check DATSUN PICK-UP 1977 Service Manual

I

J

L6

3

4

5
1

Apply
recommended

grease
to

screw

bushing
interior

plain
bushing

interior
dust
seal
inside
and

bushing

sliding
surface
of
idler
ann

Screw

bushing
tightening

torque

12

kg
m

87
ft
lb

2

Before

installing
idler
arm
assem

bly

replace
f
iller

plug
with

grease

nipple
and

apply
recommended

grease

to
idler

ann

through
this

grease
nipple

until

grease
is
forced

out
at
the

lower

end
of

the
dust

seal

lip
Remove

grease

I

8
I

II

I

I

FIODt

Inspection
and

repair

Ball

joint

1
When
ball
stud
is

worn
or
axial

play
is
too

excessive

replace
cross
rod

socket
or
side

rod
with
a
new
one

2
When

dust
cover
is

broken
or

defonned

be
sure
to

replace
with
a

new
one

Axial
end

play
0
1
to
0
5

mm

0
004
to
0
020
in

Initial

swing
torque

S
to
15

kg
cm
70
to
209
in
oz
STEERING
SYSTEM

nipple
and
reinstall

filler

plug

3
In

installing
idler
arm

assembly

make

sure
that
the

standard

dimension

A
is

adjusted
correctly

Standard
dimension

A

137
8
to

139
8

mm

S

42S
to
S
504

in

See

Figure
ST

14

Furthermore
be

sure
to

install

washers

correctly
See

Figure
ST
IS

Spring
washer

Frame

Plain
washer

Weld
nut

Self

locking
nut

ST212

Fig
ST
15
Locations

of
washers

Initial

swing
torque
5

to
15

kg
cm

70
to
209
in
oz

ST213

ST
7
sary
To
renew

grease
remove

grease

nipple
cap
and

apply
recom

mended

grease
to
ball

joint

through

grease
nipple
until

grease
is
forced

out
at
the

grease
vent
hole

Idler
arm

3B8embly

Remove
old

grease
and
dirt
and

check
idler

ann

assembly
for
wear

deformation
and

damage

CrOBS
rod
side
rod

and

gear
arm

Check
them
for

bending
damage

and
crack
and

replace
as

necessary

Inspecting
steering
system
on

the
vehicle

which
comes
into

collision

Steering
system
is

very
important

for

driving
a
vehicle
When
the

vehicle

comes
into

collision

especially
the

front
of
the

vehicle
is

damaged
special

inspection
should

be
done

for
the

following
matters

If

any
component
parts
of

steering

system
is

found

to
be

damaged
re

place
them

with
new
ones

1

Steering

angles
correctness

Inspect
side

rods
and

cross
rod
for

bend
and
sector
shaft

for
distortion

2

Level
of

steering
wheel
bar
with

the
front

wheels
in

a

straight
ahead

position

If
its
deflection
is

more
than
about

90

degrees
the

bend
or
distortion
of

sector
shaft

and
column
shaft
can
be

seen

3
Noise

during

operation
of

steering

wheel

Inspect
column
shaft

and

jacket

tube
for
bend

4
Smooth

operation
of

steering

wheel

Inspect
sector

gear
for

breakage

ball

nut
screw
for
dint
and
column

shaft

for
bend

S
Gear
arm

breakage

6
Gear

housing
breakage

In
addition

inspect
gear
housing

f

IXing
bolts
for
looseness

7
Distortion
of
sector
shaft
serra

tion

8
Sector

gear
breakage

Engine
Control
Fuel
Exhaust

Systems

REMOVAL
AND

INSTALLATION

Accelerator

wire

I

Remove
air
cleaner

assembly

2

Disconnect
accelerator
wire

from

carburetor

3

Loosen
lock

nut
and
disconnect

accelerator
wire
outer
case
from
wire

holder
See

Figure
FE
I

4

Remove

spring
clamp
and

discon

nect
accelerator
wire

from
accelerator

pedal
arm

S

Remove
two

screws

securing
ac

celerator
wire
outer
case
to

body
and

detach
