CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

(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. 42)
(1) Remove head lining as necessary.
(2) Remove A-pillar or B-pillar 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.
LIFT GATE REMOTE RELEASE CABLE
REMOVAL
(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 cable. (7) Disconnect cable end from latch.
(8) Separate cable from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR WINDOW GLASS
REMOVAL (FIG. 43)
(1) Raise lift gate to up position.
(2) Remove screws holding outward edges to rear
window moulding to lift gate frame. (3) Position protective card board covers along the
top of the quarter panels to protect painted surfaces.
Fig. 42 Sun Roof
Ä AP-BODY 23 - 115

(4) Support lift gate in the up position and remove
bolts holding lift gate hinge closed. Lower lift gate to
opening weatherstrip. (5) Remove screws holding top of rear window
moulding to lift gate frame. Separate moulding from
lift gate. (6) Pull lower rear window moulding from under
glass. (7) Cut urethane bonding from around rear win-
dow. Refer to Windshield section of this group.
INSTALLATION
Prepare the lift gate fence and rear window as de-
scribed in the Windshield Installation section of this
group. Reverse the removal operation.
LIFT GATE LUGGAGE RACK
REMOVAL (FIG. 44)
(1) Remove screws holding cross bar to outboard
skid strips. (2) Pry rubber inserts from skid strips.
(3) Remove screws holding skid strips to lift gate.
INSTALLATION
Reverse the preceding operation
Fig. 43 Rear Window Glass
Fig. 44 Lift Gate Luggage Rack
23 - 116 AP-BODY Ä

AP/27-VEHICLE CONVERTIBLE BODY COMPONENT SERVICE INDEX
page page
A-Pillar and Windshield Header Weatherstrip . . . 117
Convertible Top Adjustments ............... 131
Convertible Top Header ................... 118
Convertible Top Latch Hooks ............... 131
Door Glass Alignment .................... 131
Door Glass Rear Channel ................. 127
Door Striker Guide ...................... 128
Forward Roof Rail ....................... 121
Fourth Roof Bow and Slat ................. 120
Fourth Roof Bow Slat .................... 132
Front Door Belt Moulding and Weatherstrip .... 127
Front Door Glass ........................ 125
Front Door Stationary Glass and Division Channel ............................. 126
Front Door Stationary Glass Channel Weatherstrip .......................... 126
Front Door Striker Guide Socket ............ 127
Front Seat Belt Retractor .................. 128
General Information ...................... 117
Quarter Glass and Roller Bracket ........... 132
Quarter Panel Belt Moulding ............... 129
Quarter Trim Panel ...................... 128
Rear Roof Rail ......................... 121
Rear Seat Back ......................... 128 Rear Seat Belt Retractor
.................. 129
Rear Tensioner Plate ..................... 132
Rear Window .......................... 122
Roof Linkage ........................... 121
Roof Rail Weatherstrip ................... 118
Roof Rail Weatherstrip Retainer ............. 131
Second Roof Bow and Linkage ............. 119
Sling-Well ............................. 124
Stationary Quarter Glass and Weatherstrip .... 121
Third Roof Bow ......................... 120
Top Cover ............................. 124
Top Frame ............................ 125
Top Header Trim Cover ................... 118
Top Latch ............................. 118
Top Lift Assist Cylinder ................... 122
Top Stack Down-Stop .................... 132
Top Stack Up-Stop ...................... 132
Trunk Hinge Lid ........................ 130
Trunk Lid .............................. 130
Trunk Lid Applique ...................... 130
Trunk Lid Lining ........................ 129
Trunk Opening Weatherstrip ............... 130
Windshield Header Lining ................. 117
Windshield Header Moulding ............... 117
GENERAL INFORMATION
This section will cover components that are unique
to the AP-vehicle convertible. All components that
are common to the AP-vehicle two door hardtop are
covered in the AP-Vehicle Body Components section.
WINDSHIELD HEADER MOULDING
REMOVAL (FIG. 1)
(1) Remove windshield header lining.
(2) Remove nuts holding moulding to windshield
header. (3) Separate windshield header moulding from ve-
hicle.
INSTALLATION
Apply sealing putty around mounting studs on
back of moulding and reverse the removal operation.
WINDSHIELD HEADER LINING
REMOVAL (FIG. 1)
(1) Remove sun visors and inner sun visor hanger
clips. (2) Remove upper A-pillar trim covers.
(3) Remove dome lamp.
(4) Separate header lining from vehicle.
INSTALLATION
Reverse the preceding operation.
A-PILLAR AND WINDSHIELD HEADER
WEATHERSTRIP
REMOVAL (FIG. 2)
(1) Remove upper and lower A-pillar trim covers.
(2) Remove header lining and moulding.
(3) Pull A-pillar door opening weatherstrip from
pinch flange. (4) Pull drip rail weatherstrip from drip rail next
to windshield.
Fig. 1 Windshield Header Moulding
Ä AP/27 CONVERTIBLE 23 - 117

