1993 CHEVROLET PLYMOUTH ACCLAIM Service Manual

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Page 2209 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual 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 gr

Page 2210 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (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 instr

Page 2211 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (4) Separate wheelhouse splash shield from vehi-
cle.
INSTALLATION
Reverse the preceding operation.
TRANSAXLE SPLASH SHIELD REMOVAL (FIG. 9)
(1) Remove one front wheelhouse splash shield
push-in fast

(4) Separate wheelhouse splash shield from vehi-
cle.
INSTALLATION
Reverse the preceding operation.
TRANSAXLE SPLASH SHIELD REMOVAL (FIG. 9)
(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. 10)
(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 SHIELD
INSTALLATION
Reverse the preceding operation.
FRONT FENDER
REMOVAL (FIG. 11)
(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 side applique as necessary to clear
front fender. Refer to Body Side Applique Removal
paragraph in this section. (5) Remove bolts holding bottom of front fender at
rear of wheel opening. (6) Remove bolt holding front fender to hinge pil-
lar at rear of wheelhouse. (7) Remove bolt holding front fender to cowl at top
of front door opening. (8) Remove bolts holding front fender to underside
of 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
Fig. 8 Cowl Cover Assembly
Fig. 9 Front Wheelhouse and Transaxle Splash
ShieldsÐTypical
Fig. 10 Engine Drive Belt Splash ShieldÐTypical
Ä AG-BODY 23 - 55

Page 2212 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual mm (0.240 in) gap to front door edge. All surfaces
across gaps should be flush.
DOOR TRIM PANEL
REMOVAL (FIG. 12)
(1) Lower door glass to down position. Disconnect
battery negative cable, if equipped

mm (0.240 in) gap to front door edge. All surfaces
across gaps should be flush.
DOOR TRIM PANEL
REMOVAL (FIG. 12)
(1) Lower door glass to down position. Disconnect
battery negative cable, if equipped with power win-
dows. (2) Remove window crank screw cover. Remove
screw holding window crank to regulator and sepa-
rate crank from door, if equipped with manual win-
dows. (3) Remove screw holding inside latch release han-
dle bezel to door. Slide bezel forward and remove
from door panel. Disconnect power door lock switch
wire connector, if equipped. (4) Pull power mirror switch outward to disengage
clips holding switch to door panel. Disconnect mirror
switch wire connector, if equipped. (5) Lift upward at rear edge of power window/seat
switch bezel to disengage clips holding bezel to door
panel. Disconnect wire connectors from power win-
dow and power seat switches, if equipped. (6) Remove screw holding trim panel to door from
inside power window switch bezel opening. (7) Pry outward on reflector lens to disengage
clips. Remove screw holding trim panel to door from
behind reflector. (8) Remove hidden screws holding trim panel to
door from carpet area on trim panel. (9) Disengage push-in fasteners holding trim panel
to door at ends and bottom center of trim panel. (10) Lift trim panel from door.
INSTALLATION
Reverse the preceding operation.
FRONT DOOR SILENCER AND WATER SHIELD
REMOVAL (FIG. 13)
(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.
Fig. 11 Front Fender
Fig. 12 Door Trim Panel
Fig. 13 Front Door Silencer and Water ShieldÐTypical
23 - 56 AG-BODY Ä

Page 2213 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual FRONT DOOR REMOVAL (FIG. 14)
(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 a

FRONT DOOR REMOVAL (FIG. 14)
(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. 14)
(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.
MANUAL 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) Remove bolts holding regulator to inner door
panel. (5) Slide regulator lift arm roller from lift plate
channel. (6) Remove regulator assembly through access hole
in door.
INSTALLATION
Reverse the preceding operation.
POWER WINDOW REGULATOR
REMOVAL (FIG. 15)
(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 to keep the glass from falling.
Disconnect battery negative cable. (4) Remove bolts holding regulator to inner door
panel. (5) Remove nuts holding lift plate to glass.
(6) Remove regulator assembly through access hole
in door.
INSTALLATION
Reverse the preceding operation.
Fig. 14 Front Door Assembly
Fig. 15 Power Window Regulator
Ä AG-BODY 23 - 57

