CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

QUARTER GLASS MODULE
REMOVAL (FIG. 29)
(1) Remove quarter trim panel as necessary.
(2) Remove screws holding quarter glass module to
quarter glass opening. (3) Cut urethane from around perimeter of quarter
glass opening with a suitable cold knife. (4) Push quarter glass module out of quarter glass
opening.
INSTALLATION
(1) Clean cured urethane from quarter glass open-
ing fence. (2) Prepare quarter glass opening fence and glass
module using the same procedure described in the
Windshield section of this group. (3) Insert quarter glass module into quarter glass
opening and push inward. (4) Install screws holding module to quarter panel.
(5) Install quarter trim panel.
Fig. 29 Quarter Glass Module
Ä AJ-BODY 23 - 85

AJ/27-VEHICLE CONVERTIBLE BODY COMPONENT SERVICE INDEX
page page
Adjustment Procedures .................... 92
Folding Top Cover ....................... 90
Folding Top Headlining .................... 87
Folding Top Storage Sling Well .............. 87
Hydraulic Cylinder ........................ 95
Hydraulic Cylinder Line Seals ............... 95
Hydraulic Pump Assembly .................. 95
Hydraulic Pump Line Seals ................. 95 Hydraulic System Tests
.................... 95
Hydraulic Systems ........................ 95
Quarter Window ......................... 87
Rear Seat Back .......................... 86
Rear Seat Belt Retractors .................. 86
Rear Seat Cushion ....................... 86
Rear Window and Zipper ................... 88
Rear WindowÐWithout Zipper ............... 88
REAR SEAT CUSHION
REMOVAL (FIG. 1)
(1) Using a large flat blade screw driver, pry up-
ward at the retainer loop at each end of the seat
cushion. (2) Disengage retainer loops from retainer cups in
floor pan. (3) Separate seat cushion from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR SEAT BACK
REMOVAL (FIG. 1)
(1) Remove rear seat cushion.
(2) Remove bolts holding rear seat back to floor
pan kick-up. (3) Push seat back downward and disengage hook
retainers at top of back frame. (4) Separate seat back from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR SEAT BELT RETRACTORS
REMOVAL (FIG. 2)
(1) Remove rear seat cushion and back.
(2) Remove bolt holding shoulder belt turning loop
to seat back reinforcement panel. (3) Remove bolts holding rear seat belt retractor to
floor kick-up. (4) Remove bolts holding retractor to quarter panel
reinforcement. (5) Remove bolts holding lap belt to lower quarter
panel reinforcement. (6) Separate seat belt retractor from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 1 Rear Seat Cushion
Fig. 2 Rear Seat Belts
23 - 86 AJ/27-BODY Ä

QUARTER WINDOW
REMOVAL
(1) Disengage snaps holding sling well to rear deck
panel. (2) From each side of vehicle, Disengage clips hold-
ing sling well to belt reinforcement brace. Drape
sling well over rear seat back into passenger com-
partment. (3) Remove screw holding quarter trim panel and
door weatherstrip to door opening. (4) Remove the cowl trim and scuff plate covers.
(5) Remove the rear seat cushion.
(6) Disconnect rear speaker wire connectors.
(7) Remove screws holding seat back to floor
brackets and rear shoulder belt retractors (Fig. 1).
Separate rear seat back from vehicle. (8) Remove screws holding quarter trim to quarter
panel at the boot latches. (9) Remove screws holding quarter trim to floor
pan kick up. (10) Separate quarter trim from rear reinforce-
ment. Position trim panel out of quarter window re-
moval path (Fig. 3). (11) Raise quarter window approximately 100 mm
(4 in.) from the down position. (12) Remove bolt holding glass stabilizer bumper
to top of quarter panel opening. (13) Disconnect power window motor wire connec-
tor. (14) Remove bolts holding quarter window assem-
bly to quarter panel and lift the assembly through
the opening at the top of the quarter panel.
INSTALLATION
Reverse the preceding operation. Align the quarter
glass to have adequate pressure on the weatherstrips
for proper sealing. Insert sling well drain tubes into
the holes in the floor pan.
FOLDING TOP STORAGE SLING WELL
REMOVAL (FIG. 4)
(1) Disengage snaps holding sling well to rear deck
inner panel. (2) Disengage snaps holding sling well to quarter
inner panels. (3) Disengage snaps holding sling well to back of
quarter trim panels. (4) Remove bolts upper seat back support bar to
quarter trim panels. (5) Separate support bar from vehicle.
(6) Disconnect drain tubes from bottom of sling
well. (7) Pull sling well from the end of the support bar
retainer channel.
INSTALLATION
Reverse the preceding operation.
FOLDING TOP HEADLINING
REMOVAL (FIG. 5)
(1) Disengage snaps and hook and loop fasteners
holding headlining to quarter inner panels. (2) Disengage hook and loop fasteners holding
headlining to roof rails and top header. (3) Disengage clips holding headlining to roof rail
rearward of quarter glass opening. (4) Remove screws holding headlining to third roof
bow. (5) Remove screws holding headlining to second
roof bow. (6) Remove screws holding headlining to first roof
bow. (7) Remove screws holding headlining to top
header. (8) Separate headlining from vehicle.
INSTALLATION
Reverse the preceding operation.Fig. 3 Quarter Trim Panel
Fig. 4 Folding Top Storage Sling Well
Ä AJ/27-BODY 23 - 87

