1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

towing capacity transmission MPG fuel tank removal oil type oil temperature

Page 2169 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (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

(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. (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. 6)
(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. 7)
(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.
TRANSAXLE SPLASH SHIELD REMOVAL (FIG.7)
(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. 8)
(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.
Fig. 5 Hood Latch Release Cable Assembly
Fig. 6 Cowl Cover Assembly
Ä AA-BODY 23 - 13

Page 2170 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual FRONT FENDER
REMOVAL (FIG. 9)
(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. R

FRONT FENDER
REMOVAL (FIG. 9)
(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 rocker panel moulding as necessary to
clear front fender. Refer to Body Side Moulding and
Applique Removal paragraph in this section. (5) Remove bolts holding bottom front fender at
rear of wheel opening. (6) Remove bolt holding front fender at rear of
wheelhouse. (7) Remove bolt holding front fender at top of front
door opening. (8) Remove bolts holding front fender to front
lower brace and under 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
mm (0.240 in) gap to front door edge. All surfaces
across gaps should be flush.
FRONT DOOR TRIM PANEL
DOOR TRIM PANEL WITH POWER WINDOWS REMOVAL (FIG. 10)
(1) Move glass to down position.
(2) Disconnect battery negative cable.
(3) Using a suitable prying tool, lift upward at
front of power window switch bezel and disengage be-
zel from clip in door panel. Disconnect wire connector
from back of switch. (4) Remove door latch handle bezel insert. Discon-
nect power door lock switch wire connector, if
equipped. Remove screws holding handle bezel to
trim panel and separate bezel from door. (5) Remove screw holding armrest pull handle to
door through door latch handle bezel opening. (6) Remove hidden screw from in carpet at rear
lower corner of trim panel. (7) Using a suitable trim clip tool, disengage frog
leg clips at the ends and bottom of trim panel. After
all trim clips are loose, push inward at the top of the
trim panel and lift upward to disengage barb fasten-
ers at top of panel. Separate trim from door.
Fig. 7 Front Wheelhouse and Transaxle Splash Shields
Fig. 8 Engine Drive Belt Splash Shield
Fig. 9 Front Fender Assembly
23 - 14 AA-BODY Ä

Page 2171 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual DOOR TRIM PANEL WITH POWER WINDOWS INSTALLATION
Reverse the preceding operation.
DOOR TRIM PANEL WITH MANUAL WINDOWSREMOVAL (FIG. 11)
(1) Open door glass to full down position.
(2) Disconnect battery

DOOR TRIM PANEL WITH POWER WINDOWS INSTALLATION
Reverse the preceding operation.
DOOR TRIM PANEL WITH MANUAL WINDOWSREMOVAL (FIG. 11)
(1) Open door glass to full down position.
(2) Disconnect battery negative cable.
(3) Remove window crank cap, attaching screw,
and handle. (4) Remove door latch handle bezel insert. Discon-
nect power door lock switch wire connector, if
equipped. Remove screws holding handle bezel to
trim panel and separate bezel from door. (5) Remove screw holding armrest pull handle to
door through door latch handle bezel opening. (6) Remove hidden screw from in carpet at rear
lower corner of trim panel. (7) Using a suitable trim clip tool, disengage frog
leg clips at the ends and bottom of trim panel. After
all trim clips are loose, push inward at the top of the
trim panel and lift upward to disengage barb retain-
ers at top of panel. Separate trim from door.
DOOR TRIM PANEL WITH MANUAL WINDOWS INSTALLATION
Reverse the preceding operation.
FRONT DOOR SILENCER AND WATER SHIELD
REMOVAL (FIG. 12)
(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.
FRONT DOOR REMOVAL (FIG. 13)
(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.
Fig. 10 Front Door Trim Panel with Power Windows
Fig. 11 Front Door Trim Panel with Manual Windows
Fig. 12 Front Door Silencer and Water Shield
Ä AA-BODY 23 - 15

Page 2172 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (6) Separate door from vehicle.
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 Installatio

Page 2173 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual FRONT DOOR SIDE VIEW MIRROR
REMOVAL (FIG. 16)
(1) Remove front door trim panel.
(2) Remove side view mirror remote adjusting
knob cover, if equipped. (3) Remove screws holding mirror bezel to door
fr