Page 2214 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual MANUAL WINDOW REGULATOR
REMOVAL (FIG. 16)
(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 to

MANUAL WINDOW REGULATOR
REMOVAL (FIG. 16)
(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 to keep the glass from falling. (4) Remove bolts holding regulator to inner door
panel. (5) Remove nuts holding lift plate to glass.
(6) Remove regulator assembly through access hole
in door.
INSTALLATION
Reverse the preceding operation.
MANUAL WINDOW LIFT PLATE AND GUIDE
REMOVAL (FIG. 16)
(1) Remove door trim panel, silencer and water
shield. (2) Raise glass enough to align lift plate to large
access hole in inner door panel. (3) Remove nuts holding glass to lift plate.
(4) Separate glass from lift plate and allow glass to
rest on bottom of door. (5) Remove bolt holding guide bar to upper door
frame. (6) Remove bolts holding guide bar top inner door
panel. (7) Slide regulator lift arm roller from lift plate
channel. (8) Remove lift plate and guide bar through large
access hole in inner door panel.
INSTALLATION
Reverse the preceding operation.
DOOR GLASS
REMOVAL (FIG. 17)
(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.
GLASS RUN WEATHERSTRIP
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. 18)
(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.
Fig. 16 Manual Window RegulatorFig. 17 Door Glass
23 - 58 AG-BODY Ä

Page 2215 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual (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

Page 2216 of 2438

CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual DOOR OPENING WEATHERSTRIPS
REMOVAL
(1) Remove interior trim as necessary to gain ac-
cess to door opening weatherstrip. (2) Pull weatherstrip from pinch flange around
door opening.
INSTALLATION
(1) L

DOOR OPENING WEATHERSTRIPS
REMOVAL
(1) Remove interior trim as necessary to gain ac-
cess to door opening weatherstrip. (2) Pull weatherstrip from pinch flange around
door opening.
INSTALLATION
(1) Locate the middle to the weatherstrip at the
center of the upper pinch flange. Push weatherstrip
onto pinch flange at the top corner near the B-pillar. (2) When the weatherstrip has been installed down
the door opening to the sill pinch flange, mate the
ends of the weatherstrip together and finish install-
ing.
BODY SIDE MOULDINGS
STICK-ON BODY SIDE MOULDING REMOVAL AND INSTALLATION
(1) Warm the effected stick-on moulding and body
metal to approximately 38ÉC (100ÉF) using a suitable
heat lamp or heat gun. (2) Pull stick-on moulding from painted surface.
(3) Remove adhesive tape residue from painted
surface of vehicle. (4) If moulding is to be reused, Remove tape resi-
due from moulding. Clean back of moulding with Mo-
par, Super Kleen solvent or equivalent. Wipe moulding dry with lint free cloth. Apply new body
side moulding (two sided adhesive) tape to back of
moulding. (5) Clean body surface with Mopar, Super Kleen
solvent or equivalent. Wipe surface dry with lint free
cloth. (6) Apply a length of masking tape on the body,
parallel to the top edge of the moulding to use as a
guide, if necessary. (7) Remove protective cover from tape on back of
moulding. Apply moulding to body below the mask-
ing tape guide. (8) Remove masking tape guide and heat body and
moulding, refer to step one. Firmly press moulding to
body surface to assure adhesion.
BODY SIDE APPLIQUE
REMOVAL (FIG. 23)
DOOR APPLIQUE
(1) Remove rivets holding bottom or door applique
to door pinch flange usin ga3mm(0.125 in.) drill.
(2) Lift door applique upward to disengage appli-
que from retainer channel. (3) Separate applique from door.
SILL APPLIQUE (1) Remove push-in fasteners holding sill applique
to bottom of rocker panel. (2) Remove push-in fasteners holding sill applique
to front and rear wheel lip openings. (3) Lift sill applique upward to disengage applique
from retainer channels. (4) Separate sill applique from vehicle.
INSTALLATION
Prime and touch-up bare metal surfaces before in-
stalling applique to avoid corrosion. Reverse the re-
moval operation.
Fig. 21 Window Opening Moulding
Fig. 22 Outer Belt Weatherstrip
Fig. 23 Body Side Applique
23 - 60 AG-BODY Ä

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