REAR WINDOWÐWITHOUT ZIPPER
If the rear window zipper is damaged, perform
Rear Window and Zipper replacement procedures.
REMOVAL
(1) Release folding top latches and allow top cover
to relax. (2) Disengage hook and loop fasteners holding
headlining to quarter panel areas. (3) Pull headlining forward from behind quarter
trim panels and tape headlining around roof rails,
out of the way. (4) Disengage snaps holding folding top storage
sling well to inner quarter and deck panels. (5) Position sling well out of the way.
(6) Disengage wire connectors from terminals on
heated rear window. (7) Pull wire harnesses from pockets at each side
of rear window. (8) Remove bolts holding rear tack strip to inner
deck panel (Fig. 6). (9) Separate rear tack strip from deck panel.
(10) Position rear tack strip to gain access to sta-
ples holding material to tack strip. (11) Using a grease pencil, mark location of outer
top cover on rear tack strip to aid installation. (12) Remove staples holding top cover to rear tack
strip (Fig. 7). (13) Unzip rear window from upper zipper listing.
(14) Separate window and rear tack strip from ve-
hicle. (15) Place rear window on a suitable work surface.
(16) Using a grease pencil, mark location of rear
window apron on rear tack strip to aid installation. (17) Remove staples holding rear window lower
apron to tack strip. (18) Separate rear window from tack strip.
INSTALLATION
(1) Using old rear window as a pattern, mark new
window to the same size and shape as the old win-
dow. (2) Trim excess material from new window.
(3) Position window at index marks on rear tack
strip. (4) Install staples to hold window apron to tack
strip (Fig. 7). (5) Trim excess material from around bolt holes in
tack strip. (6) Position rear window and tack strip in opening
behind rear seat. (7) Position top cover at index marks on rear tack
strip. (8) Install staples to hold top cover to rear tack
strip. (9) Zip rear window to upper zipper listing.
(10) Place rear tack strip in proper position under
deck panel (Fig. 6). (11) Install bolts to hold rear tack strip to deck
panel. (12) Latch top header to windshield header and in-
spect top cover for excess wrinkling. If wrinkling is
apparent, the top cover and rear window apron must
be repositioned on the tack strips. (13) Route wire harnesses through pockets at each
side of window and connect ends to terminals on
glass. (14) Install sling well and rear section of headlin-
ing.
REAR WINDOW AND ZIPPER
If the window zipper is not damaged and an origi-
nal equipment rear window is being installed, use
Rear Window GlassÐWithout Zipper replacement
procedures.
REMOVAL
(1) Release folding top latches and allow top cover
to relax. (2) Disengage hook and loop fasteners holding
headlining to quarter panel areas. (3) Pull headlining forward from behind quarter
trim panels and tape headlining around roof rails,
out of the way. (4) Disengage snaps holding folding top storage
sling well to inner quarter and deck panels.
Fig. 5 Folding Top Headlining
23 - 88 AJ/27-BODY Ä