(5) Pull windshield header weatherstrip from re-
taining channel and separate weatherstrip from vehi-
cle.
INSTALLATION
(1) Apply a bead of Mopar, Glass Adhesive and
Sealer to back of windshield header weatherstrip. (2) Apply a strip of double sided adhesive tape to
windshield header rearward of the header moulding
stud holes. (3) Reverse the removal operation.
ROOF RAIL WEATHERSTRIP
REMOVAL (FIG. 3)
(1) Remove screw holding front of roof rail weath-
erstrip to convertible top header. (2) Pull weatherstrip from retaining channel above
door opening.
INSTALLATION
Reverse the preceding operation.
TOP HEADER TRIM COVER
REMOVAL (FIG. 4)
(1) Lower top.
(2) Remove screws holding header trim to top
header.
CAUTION: The screws on the rearward edge have
caps over the pointed ends to protect top operator
from injury.
(3) Separate trim from header.
INSTALLATION
Reverse the preceding operation.
TOP LATCH
REMOVAL (FIG. 5)
(1) Lower top.
(2) Remove E-ring and clevis pin and separate
latch hook from top header. (3) Remove latch pivot bolts and separate latch
from top header.
INSTALLATION
Reverse the preceding operation.
CONVERTIBLE TOP HEADER
REMOVAL
(1) Lower convertible top and remove top header
trim cover. (2) Remove screws holding forward top cover re-
taining strip to top header and separate strip from
top. (3) Using a heat gun to soften the adhesive, sepa-
rate the top cover from the top header (Fig. 6). (4) Peel top cover back over forward edge of header
to gain access to stay pad and retention cable attach-
ment.
Fig. 2 A-pillar and Windshield Header Weatherstrip
Fig. 3 Roof Rail Weatherstrip
Fig. 4 Top Header Trim
23 - 118 AP/27 CONVERTIBLE Ä

(5) Raise convertible top, do not latch top to wind-
shield header. (6) Remove pop-rivets holding stay pads and reten-
tion cables to top header. (7) Lower convertible top.
(8) Remove E-clips and clevis pins holding second
bow pivot link to top header (Fig. 7). (9) Remove bolts holding roof rail pivot bracket to
top header (Fig. 7). (10) Separate top header from convertible top
frame. If top header replacement is required, transfer
latching components to replacement header.
INSTALLATION
(1) Place replacement top header in position in
front of roof rail ends on top of cover material. (2) Install bolts to hold top header to roof rail pivot
brackets. (3) Install clevis pins and E-clips holding top
header to second bow pivot link. (4) Raise convertible top. Do not latch.
(5) Rivet retention cables to top header.
CAUTION: Do not stretch top material, top latching
effort increases if top cover or stay pads are to
tight.
(6) Rivet forward ends of stay pads to top header.
A foam tape over rivet heads. (7) Apply contact adhesive to forward rolled flange
of top header and inside forward two inches of top
cover material. Allow adhesive to cure until slight
tackiness is evident. (8) Pull top cover material forward until wrinkles
are gone. (9) Press adhesive coated surfaces together over
front edge of top header. (10) Verify opening and closing effort of the con-
vertible top and latches. (11) Verify that wrinkles in top cover, with head- ers latched, are minimal. Slight wrinkles in top cover
will decrease when top is heated by the sun or arti-
ficial heat source. If necessary, adjust top latch
hooks.
(12) Lower convertible top.
(13) Place retaining strip at front edge of top
header over edge turned material. Using a scratch
awl, align screws holes in retaining strip to holes in
top header. (14) Install screws to hold retaining strip to top
header. (15) Install top header trim panel.
SECOND ROOF BOW AND LINKAGE
REMOVAL
(1) Lower convertible top.
(2) Remove E-clip and clevis pin holding second
roof bow pivot link to top header (Fig. 8). (3) Remove screws holding second roof bow actuat-
ing link to pivot link (Fig. 8). (4) Remove screws holding second roof bow to top
cover listing retainer (Fig. 9).
Fig. 5 Top Latch
Fig. 6 Stay Pads and Retention Cables
Fig. 7 Pivot Link and Roof Rail Pivot Bracket.
Ä AP/27 CONVERTIBLE 23 - 119

