverse the preceding operation.
A-PILLAR AND ROOF RAIL MOULDINGS
A-PILLAR MOULDING REMOVAL (FIG. 12)
(1) Open front door.
(2) Disengage clips holding A-pillar moulding to
roof rail above door opening. (3) Slide A-pillar moulding upward and pull rear-
ward to separate moulding from A-pillar.
A-PILLAR MOULDING INSTALLATION
Reverse the preceding operation.
QUARTER TRIM PANEL
QUARTER TRIM PANEL REMOVAL (FIG. 12)
(1) Remove A-pillar moulding and scuff plate as
necessary. (2) Remove front shoulder harness turning loop
cover. Remove bolt holding turning loop to quarter
panel. (3) Remove bolt holding rear shoulder harness an-
chor to floor. (4) Remove rear seat cushion and back.
(5) Remove screw holding quarter trim to roof rail.
(6) Remove quarter trim extension panel. Remove
screws holding quarter trim panel to wheelhouse
kickup. (7) Remove rear reading lamp. Remove screw hold-
ing quarter trim to roof from lamp opening. (8) Pull trim panel forward and separate from ve-
hicle.
QUARTER TRIM PANEL INSTALLATION
Reverse the preceding operation.
QUARTER EXTENSION TRIM PANEL
REMOVAL (FIG. 13)
(1) Remove quarter trim panel.
Fig. 12 Interior Mouldings, Panels, and Trim Covers
Ä AJ-BODY 23 - 77

(2) Disengage clips holding expansion trim panel
to shelf panel. (3) Separate trim panel from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR SHELF TRIM PANEL
REMOVAL (FIG. 13)
(1) Remove one quarter trim panel.
(2) Remove center high mounted stop lamp cover.
Refer to Group 8L, Lamps for instructions. (3) Disengage screws holding trim to shelf panel
and separate trim from vehicle.
INSTALLATION
Reverse the preceding operation.
FRONT SEAT BELTS
OUTBOARD SHOULDER HARNESS/LAP BELT REMOVAL (FIG. 14)
(1) Remove quarter trim panel.
(2) Remove bolt holding seat belt retractor to quar-
ter panel. (3) Separate retractor from vehicle.
OUTBOARD SHOULDER HARNESS/LAP BELTINSTALLATION
Reverse the preceding operation.
INBOARD SEAT BELT BUCKLE REMOVAL(FIG. 14)
(1) Remove bolt holding inboard buckle to floor.
(2) Disconnect seat belt sensor wire connector.
(3) Separate buckle assembly from vehicle.
INBOARD SEAT BELT BUCKLE INSTALLATION
Reverse the preceding operation.
REAR SEAT BELTS
OUTBOARD SHOULDER HARNESS/LAP BELT
REMOVAL (FIG. 15)
(1) Remove quarter trim panel.
(2) Remove bolt holding lap belt to floor at wheel-
house kickup. (3) Remove bolt holding seat belt retractor to quar-
ter panel.
OUTBOARD SHOULDER HARNESS/LAP BELT INSTALLATION
Reverse the preceding operation.
INBOARD BUCKLE/CENTER OCCUPANTBELTS REMOVAL (FIG. 15)
(1) Remove rear seat cushion.
(2) Remove bolt holding inboard buckle/center oc-
cupant belt to floor. (3) Separate buckle/belt assembly from vehicle.
INBOARD BUCKLE/CENTER OCCUPANT BELTINSTALLATION
Reverse the preceding operation.
FRONT SEATS
FRONT SEAT REMOVAL (FIG. 16 OR 17)
(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.
Fig. 13 Quarter Trim Extension and Shelf Trim Panels
Fig. 14 Front Seat Belts
23 - 78 AJ-BODY Ä

