oil DATSUN 210 1979 Service Manual

Condition

Unbalanced
brakes

Brakes
fade

Brakes

drag
Brake

System

Probable

cause

Improper
tire
inflation

Improp
r

adjustment
of
shoe
to
drum
clear

ance

Grease
oil
mud
or
water
on

linings
or

pads

Mud
in
brake
drum

Deterioration

oflinings
or

pads

Excessi
wear
of

linings
or

pads

Wheel

cylinder
in

poor
condition

Poor

sliding
condition
of
brake
shoe

Looseness
of

cylinder
body
or

back

plate

securing
bolts

Scored
or

out
f
round

drums

Sticking
wheel
cylinder

cups

Deformation
of
back

plate

Incorrect

adjustment
of
wheel

bearings

Incorrect

adjustment
of
wheel

aligoment

Looseness
of
leaf

spring
securing
U
bolts

Brake
fluid

has
too

low

boiling
point

Use
of

improper

linings
or

brake

linings
are

contaminated

Brake
drums
are

out
f

round

Hydraulic
connections
master

cylinder
and

wheel

cylinders
are
corroded
or

damaged

Bleed
screw
is

open

Pedal

linkage
is

binding
or

push
rod

adjust

ment
is
too

long

Master

cylinder

compensator
part
is

ob

structed

Seized
master

cylinder

piston

Poor
shoe
condition

Poor
wheel

cylinder
condition

Deformation
of

piston

cups

Poor
condition
of

caliper
because
of

faulty

piston
seals

Excessive
runaut
of
rotor

Hand
brake

will
not
return

Clogged
m

ter

cylinder
return

port

BR
20
Corrective
action

Inflate

to
correct

pressure

Readjust

Clean
brake
mechanism
and

check
for

cause

of

problem
Replace

linings
or

pads

Clean

Replace

Replace

Repair
or

replace

Adjust

F
ten
or

replace

Recondition
or

replace
brake
drum
as
re

quired
Check
for

improper

lining
contact

with

dflllll
and

grind
lining
if

necessary

Recondition
or

replace
cylinder

Replace

Adjust
or

replace

Adjust

Tighten
or

replace

Drain
and
fill

system
with

appr
d
fluid

Replace
linings

Repair
or

replace
as

necessary

Repair
as

necessary

Close
screw

and
bleed

system

Lubricate

linkage
check

pedal
return

spring

for
condition
and

adjust
push
rod
as
neces

sary

Blowout

foreign
matter
with

compresSed

air

Disassemble

master

cylinder
and

replace

piston
Bleed

system

Clean
and

repair

Repair
or

replace

Replace

Replace
piston
seals

Turn
rotor
on
lathe
or

replace

Check
and

repair

Clean

Condition

Brakes

drag

Brake
chatters

Brake

squeals

Pedal

pulsates

Rear

lock

under

light
brake

pedal
force

Rear

lock

under

heavy
brake

pedal
force
Brake

System

Probable
cause

Clogged
brake
lines

Incorrect

adjustment
of
wheel

bearings

Improper
shoe
to
drum
clearance

Weak
shoe
return

springs

No

free
travel
in

brake
shoe
return

Groove

or
out
of
round
brake
drum

or
rotor

Loose

or
bent

support
plate

Distorted

brake

shoes
or

pads

Grease
or

brake
fluid
on

linings

Dirty
or
scored

brake
drums

Distorted
brake
shoes

or
bent

support
plate

Weak
or
broken
brake
shoe

retaining
spring

or
return

spring

Glazed
or

contaminated
brake

lining

Out
of
round
or
off
center
drum

On

disc
brakes
lateral
runout
of
brake

rotor

is

excessive

Excessive
variation
in

thickness
of
brake

rotor
surfaces

Improper
tire

pressures

Excessive

wear
of

tires

Faulty
NP
valve

Improper
tire

pressures

Excessive
wear
of
tires

Poor

front

braking
effect

Grease
oil
mud

or
water
on

linings

or

pads

Excessive
wear

of

linings
or

pads

Local
fit
of

linings
or

pads

Master

cylinder
or

wheel

cylinder
in

poor

condition

BR
2t