accelerator
wire

6
To

install
reverse
the
order

of

removal

Apply
recommended
multi

purpose
grease
slightly
to

portion

MG
shown
in

Figure
FE
I

Accelerator

pedal
assembly

I
Remove

spring
clamp
then
dis

connect
accelerator
wire
from

tip
of

pedal
ann

2
Remove

two
screws

securing
ac

celerator

pedal
bracket

to

body

3
Remove

accelerator

pedal
from

dash

panel
See

Figure
FE
I

4
To
install
reverse
the
order
of

removal

INSPECTION

I
Check
accelerator

pedal
return

spring
for

rust

fatigue
or

damage

Replace
if

necessary

2

Check
accelerator
wire

cases
and

fastening
locations
for
rust

damage
or

looseness

Repair
or

replace
if

necessary

ADJUSTMENT

Accelerstor

pedal
and
wire

Adjust
pedal

stopper
bolt

Section
A

so
as
to
obtain

specifi

ed

height
E
as
shown
in

Figure

FE
I

Secure

pedal
stopper
bolt
with

stopper
lock
nut
Refer

to
Figure

FE
I
E

78
mOl
3
07

in

Tightening
torque
01
nut

0
38

to
0
4S

kg
m

2

7
to
3
2

ft
b

2

Release
auto

choke
effect
since

throttle
lever
is

opened
by
fast
idle

earn
until

engine
warms

up

I

Keep
choke
valve

fully
open

with

fingers

2

Pull
throttle
lever

up
by
hand

1

Adjust
nut

2
Lock
nut

3
Accelerator
wire

4
Dust
co

r

5
After

completing
the

adjustment

as

previously
explained
check
the

following

I

Make
sure

that
accelerator

system
functions

smoothly
and

quietly

without

disturbing
any
adjacent

parts

2

Depress
accelerator

pedal
down

until

throttle
valve

fully

opens
Make

sure
that

the
clearance
T
between

accelerator

pedal
reverse
side
and
dash

floor
is
2
to
4
mm
0
08
to

0
16
in

without
floor

mat

Adjust
pedal

stop

per
bolt
and
lock
nut
if

beyond
limits

3

Check
throttle

lever
if
it

returns

to
the

original
position
as
soon
as

accelerator

pedal
is

released

FE
3
then
automatic

choke
effect
will

be

released

3

Set
throttle
valve
to

completely

closed

position
and
with
wire

suf

ficiently
slackened

lighten

adjust
nut

until
throttle
lever
is
about
to
move

Accelerator

pedal
play
is

zero

at
this

lime
See

Figure
FE

2

4

Unscrew

adjust
nut

approxi

mately
two
and
a

half
turns
so
that

accelerator

pedal
play
is
3
mOl

0
012

in

Tighten
lock
nut

securely
See

Figure
FE
2

1

I

1

CD
@

FE184

Fig
FE72

AdjU6ting
accelerator
wire

play

4

Apply
recommended
multi

purpose
grease
slightly
on
the

portion

as
shown
in

Figure
FE
I
Also
refer

to

the

periodic
maintenance
schedule

Kickdown
switch
Automatic

transmission
models
only

Kickdown
switch

adjustment
is

cor

rect
if
it
is

actuated

by
kickdown

switch
striker
when

accelerator

pedal

is

fully

depressed

Always
tighten
switch

stopper
nut

securely
after

proper
adjustment
is

obtained

Engine
Control
Fuel
Exhaust

Systems

2
Remove
fuel

filter

INSPECTION

Fuel

tanle

Check
fuel

tank
for

cracks
or

deformation
If

necessary
replace

2
Fuel
hose

Inspect
all
hoses
for
cracks

fatigue

sweating
or
deterioration

Replace
any

hose
that

is

damaged

3
Fuel
tube

Replace
any
fuel
tube
that
is

crack

ed
rusted

collapsed
or
deformed

Note

Inspect
hoses
and
tubes
ac

cording
to
the

periodic
mainte

nance
schedule

4

Fuel
filter

Replace
fuel
filter

according
to

the

periodic
maintenance
schedule
or

when

it
is

clogged
or
restricted

DESCRIPTION

REMOVAL