(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.
FRONT SEAT INSTALLATION
Reverse the preceding operation.
REAR SEATS
REAR SEAT CUSHION REMOVAL
(1) Remove bolts holding cushion to floor.
(2) Push center occupant seat belts through open-
ings in cushion. (3) Remove cushion from vehicle.
REAR SEAT CUSHION INSTALLATION
Reverse the preceding operation.
REAR SEAT BACK REMOVAL (FIG. 18)
(1) Hinge seat back forward and disengage push-in
fasteners holding carpet backing to trunk floor. (2) Remove bolts holding outboard hinge pivot
bracket to seat back. (3) Pull seat back outward to disengage inboard
pivot and separate from vehicle.
REAR SEAT BACK INSTALLATION
Reverse the preceding operation.
FRONT CENTER CONSOLE
REMOVAL (FIG. 19)
(1) Position front seats full forward.
(2) Remove rear ash tray.
(3) Remove rear lower carpeted end cover.
Fig. 15 Rear Seat Belts
Fig. 16 Manual Front Seat
Fig. 17 Power Front Seat
Fig. 18 Rear Seat Cushion and Back
Ä AJ-BODY 23 - 79

(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 clip from
shift mechanism through right side panel opening, if
equipped with automatic transaxle. Refer to Group
8E, Instrument Panel and Gauges for proper service
procedures. (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. 20)
(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 outboard seat belt lower attaching
bolts. (5) Remove left dash panel foot rest.
(6) Remove rear seat cushion.
(7) Pull carpet from under quarter trim covers.
(8) Fold carpet and remove through door opening.
INSTALLATION
Reverse the preceding operation.
OVERHEAD CONSOLE
REMOVAL (FIG. 21)
(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.
Fig. 19 Center Console
Fig. 20 Floor Carpet and SilencersÐTypical
Fig. 21 Overhead ConsoleÐTypical
23 - 80 AJ-BODY Ä

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 one quarter trim panel as necessary to
clear head lining removal path. (10) Disengage hook and loop fasteners holding
head lining to roof above rear window and slide head
lining from behind quarter panel. (11) Remove head lining from vehicle.
INSTALLATION
Reverse the preceding operation.
SUN ROOF WEATHERSTRIP
REMOVAL (FIG. 22)
(1) Remove sun roof sunshade and glass. Refer to
Owner's Manual for instructions. (2) Pull weatherstrip from pinch flange around sun
roof opening.
INSTALLATION
Reverse the preceding operation.
SUN ROOF AIR DEFLECTOR
REMOVAL (FIG. 22)
(1) Remove sun roof sunshade and glass. Refer to
Owner's Manual for instructions. (2) Disengage snap-on linkage at rear of air deflec-
tor in sun roof opening. (3) Remove screws holding air deflector to front of
sun roof opening.
INSTALLATION
Reverse the preceding operation.
SUN ROOF DRAIN TUBES
REMOVAL (FIG. 22)
(1) Remove head lining as necessary.
(2) Remove A-pillar or quarter trim covers as nec-
essary. (3) Remove cowl panel and sill plate trim as neces-
sary. (4) Disconnect effected drain tube from nipple at
sun roof opening. (5) Pull drain tube upward to remove from pillar
involved.
INSTALLATION
Reverse the preceding operation. Route the tube to
avoid kinks or puncture from sharp edges.
REAR WINDOW GLASS
REMOVAL (FIG. 23)
(1) Remove rear window mouldings.
(2) Remove interior 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 fence spacers at the locations shown (Fig.
23). (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.
(6) Connect rear window defogger wiring and in-
stall interior trim. (7) After urethane has cured, water test rear win-
dow to verify repair. Verify rear window defogger op-
eration, see Group 8N, Rear Window Defogger.
Ä AJ-BODY 23 - 81