Corrective
action

Check
and
clean

Adjust
or
repair

Adjust

Replace

Adjust

pedal
height

Grind
or
replace
as

required

Tighten
support
plate
bolts
to

specified

torque
or

replace

plate

Replace
as

necessary

Replace
linings

Blowout

assembly
with

compressed
air

or

refinish
drum

Replace
faulty
unit

Replace
if

faulty

Cam

ground
lining
to
elilninate

glaze
If
it

doesn
t

replace
linings

Turn
drum
or

replace
as

necessary

Check
with
dial
indicator

turning
disc

by

hand
If
runout
exceeds

specifications
re

place
disc

Measure
around
disc
face
with
micrometer

Replace
disc
as

required

Check
and

adjust

Check
and

replace

Replace

Check
and

adjust

Check
and

replace

Clean
or

replace

Replace

Shave
or

replace

Repair
or

replace

2
To
install
wheel

tighten
wheel

nuts
in
criss
cross
fashion

As

for
aluminum
wheels

proceed
as

follows

I

Snugly
tighten
four
nuts
after

wheel
is

positioned
See

Fig
WT
3

Iil
Tightening
torque

Wheel
nut

Steel
and
aluminum
wheels

8
0
to
10
0

kg
m

58

to
72
ft
Ibl

CAUTION

Two

types
of
wheel
nuts
Bre
used

one

is

designed
for
use
with
steel
wheel

Bnd

the
other
for

use
with
aluminum

wheel
Do
not

mix
different

types
of

wheel
nuts

p

WT020

For
aluminum

wheels

only
c

WH246

For
teel

wheels
only

Fig
WT
4
Wheel
Nut
Wheel
and
Tire

2

Slightly
pull
wheel
back
to

prop

erly
align
nuts
with

bolt
holes
in

wheel
and

tighten
nuts

as
much

as

possible
with

your
fingers

3

Tighten
four
nuts

evenly
with

a

wheel
wrench

in
criss

cross
fashion

f

WT016
Align
nuti
with

bolt
holes
in

wheel
and

evenly
tighten
nuts

each
one
a

little
at
a

time

Fig
WT
3

Installing
Aluminum
Wheel

Note
Be
careful
not
to
smear
thread

ed

portion
of
bolt
and
nut
and
seat

of
nut
with
oil
or

grease

TIRE

ROTATION

Tires
tend

to
wear

unevenly
and

become
unbalanced
after
a
certain

running
distance
Uneven

tire
wear

often
results
in
tire
noise
which
is

attributed
to

rear
axle

gears
bearing

etc

Front
tires
also

tend
to
wear

unevenly
because
of

improperly
align

ed
front

wheels

Accordingly
to

equalize
tire
wear

it
is

necessary
to
rotate
tires

periodi

cally
as
recommended
in
the
Periodic

Maintenance

WT
3
Bias

and
Bias
Belted
Tires

Right
front

Right
rear

c
J
c
l

X@

c
l
c
J

Left

front
Left

rear

4
WH
EELS

Right
front

Right
rear

c
J
c
l

@

9
c
J

Left
front

Left

rear

5

WHEELS

Radial
Tires

Right
front

Right
rear

c
J

c
l

@

c
l

c
J

Left
front
Left
rear

4

WHEELS

Right
front

Right
rear

c
J

c
J

c
l

Left
front

Left
rear

5
WHEELS

WT021

Fig
WT
5
Tire
Rotation

INSPECTION

WHEEL
BALANCE

The
wheel
and
tire

assembly
should

be

kept
balanced

statically
and

dy

namically

Proper
tire
balance
is

necessary

when

driving
the
car
at

high

speeds

Consequently
the

wheel
and
tire

as

sembly
should
be

properly
rebalanced

whenever

puncture
is

repaired

The
wheel
and
tire

assembly
be

comes
out

of
balance
according
to

uneven
tire

wear
Severe
acceleration

and

braking
or
fast

cornering
is

the

cause
of
wear
on
tire

resulting
in

unbalance
of
tire
and
wheel

assembly

Steering
System

6
Reriiovebolt

Securing
worm
shaft

to
rubber

coupling

7
Remove
nut

and
lock

washer

se

curing
gear
arm
to
sector
shaft

Using

Steering
Gear
Arm

Puller

512902000
I

remove

steering
gear

arm

from
sector
shaft

Gear

housinif
I

0

Cearar
8
Remove

bolts

securing
steering

gear