DESCRIPTION

The
exhaust

systems
installed
on

the
non
California
models
differ
in

specifications
from
those
installed
on

the
California
models
Fuel
filter
is

of
a

cartridge
type

and
cannot
be
cleaned

Always

replace

with
a
new
one

5
Fuel
tank

gauge
unit

Check

gauge
unit

for
rust
deforma

tion
or

deterioration
If

necessary

replace

INSTALLATION

To
install
reverse
the
order
of

removal
Observe
the

following

I

Install
hose

clamps
securely
Do

not

tighten
excessively
to

avoid

damaging
hoses

2
Fasten

clips
holding
fuel
tube
on

under

body
securely
Failure
to
follow

this
caution

could
result
in

damage
to

the
surface

of
fuel

tube

3
Do
not
kink

or
twist

hose
and

tube
when

they
are
routed

EXHAUST
SYSTEM

CONTENTS

FE
6

FE

8
INSPECTION

INSTAllATION

Non
California
models

The
exhaust

system
consists

of
a

front
exhaust
tube
a
main

muffler

assembly
with
rear

tube

mounting

hangers
brackets
and
a
heat

insulator

FE
6
4
Install
fIller
hose
after
fuel

tank

has
been
mounted
in

place
Failure

to

follow
this
caution
could
result
in

leakage
from

around
hose
connections

5
When

installing
fuel
tank

gauge

unit

align
the

projection
of

tank

gauge

unit
with
the

notch
in
fuel

tank
and

tighten
it

securely
Be

sure
to
install

gauge
unit

with
O

ring
in

place

6
Run

engine
and
check
for
leaks
at

connections

Tightening

torque

Drain

plug

5

0
to
6
0

kg
m

36

to
43

ft
Ib

Fuel
tank

securing
bolt

0
8
to
1
I

kg
m

6
to
8
ft
Ib

Reservoir

tank

securing

bolt

032
to
0
44

kg
m

2

to
3

ft
Ib

FE
8

FE
8

California
models

The
exhaust

system
cOllsists
of

a

front
exhaust

tube
a

catalytic
conver

ter

assembly
a
center
tube
a

main

muffler

assembly
with
rear
tube

mounting
hangers
brackets
and
heat

insulators

The

catalytic
converter
is
COD

nected
to
the
front

tube
and
the

center

tube
with
bolts
and
nuts

Engine
Control
Fuel
Exhaust

Systems

REMOVAL

Non
California
models

I
Remove
exhaust
tube
U

bolt

clamp

2

Break
sealant
off
at
front
tube
to

main
muffler

connectio
n

3
Remove
rear
tube

mounting
bolt

and

remove
muffler

assembly
with

rear

tube

4
Remove

front
tube
heat

insulator

5

Remove
nuts

securing
front
tube

to
exhaust
manifold
and

remove
front

tube

mounting
bolts
Then
detach

front
tube

When

disconnecting
the
exhaust

tube

connections

pay
attention

to
the

following
point

I

Break
old

se
lant
off
at

t
1e

connection

by

lightly
tapping
around

the
tube

witlJ
a
hammer
and

twisting

muffler
See

Figures
FE

7
and
FE
8

2

Using
a
rubber
hammer

tap
on

the
front

end
of
muffler
while

pushing

it

toward
rear
The
mumer

assembly

can
then
be
taken

out
See

Figure

FE
9

FE187

Fig
FE
7

Breaking
Bealant

FEl88

Fig
FE
8

Twisting
muffler
ijl

4

FE189

Fig
FE
9

Tapping
muffler
with

Q
rubber
hammer

California
models

I
Remove

all
heat
insulators

2

Remove
exhaust
tube
U
bolt

clamp

3

Break
sealant
off
at
center
tube

to
main
muffler

connection

4

Remove
rear
tube

mounting
bolt

and
remove
muffler

assembly
with
rear

tube

5
Remove

bolts

securing

catalytic

converter
to
center
tube
and
remove

center
tube

mounting
bolts

Then
detach
center
tube

6
Remove
bolts
and
nuts

securing

catalytic
converter
to
front
tube
and

detach

catalytic
converter