(5) Remove staples holding stay pads to second roof
bow. (6) Separate second roof bow from top frame.
INSTALLATION
(1) Position second roof bow on convertible top.
(2) Staple stay pads to second roof bow tack strip
in same locations as the original assembly. (3) Install screws to hold top cover listing retainer
to second roof bow. (3) Install screws, washers and spacers to hold roof
bow actuating link to pivot link. (4) Install clevis pins and E-clips to hold second
roof bow pivot link to top header. (5) Verify convertible top operation.
THIRD ROOF BOW
REMOVAL
(1) Disengage top header latches.
(2) Lower convertible top halfway down.
(3) Remove bolts holding third roof bow to rear
roof rails. (4) Separate third roof bow from rear roof rails. (5) Rotate third roof bow to gain access to staples
holding stay pads to tack strip. (6) Remove staples holding stay pads to third roof
bow. (7) Remove screws holding top cover listing re-
tainer to third roof bow (Fig. 10). (8) Separate third roof bow from top frame.
INSTALLATION
(1) Position third roof bow on convertible top.
(2) Staple stay pads to third roof bow tack strip in
same locations as the original assembly. (3) Install screws to hold top cover listing retainer
to third roof bow. (3) Install bolts to hold third roof bow rear roof
rails. (4) Align third roof bow to be centered over the
rear roof rails. (5) Verify convertible top operation.
FOURTH ROOF BOW AND SLAT
The fourth roof bow and slat is adjustable to de-
crease wrinkles in the convertible top cover sail
panel and rear window areas.
REMOVAL (FIG. 11)
(1) Lower rear window glass. position glass flat on
the bottom of the sling well. (2) Lower convertible top halfway down.
(3) Remove pivot bolts and bushings holding fourth
roof bow slat to rear roof rail (Fig. 12). (4) Remove tension spring from between rear roof
rail and fourth roof bow slat (Fig. 13). (5) Remove shoulder bolts holding fourth roof bow
to slat. (6) Separate bow from slats (Fig. 12).
(7) Allow roof bow to drop downward.
(8) Tip bow toward interior of vehicle and away
from top cover. (9) Lower convertible top enough to allow to loosen
around fourth roof bow.
Fig. 8 Second Roof Bow
Fig. 9 Second Roof Bow Retainer
Fig. 10 Third Roof Bow Retainer
23 - 120 AP/27 CONVERTIBLE Ä

(10) Locate feature strip insert at end of bow. Slide
feature strip to the side and separate strip from bow.
Do not damage foam filler strips attached to fourth
bow. (11) Separate top cover from fourth roof bow.
(12) Remove rivets holding rear window retainer
to fourth roof bow. (13) Separate retainer from bow.
(14) Mark location of stay pads and rear window
zipper apron to aid installation. (15) Remove staples holding stay pads to fourth
roof bow. (16) Remove staples holding rear window zipper
apron to fourth roof bow. (17) Remove staples holding side stay pads to
fourth roof bow. (18) Separate fourth roof bow from vehicle.
INSTALLATION
Reverse the preceding operation.
FORWARD ROOF RAIL
REMOVAL
(1) Lower convertible top and remove top header
trim cover. (2) Remove screws holding pivot bracket to for-
ward roof rail. (3) Remove bolt, washer and bushing holding cen-
ter link arm to forward roof rail. (4) Remove bolt, washer and bushing holding con-
trol link arm to forward roof rail. (5) Separate forward roof rail from frame.
INSTALLATION
Reverse the preceding operation.
ROOF LINKAGE
REMOVAL (FIG. 12)
(1) Disengage top header latches. (2) Remove bolt, washer and bushing holding bal-
ance link arm to control link. (3) Remove bolt, washer and bushing holding bal-
ance link arm to rear roof rail behind quarter trim
link. (4) Separate balance link arm from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR ROOF RAIL
REMOVAL (FIG. 13)
(1) Remove quarter trim panel.
(2) Disengage top latches, do not lower top.
(3) Remove quarter glass and weatherstrip.
(4) Loosen bolts holding rear roof rail main pivot
plate to quarter panel. (5) Remove clip and clevis pin holding gas assist
cylinder to rear roof rail. (6) Remove fourth roof bow slat spring.
(7) Remove pivot bolt holding slat to rear roof rail.
(8) Remove pivot bolt holding center link to rear
roof rail. (9) Remove bolts holding third roof bow to rear
roof rail. (10) Remove pivot bolt holding rear roof rail to
main pivot bracket. (11) Separate rear roof rail from roof frame.
INSTALLATION
Reverse the preceding operation.
STATIONARY QUARTER GLASS AND
WEATHERSTRIP
REMOVAL (FIG. 14)
(1) Lower convertible top.
(2) Remove quarter trim panel.
(3) Remove nut holding quarter glass to rear roof
rail.
Fig. 11 Fourth Roof Bow
Fig. 12 Roof Rails and Linkage
Ä AP/27 CONVERTIBLE 23 - 121