(5) Position sling well out of the way.
(6) Disengage wire connectors from terminals on
heated rear window. (7) Pull wire harnesses from pockets at each side
of rear window. (8) Remove bolts holding rear tack strip to inner
deck panel (Fig. 6). (9) Separate rear tack strip from deck panel.
(10) Remove bolts holding side tack strips to inside
of quarter panels (Fig. 6). (11) Separate tack strips from quarter panels.
CAUTION: Cover all painted and upholstered sur-
faces to avoid damage while performing the follow-
ing operations.
(12) Reposition tack strips above rear deck and
quarter panels. (13) Using a grease pencil, mark location of outer
top cover on rear tack strip to aid installation. (14) Remove staples holding top cover to rear tack
strip (Fig. 7). (15) Fold rear of top cover, tack strips and rear
window up and over the third (rear) roof bow (Fig. 8). (16) Unzip and separate rear window from vehicle.
(17) Mark location of rear stay straps on third roof
bow. (18) Remove staples holding rear stay straps to
third roof bow (Fig. 8). (19) Mark location of top cover hold down listing
on third roof bow. (20) Remove staples holding top cover listing to
third roof bow (Fig. 8). (21) Mark location of rear window zipper upper
half listing on third roof bow. (22) Remove staples holding zipper listing to third
roof bow (Fig. 8). (23) Separate rear window zipper from third roof
bow. The following is a work bench operation
(24) Place rear window on a suitable work surface.
(25) Using a grease pencil, mark location of rear
window apron on rear tack strip to aid installation. (26) Remove staples holding rear window lower
apron to tack strip. (27) Separate rear window from tack strip.
INSTALLATION
(1) Using old rear window as a pattern, mark new
window to the same size and shape as the old win-
dow. (2) Trim excess material from new window.
(3) Position window at index marks on rear tack
strip. (4) Install staples to hold window apron to tack
strip (Fig. 7). (5) Trim excess material from around bolt holes in
tack strip. (6) Using old zipper upper half listing as a pattern,
mark new listing to the same size and shape as the
old listing. (7) Trim excess material from new listing.
Fig. 6 Tack Strips
Fig. 7 Rear Window Glass
Fig. 8 Third Roof Bow
Ä AJ/27-BODY 23 - 89

(8) Position zipper upper half listing at index
marks on the third roof bow. Verify that start end of
zipper upper half is at the same end as the rear win-
dow half. (9) Install staples to hold zipper listing to third
roof bow (Fig. 8). (10) Position top cover hold down listing at index
marks on third roof bow. (11) Install staples to hold top cover listing to third
roof bow (Fig. 8). (12) Position stay straps at index marks on the
third roof bow. (13) Install staples to hold stay straps to third roof
bow. (14) Zip rear window into position.
(15) Fold rear of top cover, tack strips and rear
window up and over the third roof bow to the rear of
the top opening (Fig. 8). (16) Position top cover at index marks at each end
of rear tack strip. (17) Install staples to hold top cover to rear tack
strip (Fig. 6). (18) Position side and rear tack strips behind quar-
ter and deck panels. (19) Install bolts to hold side tack strips to inside
of quarter panels (Fig. 6). (20) Install bolts to hold rear tack strip to deck
panel. (21) Latch top header to windshield header and in-
spect top cover for excess wrinkling. If wrinkling is
apparent, the top cover and rear window apron must
be repositioned on the tack strips. (22) Route wire harnesses through pockets at each
side of window and connect ends to terminals on
glass. (23) Install sling well and rear section of headlin-
ing.
FOLDING TOP COVER
REMOVAL
(1) Release folding top latches and allow top cover
to relax. (2) Remove headlining.
(3) Disengage snaps holding top storage sling well
to rear deck and quarter panels. (4) Position sling well out of the way.
(5) Remove bolts holding rear tack strip to inner
deck panel. (6) Separate rear tack strip from deck panel.
(7) Remove bolts holding side tack strips to inside
of quarter panels. (8) Separate tack strips from quarter panels.
CAUTION: Cover all painted and upholstered sur-
faces to avoid damage while performing the follow-
ing operations. (9) Reposition tack strips above rear deck and
quarter panels. (10) Using a grease pencil, mark location of outer
top cover on rear tack strip to aid installation. (11) Remove staples holding top cover to rear tack
strip. (12) Fold rear of top cover, tack strips and rear
window up and over the third (rear) roof bow. (13) Unzip and separate rear window from vehicle.
(14) Mark location of top cover hold down listing
on third roof bow. (15) Remove staples holding top cover listing to
third roof bow. (16) Remove screws holding roof rail tension cable
springs to roof rear roof rail behind quarter glass
opening. (17) Pull quarter glass weatherstrips from roof rail
channels. (18) Remove screws holding roof rail channels to
roof rails. (19) Separate roof rail channels from vehicle.
(20) Separate top cover listing from adhesive on
roof rail. (21) Lower folding top to the mid point.
(22) Pull top header weatherstrip from retaining
channel. Separate first 50 mm (2 in.) of weather strip
from roof rail channels. (23) Remove screws holding weatherstrip channel
to top header. (24) Separate channel from top header.
(25) Remove staples holding top header feature
strip to top header. (26) Separate feature strip from header.
(27) Mark location or top cover on top header.
(28) Remove staples holding top cover to header.
(29) Close folding top, do not latch.
(30) Remove rubber plugs holding roof rail tension
cable ends into key-hole slots in roof rails (31) Disengage roof rail tension cables from roof
rails. (32) Pull tension cables from rear of pockets on
back of top cover. (33) Remove screws holding top cover retainer rod
to second roof bow. (34) Separate retainer rod from second roof bow.
(35) Remove screws holding top cover retainer rod
to first roof bow. (36) Separate retainer rod from first roof bow.
(37) Separate top cover from vehicle.
(38) Pull retainer rod from listing pockets on back
of top cover.
INSTALLATION
The new top cover must be trimmed to the same
size and shape as the old top cover to minimize wrin-
kling after installation. Use the rear sections of the
old top as a pattern.
23 - 90 AJ/27-BODY Ä