FRONT DOOR SIDE VIEW MIRROR
REMOVAL (FIG. 16)
(1) Remove front door trim panel.
(2) Remove side view mirror remote adjusting
knob cover, if equipped. (3) Remove screws holding mirror bezel to door
frame and separate bezel from door. Loosen set-screw
holding bezel to mirror adjuster cable, if equipped. (4) Remove silencer seal from door frame behind
mirror bezel. (5) Disconnect power mirror wire connector, if
equipped. (6) Remove access hole cover.
(7) Remove nuts holding mirror to door frame and
separate mirror from door.
INSTALLATION
Reverse the preceding operation.
FRONT DOOR GLASS
REMOVAL (FIG. 17)
(1) Remove door trim panel, silencer pad, and wa-
ter shield. (2) Position door glass half way up in door glass
opening. (3) Insert door glass removal tool C-4867 between
the glass slide and channel retaining lip at approxi-
mately 50 mm (2 in.) down from top rearward corner
of glass. Push handle of tool toward glass to open
channel. Push downward at the front of the glass to
separate the slide from the channel. (4) Insert door glass removal tool C-4867 between
the glass slide and channel retaining lip at approxi-
mately 50 mm (2 in.) up from bottom rearward cor-
ner of glass through opening in inner door panel.
Push handle of tool toward glass to open channel.
Pull upward at front of glass to separate the slide
from the channel. Do not allow upper slide to snap
bank into channel. (5) Rotate front of glass downward and slide glass
forward to separate glass lift channel from regulator
lift arm roller. (6) Remove door glass through opening at top of
door.
INSTALLATION
(1) Lower door glass into opening at top of door.
(2) Tip rear of glass downward and insert window
regulator lift arm roller into glass lift channel. (3) Guide door glass into glass run weatherstrip at
front of door. (4) Push top of glass rearward to snap top slide
into glass run channel. (5) Push downward at front of glass to snap bottom
slide into glass run channel. (6) Install water shield, silencer pad and trim
panel.
FRONT DOOR BELT MOULDING AND
WEATHERSTRIP
BELT MOULDING AND WEATHERSTRIP REMOVAL (FIG. 18)
(1) Remove trim panel, silencer pad, and water
shield as necessary to gain access to belt moulding
attaching screws. (2) Remove door glass.
(3) Remove screws holding belt moulding and
weatherstrip to outer door panel and separate moul-
ding from door.
BELT MOULDING AND WEATHERSTRIP INSTALLATION
Reverse the preceding operation.
Fig. 16 Front Door Side View Mirror
Fig. 17 Front Door Glass
Ä AA-BODY 23 - 17

Page 2174 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual FRONT DOOR GLASS CHANNEL AND RUN
WEATHERSTRIP
GLASS CHANNEL AND RUN WEATHERSTRIP
REMOVAL (FIG. 19)
(1) Remove door belt moulding and weatherstrip
assembly. (2) Remove front and rear door glass openi