7

Remove
nuts

securing
front

tube

to
exhaust
manifold
and

remove
front

tube

mounting
bolts

Then
detach

front
tube

INSPECTION

I
Check
muffler
and
tubes
for

cracks

Qr

damage

Replace
any

part
that
is

damaged

beyond
limits

2

Replace
bracket
and

mounting

insulator
that
are
cracked

fatigued
or

sweated

FE
8
INSTALLATION

Install
the
exhaust

system
assembly

in

reverse
order
of
removal
Observe

the

following

Notes

a
Insert
front
tube
until
it
touches

emboss

b
When
there
is

110
clearance
between

front
tube
and
floor

or

propeUer

shaft
turn
tube

along
center
line
of

tube

in
the
manifold

connecting

unit
and
obtain

proper
clearance

c
Check
all
tube
connections
for
ex

haust

gas
leaks
and
entire

system

for
unusual
noises

with

engine

running

d
After
installation
check
that

mounting
brackets
and

mounting

rubbers
are
free
from
undue
stress

If

any
of
the
above

parts
is
not

installed

properly
excessive
noises

or
vibrations

may
be
transmitted
to

the
vehicle

body

e

Tightening
torque

Exhaust
manifold
to

front
tube

nut

1
9

to
2
5

kg
m

14
to
18
ft
lb

U
bolt

securing
nut

1
9
to
2
1

kg
m

14
to
15

ft
lb

Mounting
bracket
bolt

1
0
to
1
2

kg
m

710
9
ft
lb

Front

tube

mounting
bracket

bolt

california
models

1
9

to
2
1

kg
m

14
to
15
ft
lb

Catalytic
converter
to
front

and
center
tube
bolt

California
models

3
2

to
4
3

kg
m

23
to
31
ft
Ib

If
exhaust

tubes
are

separated
at

connection

t
renew
muffler

assembly

etc
use
the
Genuine
Nissan

Sealant

Exhaust
Sealant
Kit
20720
N2225

or

equivalent
See

Figure
FE
IO
to

eliminate

gas
leakage
at
the

joint
Be

sure
to
observe
the

following

Engine
Control
Fuel
Exhaust

Systems

I

Wipe
clean
all
the

contact

por

tions
of
tube

joints
allow
them

to

dry

thoroughly

2

Temporarily
mount
in

place

muffler
assembly
as
an

assembled
unit

on
the
vehicle

3
Insert

front
tube
until
it
touches

emboss

m
b
nlfrnnjj

mm

lJ
Ij

@L
J

FE263

Fig
FE
ll
Exhawt
tube

connection

4

Torque
nut

securing
the
male
and

female

tubes
at
the
connection

Tightening
torque
is
1
6

to
2

0

kg
m

12
to
14

ft
lb

5

Squeeze

approximately
5

CC
0
31

cu
in

of
sealant
into

injection
from

sealant
tube
See

Figure
FE
12
Sealant
tube

polyethylene

Injector

Fig
FE
IO
Exhaust
sealant
kit

Be

sure
to

place
cap
back
to
sealant

tube
since
sealant
will

dry

Approximately

5
cc

0
31
Cll
in

FE1l1

Fig
FE
12

Squeezing
sealant
to

injec
tor

6

Position
nozzle
of

injector
to
the

guide
and

press
it

there

firmly
Inject

sealant

slowly
until
sealant
begins
to

flow
out

of
the
slit
of
tube
This

indicates

that
the
bead

requires
no

further
sealant
Excessive
sealant
can

cause
a

clogged
tube

See

Figure

FE

13

After

injecting
wash

injector

thoroughly
in
clean

water
to
remove

all
traces

of
sealant

FE191

Fig
FE
13
Injecting
sealant

FE
9
7
Start

engine
and
let
it
idle

slowly

for
ten
minutes

minimum
to

hilfden

sealant
with
the
heat
of
exhaust

gas

8
Check
the

condition
of

sealant

before

driving
the
vehicle
It

is
also

essential
that
the

vehicle
should
not

be

accelerated

sharply
for
20
to
30

minutes

subsequent
to
this

operation

Noles

a
The
sealant

should
be
used
within

guaranty
term
indicated
on
the

kit

case

b

Exposure
of
sealant