TRUNK LID
REMOVAL (FIG. 24)
(1) Raise trunk lid to full up position.
(2) Disconnect the trunk 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 trunk lid, align all marks and secure bolts. The
trunk lid should be aligned to 4 mm (0.160 in.) gap to the quarter panels and flush across the top sur-
faces along quarter panels. (4) Remove the top trunk lid to hinge attaching
bolts and loosen the bottom bolts until they can be
removed by hand. (5) With assistance of a helper at the opposite side
of the vehicle to support the trunk lid, remove the
bottom trunk lid to hinge attaching bolts. Separate
the trunk lid from the vehicle.
INSTALLATION
Reverse the preceding operation.
TRUNK LID HINGE
REMOVAL
(1) Remove rear parcel shelf trim cover.
(2) Disconnect trunk lid lift torsion bars from
hinges. (3) Mark all attaching bolt, nut, and component lo-
cations with a suitable marking device. Use marks
as a reference when installing hinge. (4) Remove bolts holding trunk lid to hinge.
(5) Remove nuts and bolts holding hinge to closure
panel below rear window glass. (6) Separate hinge from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 22 Sun Roof
Fig. 23 Rear Window Glass
23 - 82 AJ-BODY Ä

TRUNK LID TORSION BAR
REMOVAL
(1) Raise and support trunk lid in the full up posi-
tion. (2) Remove trunk lining as necessary to gain ac-
cess to torsion bars. (3) Disengage adjusting end of torsion bar from the
slot in the tension adjustment bracket. (4) Pivot torsion bar out of lift arm swivel.
(5) Disconnect torsion bar from hinge.
INSTALLATION
Reverse the preceding operation.
TRUNK LID LATCH
REMOVAL
(1) Raise trunk lid to the full up position.
(2) Remove push-in fasteners holding lining to
trunk lid as necessary. (3) Disconnect remote release cable from latch.
(4) Remove bolts holding latch to trunk lid and
separate latch from vehicle.
INSTALLATION
Insert trunk lock chill into latch release driver and
reverse the preceding operation.
TRUNK LID LOCK
REMOVAL
(1) Remove trunk lid tail light assembly. Refer to
Group 8L, Lamps for proper procedures. (2) Remove trunk latch.
(3) Remove nuts holding lock cylinder and chill to
trunk lid and separate the lock from the vehicle.
INSTALLATION
Reverse the preceding operation.
TRUNK OPENING WEATHERSTRIP
REMOVAL (FIG. 25)
(1) Raise trunk lid to the full up position.
(2) Pull the weatherstrip from the pinch flange
around the trunk opening.
INSTALLATION
A new trunk lid opening weatherstrip should be
heated to approximately 38É C (100É F) before instal-
lation. The weatherstrip butt splice should be located
at the center rear of trunk opening. Reverse the re-
moval operation. After weatherstrip has been in-
stalled, close trunk lid and allow weatherstrip to
cool. The weatherstrip will form to the trunk lid con-
tour as it cools.
TRUNK LID LUGGAGE RACK
REMOVAL (FIG. 26)
(1) Remove screws holding spoiler to trunk lid.
(2) Pry rub strip inserts from skid strips.
(3) Remove screws holding skid strips to trunk lid.
INSTALLATION
Reverse the preceding operation
TRUNK LID AND FUEL FILL DOOR RELEASE
CABLES
REMOVAL (FIG. 27)
(1) Remove interior trim as necessary to gain ac-
cess to release cables. (2) Remove left front door 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) Remove trunk lining as necessary to gain ac-
cess to the release cables.
Fig. 24 Trunk LidÐTypical
Fig. 25 Trunk Opening WeatherstripÐTypical
Ä AJ-BODY 23 - 83

(7) On fuel fill door cable, remove nut holding ca-
ble latch to fuel fill opening. (8) On trunk lid latch, remove trunk latch cover
and disconnect cable end from latch. Route cable
back through trunk lid.
INSTALLATION
Reverse the preceding operation.
FUEL FILL DOOR
REMOVAL (FIG. 28)
(1) Open fuel fill door.
(2) Separate trunk lining from right quarter panel.
(3) Remove nuts holding fuel fill door to quarter
panel. (4) Separate fuel fill door from quarter panel open-
ing.
INSTALLATION
Reverse the preceding operation. Align to achieve
equal spacing around fuel fill door and flush to the
quarter panel.
Fig. 26 Trunk Lid Luggage Rack
Fig. 27 Trunk Lid and Fuel Fill Door Release Cables
Fig. 28 Fuel Fill DoorÐTypical
23 - 84 AJ-BODY Ä