housing
to

body
side
member

and
withdraw

steering
gear
housing

from

engine
compartment

n

ST289

Fig
ST

IB

Removing
Ste

i1l
Gear

Arm

Disassembly

f

Tightening
torque
of
bolts

and
nuts

kg
m
ft

Ib

@
2
0
to
3

0
14
to

22

@
2

0
to
3
0

14
to

22

@
7

0
to
8
0
51

to
58

@
2

0
to
3

0
14
to
22

ST864
1
Lock
nut

2
Filler

plug

3

Adjusting
shim

4

Adjusting
screw

5
Sector

shaft

bushing

6

Steering
gearhou
ing

7
Oil
seal

8
BaU

nut
9
Worm

shaft

10
Wonn

bearing

11
Wann

bearing
adjUsting

shim

12
Rear

cover

13
Oil
seal

14
Sector
shaft

Fig
ST

19

Steeri1l
Gear

SHi
Thoroughly
drail

steCring
gear
oil

by

removing
filler

plug
Place
steer

ing
gear
in

a
vise
with

Steering
Gear

Attachment
KV48100300
in

place

2

Loosen
lock
nut
and

remove
see

tor
shaft
cover

attaching
bolts
After

removing
sector
shaft
with
cover
re

move
cover
from
sector
shaft

by
turn

ing
screw
clockwise

1

Filler

plug

2
Lock

nut

3
Sector

shaft
cover

attaching

bolts

Fig
ST
20

Mounti1l

Steeri1l
Gear

in
a
Vue

3
Remove

rear
cover

securing
bolts

and
detach

rear
cover

4
Remove

bearing
adjusting

shim

s
and

steering
worm

assembly

ST
426

Fig
ST
21

Drawi1l
Steeri1l
Worm

A
em

b
y

CAUTION

a
Be
careful
not
to
allow
ball
nut
to

run
down
to
either
end
of
worm

The
ends
of
ball

guides
will
be

damaged
if
nut
is
rotated
until
it

stops
at
the
end
of

worm

b
00
not
detach
ball
nut
from

worm

shaft

assembly
If

necessary
replace

assembly

c
Do
not

remove
sector
shaft
bush

ings
from

steering
gear
housing

If

necessary
replace
gear
housing

assembly

d
Be
careful
not
to
allow

penetration

of

any
other
element
like
dust
or

dirt

Inspection

Wash
clean
all
the
disassembled

parts
in

cleaning
solvent
and
check
for

condition

Sector
shaft

I
Check

gear
tooth
surface
for

pitting
burrs
cracks
or

any
other

damage
and

replace
if

damaged

2
Check

sector
shaft
for
distortion

of
its
serration

and
if

necessary
re

place
In
this

case
be
8ure
to
check

gear
housing
and

steering
worm

as

sembly
for
deformation

Steering
worm

assembly

I

Inspect
ball
nut

gear
tooth
sur

face
and

replace
if

pitting
burrs

wear

or

any
other

damage
is
found

2

Ball
nut
must
rotate

smoothly
on

worm

gear
If
found
too

tight
as

sembly
should
be

replaced
Check
as

follows

I

Move
ball
nut
to
either
end
of

worm

gear
and

gradually
stand

worm

shaft
and
ball
nut

assembly
until
ball

nut

moves
downward
on
worm

gear

under
its

own

weight

2
In
the

above
test
if
ball
nut
does

not
move

freely
over
entire

stroke

assembly
may
be

damaged
Replace

with

a
new
one

Note
In
this

inspection
be
careful

not
to

damage
ball
nut

guide
tube
Steering

System

ST037

Fig
ST
22
In

pecting
Steering
Worm

and
Ball
Nut

A8sembly

Bearings
and

bushings

I

Inspect
worm
bearing
for
wear

pitting
or

any
other

damage
Replace

with
a
new
one

as

required

Note
When

replacing
worm

bearing

replace
it

as
a
set

of
bearing
and

outer

race

2

If
sector
shaft

bushings
in

gear

housing
are
found
worn
or

damaged

replace
as
an

assembly
of

gear
housing

and

bushings

Oil
seals

Discard
oil
seal
which
is
once
re

moved

Replace
oil
seal
if

sealing
lip
is

deformed

or
cracked
Also
discard
oil

seal
if

spring
is

fatigued
or
dislocated

Assembly
snd

adjustment

Assemble

steering
gear
in
reverse

order
of

disassembly
Observe
follow

ing
instructions

Clean