to
the
skin

may

cause
a

rash
Wash
sealant
off
the

skin
with
water

c
Do
not

keep
the

sealant
tube
in

a

place
where
the
ambient

tempera

ture
is

above
400C
I040F
A

sealant
hardened
above
4QoC

I040F
cannot
be
used
The
most

suitable

storage
temperature
is

from

15
to
350C
59
to
950F
If
sealant

becomes
hardened
because
of
low

temperatures
wann
the
sealant

tube
with
lukewarm
water
until
the

sealant
is

softened
Do
not
warm

tube

at
a

temperature
over
400C

1040F
for
a

long
time

d

Thoroughly
read
the
instruction

sheet
furnished
with
the
kit
before

using
the
sealant
i

Body
Frame

BODY
FRONT
END

1
Hood

2
Hood

support
rod
@

3
Hood

bumper

4
Fender

@

5

Bumper
bracket
shim

6
Bumper
side
bracket

7
Bumper

8

Bumper
stay

9
Front

apron

10
Radiator

grille

FRONT
BUMPER

REMOVAL
AND

INSTALLATION

L
Remove

bumper
to
fender
at

taching
bolts

2
Remove
four

bumper
stay
to

side

frame
front

attaching
bolts
Pull
bum

per
assembly

straight
forward

3
For
installation
reverse
above

steps
Align
bumper
with
front
fender

and

apron
then

tighten
them

up

RADIATOR
GRILLE

REMOVAL
AND

INSTAUATION

I

Remove
radiator

grille
by
re

moving

attaching
screws
six

on

top

and
two
on
both
ends

Remove
ornament
on
radiator

grille
by
removing
nuts
from
behind

radiator

grille
4

ZID

@

7

BF029B

Fig
BF
11

Body
front
end

FRONT
APRON
3

For
installation
reverse
above

steps
observing
the

following

I
Check
to
be
certain

that
six

guide
studs
enter
holes
in
radiator

support
lower
frame
before

tightening

top
screws

CD

@
REMOVAL
AND

INSTALLATION

I

Remove
front

bumper

2
Remove

radiator

grille

3

Disconnect
front
turn

signal
wire

harness
a
t
connector

4

Remove
front

apron
by
removing

attaching
bolts

S
For
installation
reverse
above

steps

B

632

1
Radiator

grille

2
Guide
stud

3
Guide

stud
hole

4
Radiator

support
lower

frame

Fig
BF
12
Radiator

grille
guide

studs

2

Align
grille
with
head

lamps
and

fenders

BF
7

REMOVAL
AND

INSTALLATION

I

Remove
hood
lock
male

by
re

moving
two

attaching
bolts

2
To
remove
hood
lock
female
first

remove
radiator

grille
Back
off
two

bolts

securing
hood
lock
female

in

position
Hood
lock
female

can
now

be
taken
out

3
Remove

two
bolts

attaching
hood

lock
handle

assembly
to
dash
side

paneL

Disconnect
cable
at
hood
lock

female
and
remove
cable

clamps
Pull

cable
out
into

cab

4

To
install
hood
lock
male
and

female
reverse
removal

procedure

Mter
installation
check
to
insure
that

they
are

properly
aligned

5
To

install
hood
lock
handle

as

sembly
reverse

steps
observing
the

following
notes

I
Check
to
be
certain
that

cable

clamps
are

tight
and
secure

2
Install
hood
lock
handle
bracket

in

place
by

using
two
of
four
holes

See

Figure
BF
19
Body
Frame

@

1

Hood
tock
handle

2

Hood
lock
handle

bracket
BF645A

3

Clamp

4

Hole

5

Attaching
bolt

Fig
BF

19

1MtalIing
hood
lock
handle

brocket

ADJUSTMENT
AND

INSPECTION

I
If
hood
lock
handle

is

heavy
turn

dove
tail
bolt
of
hood
lock
male
coun

terclockwise
to
reduce
tension
of

hood

lock

spring

Lock
nut
of
dove
tail
bolt
should

fust
be
loosened

If
looseness
is
noticed
hood
is

not

tight
and
will
vibrate
To
correct
this

turn
bolt
clockwise
and
recheck

2
Check
hood
lock
mechanism
as