(4) Remove nuts and plastic insulators holding
quarter glass to lower mounting bracket. Separate
mounting stud plate and plastic insulators from
glass. (5) Slide glass downward to clear upper stud from
top rail. (6) Separate glass and weatherstrip from convert-
ible top frame.
INSTALLATION
(1) Install roof rail weatherstrip on glass (Fig. 15). (2) Position glass assembly in convertible top
frame opening. (3) Install nut and washer to hold upper glass stud
to top rail. (4) Install lower glass stud plate and plastic insu-
lators through holes at bottom of glass. (5) Install plastic insulators and nuts to hold glass
and stud plate to spring bracket. (6) Before tightening nuts at top and bottom of
glass, verify alignment to door glass and top rail
weatherstrip. (7) Secure all nuts holding glass to vehicle and in-
stall quarter trim panel.
TOP LIFT ASSIST CYLINDER
REMOVAL (FIG. 16)
(1) Remove interior trim as necessary to gain ac-
cess to quarter panel to top frame attachment bolts
and gas cylinder. (2) With top in up position (not latched). Loosen
top frame to quarter panel reinforcement bolts to al-
low top frame to shift rearward. (3) Remove clevis pin holding gas cylinder to top
frame. (4) Remove door ajar switch from B-pillar below
door striker. (5) Through door ajar switch mounting hole, re-
move bolt holding bottom of gas cylinder to quarter
panel reinforcement. (6) Separate top lift assist cylinder from vehicle.
INSTALLATION
Reverse the preceding operation.
REAR WINDOW
REMOVAL (FIG. 17)
There are foam strips attached to the outboard cor-
ners of the No. 4 bow on short tacking strips. These
are used to prevent any read-through of the bow. The
Fig. 13 Rear Roof Rail
Fig. 14 Stationary Quarter Glass and Weatherstrip
Fig. 15 Quarter Glass Roof Rail Weatherstrip
23 - 122 AP/27 CONVERTIBLE Ä

foam is easily damaged and may need replacement.
Inspect them, if they are either loose or missing re-
place them as necessary.(1) Unlock and raise the trunk lid.
(2) Remove rear seat back.
(3) Apply masking tape to the painted surfaces
around the top of the quarter panels to avoid damage
during tack strip removal. (4) Remove the nuts and bolts holding top cover
rear tack strip to deck filler panel and quarter pan-
els. (5) Separate the tack strip from the quarter panel
flanges. (6) Using a suitable white marking pencil, mark
the edges of top cover on the tack strip to aid instal-
lation. (7) Remove staples holding top cover to the tack
strip. (8) Separate top cover from the tack strip.
(9) Using a suitable white marking pencil, mark
the locations of the rear stay pads tack strip to aid
installation. (10) Remove staples holding lower end of rear stay
pads to tack strip. (11) Mark location of suspender strap on the tack
strip to aid installation. (12) Remove staples holding lower end of sus-
pender straps to tack strip. (13) Slide feature strip from retainer channel on
the fourth roof bow. (14) Separate top cover from the fourth roof bow
retainer. (15) Remove rivets holding retainer channel to
fourth roof bow. (16) Separate retainer channel from fourth roof
bow. (17) Remove staples holding rear stay pads and
suspender straps to fourth roof bow. (18) Separate rear stay pads and suspender straps
from the vehicle. (19) Using a suitable white marking pencil, mark
the edge of the upper rear window on the fourth roof
bow to aid installation. If the foam filler strips must be replaced, mark the
locations of the filler strips on the fourth roof bow to
aid installation. (20) Remove staples holding rear window to fourth
roof bow. (21) Remove staples holding outboard corners of
rear window valance and carrier from rear tack strip. (22) Separate bottom of rear window from rear tack
strip. (23) Separate top of rear window from fourth roof
bow. (24) Separate rear window from vehicle.
INSTALLATION
Cut square holes in lower edge of rear window fab-
ric for mounting studs of rear tack strip. Holes
should be no higher or wider than fastener holes.
Holes should be open ended on the bottom edge. Use
original rear window as a template for marks and
hole locations. (1) Tape paper to front and back sides of new rear
window without attaching tape to rear window. (2) Position centerline of upper rear window val-
ance to the centerline of the fourth roof bow. (3) Staple the rear window to the fourth roof bow
tack strip from center, outward. Install staples at one
inch spacing across the roof bow to allow for staples
to hold on the suspender straps and stay pads. (4) Install foam filler strip at the ends of the
fourth roof, if replacement is required. (5) Install side stay pads on fourth roof bow.
(6) staple side stay pads to fourth roof bow.
Fig. 16 Gas Assist Cylinder
Fig. 17 Rear Window
Ä AP/27 CONVERTIBLE 23 - 123