all

parts

2
Lubricate

bearing
turning
surface

gear
surface

gear
tooth
and
other

sliding
parts
with

clean

gear
oil

3
Fill

space
between

sealing
lips
of

new
oil
seal
with
recommended
multi

purpose
grease
and
fit
it

to

gear

housing
and
rear
cover

Note

a
To

facilitate
installation
coat

seal

contacting
face
of
oil
seal
with

gear

oil

b
Press
oil
seal
into

place
with
its

lettered
side

facing
outside
of

gear

housing
or
rear
cover

5T
7
CAUTION

Be
careful
not
to
assemble
with

any

other
element
like
dust
or
dirt

Adjustment
of
worm

bearing

preload

4

Properly
position
steering
worm

assembly
in

gear
housing
with
worm

bearings
Install
rear
cover
on

gear

housing
with
worm

bearing
shims

fJ
Tightening
torqu

Rear

coyer

2
0

to
3
0

kltm

14
to
22
ft

Ibl

Note
Be
sure
to
install
the
thicker

shUn

on

gear
housing
side

Standard
shim
total
thickness
is
1
5

mm
0
059
in

Available
worm

bearing
shUn

No
Thickness
mm
in

I
0
762
0
0300

2
0
254

0
0100

3
0

127
0
0050

4
0

050
0
0020

5

Selecting
suitable

bearing
shims

adjust
worm

bearing
preload
with

Drive
Pinion
Preload

Gauge

ST3I
27S000

Initial

turning
torque

Worm

bearing

4
0

to
6
0

kg
m

3
5

to
5
2
in

bl

Note

a
Rotate
worm

shaft
a
few

turns
in

both
directions
to

settle
worm

bear

ing
in

and
measure

preload

b
When

adjusting
worm
bearing

pre

load
add
and
then
remove

shim
s

until
correct

adjustment
is

achieved

Fig
ST
23
Mea

uring
Initial

Turning

Torque

6
After
correct
worm

bearing
pre

load
has
been

obtained
remove
rear

cover
and

apply
sealant
on

housing

and

cover
sides
of
shims

Reinstall
rear
cover
with
shims
at

tached
under
cover

fJ
Tightening

torque

2
0

to
3
0

kg
m

14
to
22
fHbl

Adjustment
of

sector
shaft

and

adjusting
screw

7

Insert

adjusting
screw
with

adjust

ing
shUn

into
T

shaped
groove
at
the

sector
aft

head
and

adjust
the

end

play
between

sector
shaft

and

adjust

ing
screw

End

play
betwean
sector

shaft
and

IKljusting
screw

0

01
to
0

03
mm

0
0004

to
0
0012
in

Available
sector
shaft

adjusting

screw
shims

No
Thickness
mm
in

2
1
575

to
1

600

0

0620
to
0

0630

1

550
to
1
575

0
0610

to
0

0620

1
525
to
1

550

0

0600
to
0

0610

1
500
to
1

525

0
0591
to
0

0600
3

4

Note
When

installing

adjUsting
shim

pay
attention
to

which
face
is

upper
and
which

is
lower
Steering
System

Adjusting
shilli

Upper
1

sector

l

cover
side

ST258

Fig
ST

24

Measuri
End
l
UJy

tween
Sector

Shaft
and

AeVusting
Screw

8

Rotate
wonn
shaft

by
hand
until

ball
nut
is
in
the
center
of
travel
then

install

sector
shaft

together
with
ad

justing
screw
in

gear
housing
ensuring

that
center

gear
of
sector
shaft

engages

with
the
center

gear
of
the
ball
nut

Note
Be

careful
not
to

damage
seal

ing
lips
of
oil
seal

during
thi5

operation

9

Install
sector
shaft
cover
to

gear

chousing
Be
sure
to

apply
sealant
to

each
face
of
sector
shaft
cover

packing

when

installing
cover

By
turning
adjusting
screw
counter

clockwise
attach
sector
shaft
cover
to

gear
housing
and
then

temporarily

secure
it

with
its

futing
bolts

10
Pull
sector
shaft
toward
cover

approxUnately
2

to
3
mm
0
08
to

0
12
in

by
turning

adjusting
screw

counterclockwise
and

tighten
sector

shaft
cover

fIXing
bolts

fJ

Tightening
torque

Sector
shaft
co
er
bolts

2
0

to
3
0

kg
m

14

to
22
ft
Ib

II

Push
sector

shaft

against