follows

BF
10
I
Check

safety
catch

lever
and

spring
for
deformation

fatigue
or

rusting

2
Check

female
lever
and

return

spring
for
deformation

fatigue
or
rust

ing

Improper
operation
of
female

lever

may
cause

disengagement
be

tween
female
lever

and
dove
tail
bolt

3
Make
sure
that

safety
catch

hooks

engine
hood

properly
when

hood
latch
has
been

disengaged

0l

11
mm

I
nun
BF409A

0
433
in

0
3t5
in

Fig
BF
20

Safety
catch
lever
to

radiator

upper

support

acVu5tment

Lubrication

When

checking
or

adjusting
the

hood

lock
lubricate
the

pivot
catcher

and

return

spring
of

secondary
latch

thoroughly
Also
lubricate
the
lever
of

the
hood
lock
female
for

smooth
and

correct

operation

@

I

r

L

c

@

DESCRIPTION

The

door
consists

of
inner

and

outer

panels
welded

together
to

form
a

rigid
structure

The
curved

glass
provides
greater

shoulder
room

A
door

that

incorporates
a

ventila

tor

window
is
also
available

as
an

option

The

weatherstrip
is
inserted
into

the

groove
on
the

door
sash
side
and
is

attached

by
clips
on
the
door

side

DOOR

REMOVAL
AND

INSTALLATION

I
With
door
in
full

open
position

place
a

garage
jack
or
stand
beneath

door
to

support
its

weight
when
bolts

are
removed
Place

rag
between
door

and

jack
or
stand
to

avoid
damaging

painted
surface
Body
Frame

CD

1

@

@

ID

@

AJ

@

@

@
1

Door
sash

2

Window
outside

weatherstrip

3

Window
inside

weatherstrip

4

Door

atherstrip

5
Rear

glass
run

rubber

6
Door
finish
holder

7
Rear
lower

sash

8
Seal
screen

9
Door

weatherstrip
clip

10
Front

glass
run

rubber

11
Lower
door

hinge

12

Upper
door

hinge

13

Front
lower

sash

14
Door

glass

15

Glazing
rubber

16
Door

glass
bottom
channel

11

Lower

support

18

Upper
support

19
Door
ventilator

assembly

BF031B

Fig
BF
22
Door
with
ntilator
window

Optional

BF023

Fig
BF
23

Supporting
door

2

Separate
lower
door

hinge
hole

cover
from
dash

side
trim

3

While

supporting
door
as
above

back
off

body
to

upper
and
lower

hinge

attaching
bolts
accessible

from

inside
cab
three
each
Door

can
now

be
taken
out
from
cab

body

I
t

I

l
f
p1

1
W
JJ

i

Sl
j

Fig
BF

24

Removing
door

hinge

bolt

8F
12
4

To

install
reverse

removal

pro

cedure

ALIGNMENT

Elongated
holes
three
each
in

door

hinge
and
door

lock
striker

pro

vide
for

up
and

down
forward
and

backward
and
or

sideways
adjustment

to

assure

proper
door

fit

to
door

opening

To

adjust
door

alignment
loosen

bolts
and
move
door
to

desired

posi

lion

to
obtain
a

parallel

space
between

door
sides

and
door

opening
Also

check
to

be
certain

that

weatherstrip

contacts

body
opening

evenly
to

pre

vent

entry
of
mud
and
water

DOOR
TRIM
AND

SEAL

REMOVAL
AND

INSTALLATION

1

Remove
screw

securing
inside

door
handle

escutcheon
remove
es

cutcheon

2

Remove

screws
which
hold

pull

handle
and
arm
rest
in

position
Pull

handle
and

arm
rest
can
then
be

taken

out

3

Pull

retaining
spring
off

regulator

handle
Take

out

regulator
handle

and

seat
washer

WINDSHIELD
GLASS

DESCRIPTION

The

windshield

glass
is
retained
in

the

body
glass
opening
through
the

weatherstrip
There
are
twelve

water

drain
holes
one
on
each

side
of
the

bottom
of
the

glass
opening
and