(7) Install lower portion of rear window in position
on rear tack strip, align to the bottom center mark. (8) Staple the corners of the rear window valance
and carrier to the rear tack strip. Verify the edges
are even. (9) Position rear stay pads and suspender straps
over fourth roof bow and over the outboard ends of
the rear window fabric. (10) Stretch lower end of suspender straps to edge
of rear tack strip. (11) Staple lower end of suspender straps to rear
tack strip. (12) Staple lower end of rear stay pad to rear tack
strip. (13) Position top cover retainer channel on fourth
roof bow. (14) Rivet top cover retainer channel to fourth roof
bow with aluminum pop-rivets. (15) Position top cover over the fourth roof bow re-
tainer locating the centerline reference marks. (16) Slide feature strip insert into the fourth roof
bow retainer channel. (17) Position top cover on rear tack strip.
(18) Staple top cover to rear tack strip starting
from the outboard corner and stapling inward. (19) Position rear tack strip over the mounting
studs on inside of quarter panels. (20) Install nuts and bolts to hold rear tack strip to
the quarter panels an deck panel. (21) Install rear seat back.
(22) Remove protective materials that was applied
to the body during to removal operation.
TOP COVER
REMOVAL (FIG. 18)
(1) Open rear window and position glass, as flat as
possible, in the drop well. (2) Lower convertible top.
(3) Remove rear seat cushion and back.
(4) Remove quarter trim panels.
(5) Remove quarter glass assemblies.
(6) Raise top to mid-point.
(7) Remove screws holding cover retainer to top
header. Separate retainer from header. (8) Separate top cover from adhesive on top
header. (9) Open trunk lid. Remove screws holding rear
deck filler panel to rear deck below rear window.
Mark screw locations before removal to aid installa-
tion. The rear deck filler panel applies pressure to
top cover to eliminate wrinkles. (10) From in luggage compartment, remove nuts
and bolts holding lower top tack strip to deck and
quarter panels. Lift sling well upward to gain access
to fasteners. CAUTION: Do not damage painted surfaces when
separating tack strip from mounting locations.
(11) Separate tack strip from deck and quarter
panels and remove staples holding top cover. Leave
rear window skirt, pads and drop well attached to
tack strip. (12) Pull top cover from adhesive in quarter glass
weatherstrip channel. (13) Remove rivets holding top cover roof rail ten-
sion cables to top header. Pull tension cables from
rear of listing pockets on top cover. (14) Remove screws holding top cover fastener
strip to center roof bows. Separate top cover from
roof bows and pull retainers from listing pockets on
top cover. (15) Fold top cover so that all material is above
rear roof bow. Slide rear top cover retainer to one
side from rear roof bow channel. (16) Separate top cover from vehicle.
INSTALLATION
Reverse the preceding operation. Use contact adhe-
sive to secure top cover to header and quarter glass
weatherstrip channels. Fold replacement convertible
top along center line and mark with tailors chalk.
Measure and mark the center line of header, center
bow and tack strip. Install top cover from the center
line out. Do not over stretch top cover when remov-
ing wrinkles. Allow for some shrinkage. Water leak
and wind noise tests should be performed before re-
turning vehicle to use.
SLING-WELL
REMOVAL
(1) Remove rear seat cushion and back.
(2) Remove quarter trim panels.
(3) Remove rear shoulder harness turning loop cov-
ers. (4) Remove bolts holding shoulder harness turning
loops to seat back support. (5) Remove seat back support trim cover.
(6) Disengage wire hanger from hole in quarter
panel near front seat belt retractor. (7) Disengage convertible top header latches.
(8) From in luggage compartment, remove nuts
and bolts holding lower top tack strip to deck and
quarter panels. Lift sling well upward to gain access
to fasteners.
CAUTION: Do not damage painted surfaces when
separating tack strip from mounting locations.
(9) Separate tack strip from deck and quarter pan-
els and remove staples holding sling well and top
cover to tack strip. (10) Separate sling well from vehicle.
23 - 124 AP/27 CONVERTIBLE Ä