ball
nut

gear
by

gradually
turning

adjusting

screw
clockwise
until
sector
shaft

gear

lightly
meshes
with

ball
nut

gear
and

then

temporarily
secure

adjusting

screw
with
lock
nut

12

Install

gear
arm
to
sector

shaft

and
move
sector
shaft
several
times

from

the
side
of

gear
ann

and
make

sure

that
it

turns

smoothly

SHl
13

Adjust
backIashat
neutral

posic

tion
of

steering
gear
by

turning
adjust

iog
screw
in

or
out
so
that

movement

of

gear
arm

top
end
is

less
than

specified
value

Backlash
at

gear
arm

top
end

Less
than

0
1

mm
0
004
in

ST
427

Fig
ST
25

Measuri
Bocklash

14

Then

tighten
lock
nut
after

mov

ing
sector

shaft
several
tUnes

fJ

Tightening
torqu

Lock
nut

2
0
to

3
0

kg
m

14

to
22
ft

Ibl

ST
428

Fig
ST
26

Tighteni
Loek

Nut

15
Measure
initial

turning
torque
of

wonn
shaft

assembly

At
center

portion

4
0
to
9
0

kt
c
m

3
5

to
7
8
in
lbl

Maximum

turning
torque

Less
than

11
0

kg
c
m
9
5
in
Ib

If
found

out
of
above

turning

torque

readjust
adjusting
screw
uniil

correct

turning

torque
is
obtained

16

Pour
recommended

gear
oil
into

assembly

through
fdler
hole
and
install

filler

plug

REMOVAL

I
Jack

up
the
front
of
car
and

support
it

on
the

safety
stands

2
Remove
cotter

pins
and
nuts

fastening
side
rod
ball

studs
to
knuckle

arms

3
To

detach
side
rod
ball

studs

from

knuckle
arms

iJuert
Steering
BaII

Joint

Remover
HT72520000
between

them

and

separate
them

ST675

Fig
ST
28

Remouing
Ball
Joint

4

Remove
ball

studs
of
cross
rod

from

gear
arm

and
idler
arm
from

cross
rod
in
the

same
manner

as

descnbed
in

step
3
above

Cross
rod

and
side
rods
can
be

removed

as
an

assembly

5
Remove

idler

assembly
from
side

member

by

taking
off
two

fixing
bolts

Note

Steering

linkage
assembly
can

be
removed
from

CIC

by

rem
mng

gear
arm
from
sector

shaft
with

Steering
Gear

Arm
Puller

ST2902000

I
and

by

removing
idler

assembly
from
side
member

INSTAllATION

I

Install

steering

linkage
in
the

re

verse
order
of

removal

iJJ
Tightening
torque

Il8l1ltud

3
0
to

7
0

q
m

122
to
51
ft

Ibl

Idler

body
to
frame

bolts

7
0

to
8

0

q
m

151
to

58
ft

Ibl

2
Check
wheel

alignment
and
if

necessary
adjust
Refer
to
SectionF
A

DISASSEMBLY

I

Disconnect
both

side
rods
from

the

cross
rod

following
the

procedure
Steering
System

for
removal
of
the
side
rod
ball

joints

at
knuckle
arm
sides

2

Remove
the
idler

arm
nut
and

disassemble
idler

assembly

ASSEMBLY
AND

ADJUSTMENT

A
mble
st

rwg
linkage
in
the

reverse
order
of

disassembly

observing

the

following
instrucitons

Ban

Joint

Before

installing
a

new
dus
cover

be
sure
to

pack
with
the
recommended

grease

t
J
Tightening
torque

Ballltud

3
0

to
7
0

kg
m
122

to
51
ft
lbl

Note

a
When

tightening
ball
stud
be
care

ful
not
to

aBow

grease
to

get
On
its

tapered
section

b

Tighten
nut
to
the

specified
torque

and

align
the
cotter

pin
holes
in
the

tightening
direction

c
Be

sure
to
insert
new
cotter

pin
and

bend

it

securely

Idl
r
rm
mbl

Assembly
of
the
idler

arm
assembly

is

accomplished
as
follows

I

Apply
recommended

grease
to

the

sliding

portion
of
idler
arm
and

rubber

bushing

2

Apply
soapy
water

on
the

outer

circumference
of

bushing

Pre
ss
the

bushing
into

idler

body

carefully
until
the
bushin

protrudes

iJJ
Tightening

torque

Idler
nut

5
5
to
7
0

q
m