ten

along
the

length
of
the

weatherstrip

1

Weatherstrip

2
Windshield

glass

3

Water
drain
hole

Fig
BF
35
Windshield

glass
and

weatherstrip
BF473A

REMOVAL

1
Place

protective
covers
over
en

gine
hood
front
fender
seat
and
in

strument

panel

2
Remove
inside
rearview
mirror

and
sun
visor

3
Remove
windshield

mouldings
if

so

equipped

4

Using
a

putty
knife
or
similar

flat
bladed
tool

pry
lips
of
weather

strip
out
of

place
from

top
and
side

flanges
of

body
opening

If

weatherstrip
is

to
be
reused
it
is

important
that
it

not
be

damaged

during
this

operation

BF041

Fig
BF
36

Removing
weatherstrip
Body
Frame

WINDSHIELD
GLASS

5

Working
from
inside
vehicle

push

windshield

glass
out

of

body

opening

by
hand

starting
at

right
and
left

upper
COIners
and

working
out
toward

ends

6
After

removing
weatherstrip
from

top
and
sides
of

body
opening
lift

glass

up
sufficiently
to

permit
removal

of

weatherstrip
from
bottom

flange

pry
weatherstrip
out
of

position

This

operation

requires
two
men

INSPECTION

Prior
to

installing
windshield

glass

make
the

following
checks
on
body

glass

opening
and

weatherstrips

I
Clean

weatherstrip
channels
re

placing
those
found
with

cracks
or

signs
of
deterioration

2
Clean

body
openings
noting
if

these
are
distorted
or
corroded

INSTALLATION

L

Fit

weatherstrip
on

glass

making

sure
it
is

properly
seated
and

posi

tioned
Adhesive
need
not
be

applied

0

BF641

Fig
BF

37

Fitting
weatherstrip
on

glass

2

Insert
a
draw
cord

completely

around

weatherstrip
outer
channel

Q
i

I

dYii

1

Windshield

glass

2
Draw
cord

3

Weatherstrip

Fig
BF

38
In8erting
draw
cord
around

weatherstrip
outer
channel
8F648

BF
16
3

With
aid
of
a

helper
press
wind

shield

assembly
against
body
opening

from
outside

being
sure
weatherstrip

lip
aligns
ith

body
opening
flange

4

Slowly

pull
cord
ends
from
inside

to

overlap
weatherstrip
channel
on

body
opening

flange
starting
at
center

top
and

working
out
toward
ends
This

operation
should
be
done
while
one

man
pushes

glass
against
body
opening

from
outside

The

same

technique
should
be

ap

plied
to

right
left
and
bottom

wea
th

erstrips

Fig
BF
39

Fitting
weatherstrip

top

BF650

Fig
BF

40

Fitting
weatherstrip

bottom

5
Install

windshield

moldings
on

weatherstrip
if
so

equipped

6
Install
inside
rearview
mirror
and

sun
visor

BACK
WINDOW

GLASS

AND
SIDE

WINDOW

GLASS

Refer
to
relative

topics
under
Re

moval

Inspection
and
Installa

tion
of
windshield

glass

Body
Frame

Note
When

installing
emergency

locking
retractor
make
sure
that
it

is
set

vertically

@

I
g@

BF650A

Fig
BF
51
Seat
belt

anchorages

8F
21
INSPECTION
OF

BUCKLE
SWITCH

The
contacts
of
the

buckle
switch

are

normally
closed
When

tongue

latches
the

buckle

tip
end
of

the

tongue
pushes
the

push
rod
to

open

the
switch

contacts

I

Disconnect

battery
ground
cable

2

Disconnect
buckle
switch
wire

harness

3

Using
a
test

light
check
buckle

switch
for

proper
operation
The

light

should

go
out
when

tongue
of
outer

lap
belt
latches
buckle
and

go
on

when
it

unlatches
buckle

Replace
belt

assembly
if

necessary

Note
When

checking
buckle
switch

operation
make
sure

that

power
is

held
below
16
volts

and
13
mA