FRONT DOOR GLASS CHANNEL AND RUN
WEATHERSTRIP
GLASS CHANNEL AND RUN WEATHERSTRIP
REMOVAL (FIG. 19)
(1) Remove door belt moulding and weatherstrip
assembly. (2) Remove front and rear door glass opening cor-
ner seals (Fig. 18) (3) Pull door glass run weatherstrip from forward
lower channel and upper door frame back to rear up-
per corner of door frame. (4) Separate weatherstrip from top of rear door
frame down to first clip. Using a suitable hook tool,
disengage clip barb from door frame channel. Pull
weatherstrip outward to disengage clip. Repeat this
procedure at each clip down the rear channel. (5) Separate glass channel and run weatherstrip
from door.
GLASS CHANNEL AND RUN WEATHERSTRIP INSTALLATION
(1) Insert glass run weatherstrip into top of glass
opening upper channel. Align molded corners of
weatherstrip to corners of glass opening. (2) Push weatherstrip and glass run channel into
upper rear glass opening channel. Seat the top re-
taining clip by placing a fiber trim stick (C-4755)
over the clip attaching rivet inside the glass run
channel and push or tap firmly inward until clip
seats. Verify the alignment of the weatherstrip in
the top rear corner. Repeat this procedure on each
clip going down the run. (3) Install glass opening corner seals.
(4) Install door belt moulding and weatherstrip as-
sembly.
FRONT DOOR GLASS RUN LOWER CHANNEL
FRONT OR REAR LOWER CHANNEL REMOVAL (FIG. 20)
(1) Remove door glass channel and run weather-
strip as necessary to gain access to lower channels
and attaching rivets. (2) Drift punch rivet center expansion pins from
each pop-rivet fastener holding channel to door panel
or mirror support frame. (3) Drill pop-rivet fasteners out of door panel or
mirror support frame and separate front or rear
channel from door.
FRONT OR REAR LOWER CHANNEL INSTALLATION
(1) Install lower channel into at design location.
(2) Install pop-rivets using a suitable pop-rivet
gun. (3) Install Glass channel and run weatherstrip.
(4) Install belt moulding and weatherstrip assem-
bly. (5) Install door glass.
(6) Install window opening lower corner seals.
(7) Install door water shield silencer pad and trim
panel.
FRONT DOOR WINDOW REGULATOR/MANUAL
MANUAL WINDOW REGULATOR REMOVAL (FIG. 21)
(1) Remove trim panel, silencer pad, and water
shield.
Fig. 18 Front Door Belt Moulding and Weatherstrip
Fig. 19 Front Door Glass Channel and Run Weatherstrip
23 - 18 AA-BODY Ä

Page 2175 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (2) Raise glass to 25 mm (1 in.) from full up posi-
tion. Using suitable tape, secure door glass to upper
window frame. (3) Remove bolts holding window regulator to in-
ner door panel. (4) Slide roll

Page 2176 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual REAR DOOR TRIM PANEL
DOOR TRIM PANEL WITH POWER WINDOWS REMOVAL (FIG. 24)
(1) Move glass to down position.
(2) Disconnect battery negative cable.
(3) Remove screw holding latch release handle be-
zel

REAR DOOR TRIM PANEL
DOOR TRIM PANEL WITH POWER WINDOWS REMOVAL (FIG. 24)
(1) Move glass to down position.
(2) Disconnect battery negative cable.
(3) Remove screw holding latch release handle be-
zel to door. Slide bezel forward and separate from
door trim. (4) Remove ash tray. Remove screw holding trim
panel to door from ash tray opening. (5) Pry power window switch from retainer in door
trim and disconnect wire connector. (6) Using a suitable trim clip tool, disengage frog
leg clips at the ends and bottom of trim panel. After
all trim clips are loose, push inward at the top of the
trim panel and lift upward to disengage barb fasten-
ers at top of panel. Separate trim from door.
DOOR TRIM PANEL WITH POWER WINDOWS INSTALLATION
Reverse the preceding operation.
DOOR TRIM PANEL WITH MANUAL WINDOWSREMOVAL (FIG. 25)
(1) Move glass to down position.
(2) Remove screw holding latch release handle be-
zel to door. Slide bezel forward and separate from
door trim. (3) Remove ash tray. Remove screw holding trim
panel to door from ash tray opening. (4) Pry window crank cap from crank. Remove
screw holding crane to regulator and separate from
door (6) Using a suitable trim clip tool, disengage frog
leg clips at the ends and bottom of trim panel. After
all trim clips are loose, push inward at the top of the
trim panel and lift upward to disengage barb fasten-
ers at top of panel. Separate trim from door.
DOOR TRIM PANEL WITH MANUAL WINDOWS INSTALLATION
Reverse the preceding operation.
REAR DOOR SILENCER AND WATER SHIELD
REMOVAL (FIG. 26)
(1) Remove 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.
REAR DOOR AND HINGE
The rear door hinge is welded to the door and
bolted to the B-pillar. The door half of the hinge piv-
ots 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
Fig. 24 Rear Door Trim Panel with Power Windows
Fig. 25 Rear Door Trim Panel with Manual Window
Fig. 26 Rear Door Silencer and Water Shield
23 - 20 AA-BODY Ä

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