4010
51
ft

Ib

Note
When

installing
rubber

bushing

use
care
not
to
allow

grease
or

oil

Hj1

ST

10
to

get
on
its
onter
surface

ST676

Fig
ST
29
Idler
Arm

Cro
rod
nd
Id
rod

I
When

side
rod

sockets
and
side

rod

adjusting
tube

are

separated

adjust
side
rod

length
correctly

Adjustment
should
be
done
be

tween
ball
stud
centers

Standard
distance
AU
between

inner
and
outer
ballltud

conte

315
mm
12
40
in

Note

a
Standard
distance
A

i
an

ap

proximale
value
to

adjust
toe

in

descnbed
in
Section
FA

Maire
sure
tbat

specified
toe
in

is

obtained
with
O
OSs
and
side
rods

installed

on
car

ReadjUst
if

Specified
toe

in
is

not

obtained

b
Be

sure
to
screw

adjusting
bar
in

clret

evenly

c
Make

sure
that

adjusting
bar
is

screwed
in
socket
20
mm
0
79
in

or

more

I

lf

A

ST
77

Fig
ST
30
Standard
Side
Rod

Length

RADIATOR

GRILLE

REMOVAL
AND

INSTALLATION

I

Open
hood

2

Remove

radiator

grille
attaching

screws

3

Detach

radiator

grille
from
front

end
of

car

4

Disconnect
front

combination

lamp
connectors
Then
remove
radia

tor

grille

S

Installation
is
in
the

reverse
order

of
removal

Note

a

Radiator

grille
is
made
of

plastic
so

do
not

use
excessive

force

b

Take
care
to

keep
any
oil

away

from
radiator

grille

FRONT
APRON

REMOVAL
AND

INSTALLATION

1
Remove

screws

attaching
front

apron
to
front

fender

2

Remove

screws

attaching
front

apron
to
hood
lock

stay

3
Remove

screws

attaching
front

apron
to

radiator
core

support

4

Remove
screws

attaching
front

apron
to
bracket

S

Installation
is
in
the

reverse

order

of

removal
Body

BODY
FRONT
END

8F7448

Fig
BF
11

Removing
RadiIJtor
Grille

S

1

i
oo

1
0

ole

I

Q
I
f

J

0

0

i
I

g

nl

o

A

BF
9
4

1

J
n

Jf

rf

BF745B

Fig
BF

12

Remouing
Front

Apron

DESCRIPTION

The
rear

window

glass
is

butyl

sealed
aU
around
the

periphery
and
is

retained
with

screws
in
the

corner

areas
In
addition
it
is
also

bonded

with
adhesive
at
the

upper
and
lower

middle

portions
The

molding
is

glued

to

the

straight
line
of
the

glass
and
the

corner

moldings
are
fitted

to
the

glass

REMOVAL

CAUTION

00
not

attempt
to

pry
moldings
glued

to
rear

window

glass

1

Remove
rear
window
welt

2

Remove

luggage
rear
finisher

3

Disconnect

rear
window

defogger

connections

4

Remove
rear
window

wiper
arm

along
with
blade
if

equipped

5

Remove
rear
window
comer

moldings

6

Loosen
window

glass
retaining

screws
and

remove
rear

window

glass

retainers

II

1

BF753B

Fig
BF

64
Removing
RNr
Window

G
Retainer

7
Cut
off

butyl
seal
around

entire

periphery
of

glass
as
follows

I
Secure
one
end
of

steel
music

wire

0
5
mm
0

020
in
in

diameter

to
a

piece
of
wood

that
can
serve

as
a

handle

Using

long
nose

pliers
insert

other

end
of
wire

through
butyl
seal

at

edge

of

glass
then

secure
that
end
of
wire

to
another
wood

handle

2
With
the
aid
of

an
assistant

carefully
cut

through
bytyl
seal
Body

arDUna
entire

periphery
ofwirid6

by

pull
wire

with
a

sawing
motion

BF754B

Fig
BF

65

Cutting
Butyl
S
I

CAUTION

To

avoid

damage
to

defogger
lead

plate
harness
running
along
the

periphery
of

rear
window

glass
on
left

and

right
lower
half

portions
pull
out

steel
music
willi
as
it

comes
near

upper

side

of

harness
and
then
insert

it
into

area

near
lower
side
of
harness

to

continue

cutting
butyl