(1) On old top cover mark a line from the top of
the quarter glass opening to the center of rear glass
opening on each side of the top. (2) Using a suitable cutting tool, cut the rear quar-
ter sections off of old top. (3) Mark locations of old top cover on side tack
strips. (4) Remove staples holding old top cover to side
tack strips. (5) Using quarter sections cut from old top cover as
a pattern, mark lower tack strip edge of new top to
same size and shape as old top. (6) Trim excess material from new top cover.
(7) Position side tack strips under edge of new top
and align index marks. (8) Install staples 100 mm (4 in.) apart to hold top
cover to side tack strips. (9) Install retainer rod in listing pockets on back of
top cover. (10) Position top cover over top bows on vehicle
and center top cover side to side. (11) Mate retainer rod to first roof bow.
(12) Install screws to hold top cover retainer rod to
first roof bow. (13) Mate retainer rod to second roof bow.
(14) Install screws to hold top cover retainer rod to
second roof bow. (15) Route roof rail tension cables through rear of
pockets on back of top cover. (16) Connect roof rail tension cables to key-hole
slots in roof rails. (17) Install rubber plugs to hold roof rail tension
cable ends into key-hold slots in roof rails. (18) Apply suitable contact adhesive to roof rail
rear of quarter glass opening and back of top cover
hold down listing. (19) Stick top cover listing to roof rail.
(20) Place roof rail weatherstrip channel in proper
position. (21) Install screws to hold channel to roof rail.
(22) Position top cover listing at index marks on
third roof bow. (23) Install staples 10 mm (0.3 in.) apart to hold
top cover listing to third roof bow. (24) Zip rear window into position.
(25) Fold rear of top cover, tack strips and rear
window down and over the third roof bow. (26) Position top cover at index marks on rear tack
strip. (27) Install staples 100 mm (4 in.) apart to hold
top cover to rear tack strip.
CAUTION: Cover all painted and upholstered sur-
faces to avoid damage while performing the follow-
ing operations.
(28) Reposition tack strips under rear deck and
quarter panels. (29) Place side tack strips in position behind quar-
ter panels. (30) Install enough bolts to temporarily hold side
tack strips to inside of quarter panels. (31) Place rear tack strip in position behind deck
panel. (32) Install enough bolts to temporarily hold rear
tack strip to inner deck panel. (33) Close and latch folding top.
(34) Pull top cover forward over top of windshield
and hold cover material taut. (35) Mark location of froward lower edge of top
header on top cover material. (36) Release top latches and lower top to mid-
point. (37) Align marks on top material to front lower
edge of top header. (38) Verify that top cover will be wrinkle free and
aligned side to side. (39) Install staples 10 mm (0.3 in.) apart to hold
top cover to header. (40) Place top header feature strip in position un-
der top header. (41) Install staples 10 mm (0.3 in.) apart to hold
feature strip to top header. (42) Place weatherstrip channel in position under
top header. (43) Install screws to hold channel to top header.
(44) Insert top header weatherstrip into header
and roof rail channels. (45) Install screws to hold roof rail tension cable
springs to roof rear roof rail behind quarter glass
opening. (46) Close and latch top windshield header.
(47) Inspect top cover for excess wrinkling. If ex-
cess wrinkles are apparent, the top cover must be re-
positioned on the tack strips. (48) If top cover is smooth, release top header
latches to allow top cover to relax. (49) Remove bolts holding tack strips to deck and
quarter panels. (50) Install staples 10 mm (0.3 in.) apart to hold
top cover to rear and side tack strips. (51) Place side and rear tack strips in position.
(52) Install bolts to hold tack strips to deck and
quarter panels. (53) Insert quarter glass weatherstrips into roof
rail channels. (54) Place sling well into position.
(55) Engage snaps to hold sling well to rear deck
and quarter panels. Verify that drain tube is con-
nected to bottom of sling well. (56) Install headlining.
(57) Close top and latch header to windshield
header.
Ä AJ/27-BODY 23 - 91