seal

71
A

L

0

fr

f

1
Lead

plate

BF755B

Fig
BF
66
Location

of
Rear
Window

Defogger
Lead
Plate

and

Harness

8

Support
rear
window

glass
with

SuckerST08800000

BF756B

Fig
BF
67

Supporting
Rear
Window

GLus

BF
24
9

From
inside
car

push

glass
up

and

out
of
window

opening
Then

dis

connect
rear
window

defogger
harness

10

Using
a

rag
dampened
with
un

leaded

gasoline
wipe
any
trace
of

butyl
seal
or

adhesive
off

tailgate

II

Remove
most

of
adhesive
from

bonded

areas
of
rear
window

opening

with

a
razor
blade
or

scraper

leaving
it

approx
1

0
to
2
0

mm
0

039

to

0

079
in

thick

CAUTION

If

body

painted
surtin
e
is

scratched

be
sure
to

repair
that
area
with

paint

INSTALLATION

I

Remove

tailgate
from

body
Re

fer
to

Tailgate
for
removal

2

Place
a

suitable
stand
s
under

tailgate
so
rear

window

gla
s
is

set

level

CAUTION

Securely
support
tailgate
to

prevent
it

from

being
deformed

3

Clean

contacting
surfaces
of
tail

gate
and
rear

window

glass
with
a

rag

dampened
with
unleaded

gasoline

CAUTION

00
not
allow
oil

grease
or

water
to

get

on
clean
surfaces

4

Attach

butyl
seal
around

entire

periphery
of

rear
window

glass
so
that

outer

edge
is

6
mm
0
24

in

beyond

glass
See

Fig
BF

68

Note

a
Do

not
touch
surfaces

of

butyl

seal
which
comes
into

contact

with

glass
and

tailgate
with
hands

as
this
will
reduce

sealing
effects

b

Always
amx
a

continuous
bead
of

butyl
seal

be
sure
to

overlap
one

end
of

butyl
bead

approximately

i
0

mm
0
39
in
over

the
other

end

A
bread
can
cause
water

leakage

Body

REAR
SIDE
WINDOW
GLASS
Wagon

4

1

Body

2
Rear

side
window

molding

3
Rear
side

window
glass

4

Butyl
seal

5
Rubber

Bf7628

Fig
BF
78

Rear
Side
Window
Glo
8

DESCRIPTION

The

rear
side
window

glass
is

butyl

sealed

all
around
its

periphery
and
is

retained

with
four

bolts

REMOVAL

CAUTION

Do
not

attempt
to

pry
moldings
glued

to
the
rear
side

window

glass

BF763B

Fig
BF
79

Removing
Nuts

front

portion

1

Remove
rear
side
window
welt

2

Remove

luggage
side

upper
finish
4
Remove
air
outlet

grille

S
Remove

bolts

securing
rear

por

tion
of

rear
side
window

glass
er

3
Remove

nut

securing
front

por

tion
of

rear
side
window

glass

lt

BF7648

Fig
BF
80

Removing
Bolts

rear

portion

BF
27
6

Using
a
knife
cut
off

butyl
seal

around
entire

periphery
of

glass

Note
It
is
advisable
to
start

cutting

butyl
seal
at
rear

portion
of

window

glass
while

pulling
glass

outward

BF765B

Fig
BF

81
Cutting

Butyl
Seal

7
Remove
rear

side
window

glass

8

Using
a

rag
dampened
with
un

leaded

gasoline
remove

any
trace
of

butyl
seai
from

car

body

INSTALLATION

I
Clean

contacting
surfaces
of

body

and
rear
side
window

glass
with
a

rag

dampened
with

unleaded

gasoline

CAUTION

Do
not
allow
oil

grease
or
water
to

get

on
clean
surfaces

2

Attach

butyl
seal
around
entire

periphery
of
rear
side
window

glass
so

that
inner

edge
is

at

specified
distance

from

printed
black
area
on

glass
See

Figs
BF
82
and
BF

83

Note

a
Do

not
touch
surfaces
of

butyl
seal

which

comes
into
contact
with

glass

and

tailgate
with
hands
as

this

will
reduce

sealing
effects

b

Always
affix

a
continuous
bead
of

butyl
seal
be
sure
to

overlap
one

end
of

butyl
bead

approximately

10
mm
0
39
in
over
the
other

end
A
break
can
cause
water
leak

age