ADJUSTMENT PROCEDURES
DOWEL PIN ADJUSTMENTS (FIG. 9)
(1) Loosen dowel pins.
(2) Position dowel pins to the center of the receiver
holes in the windshield header. (3) Tighten dowel pins and verify adjustment.
Refer to Cam Adjustment or Control Link Adjust-
ment paragraphs of this section to adjust forward or
rearward position of the top header.
LATCH HOOK ADJUSTMENT (FIG. 9)
If the convertible top latching effort is excessive, it
can be reduced by lengthening the latch hook. The
top header weatherstrip requires enough compression
to prevent air and water leaks. Adjust latch hook to
achieve reasonable latching effort and proper sealing.
FRONT TO CENTER RAIL ADJUSTMENT (FIG. 10)
To align the roof rail weatherstrips to the door and
quarter glass contact, adjust the front to center rail
adjusting screw. To decrease pressure on door glass
turn adjuster inward. To increase pressure on door
glass turn adjuster outward.
TOP FRAME CAM ADJUSTMENT (FIG. 11)
The top frame cam changes forward or rearward
position of the top header in relation to the wind-
shield header. The cam turns inside the rear side rail
and thrust link. It may be necessary to lengthen the
control links 1 or 2 serration after a cam adjustment.
The position of the cam high side determines the an-
gle between the center and rear side rails. When the
high side is fully forward, the angle is at a mini- mum, and when turned rearward, the angle is in-
creased. An increased angle increases the forward
movement of the top. The cam high side is indicated
by a arrow on the cam threaded end.
TO ADJUST CAM SETTING (1) Lower top to half down position to remove all
possible strain from the cam. (2) Loosen set screw and tap cam threaded end
with a soft faced hammer to loosen any paint bond
between cam and linkage. (3) Using a 3/16 Allen wrench, rotate cam as nec-
essary and secure set screw.
CONTROL LINK ADJUSTMENT (FIG. 12)
WARNING: DO NOT PLACE HANDS OVER GAPS IN
MOVABLE CONVERTIBLE TOP COMPONENTS
DURING SERVICING. PERSONAL INJURY CAN RE-
SULT.
(1) Remove convertible top head lining as neces-
sary to gain access to adjusters. (2) With the top latched in up position, loosen both
bolts just enough to permit moving link up or down. (3) Push upward in the area of the front to center
rail joint. Push rails up by hand as far as possible. (4) With the control link adjusting bolts loosened,
allow the control link to seek proper position. (5) Tighten bolts while rail is held in position.
Fig. 9 Roof Latch and Guide Dowel Pin
Fig. 10 Roof Rail Adjustment
23 - 92 AJ/27-BODY Ä

Fig. 11 Cam Assembly
Fig. 12 Control Link Adjustment
Ä AJ/27-BODY 23 - 93

CONVERTIBLE TOP DIMENSIONS
23 - 94 AJ/27-BODY Ä