1987 NISSAN PULSAR ESP

Engine


Main bearing cap removed showing the location of the rear seal and sealant grooves.
until the sealant appears at the inner, lower edge of the
bearing cap to cylinder block joint. Install the bearing
cap bolts and tighten to the specified torque.

(5) Tighten the remaining main bearing cap
bolts and the connecting rod cap bolts to their
respective tensions and rotate the crankshaft to check
for binding. (6) Install the crankshaft oil seal to the end of the
crankshaft after applying lithium grease to the lip of
the oil seal. Ensure that the l i p of the seal is facing
towards the engine.
(7) Install the remainder of the engine compo-
nents by referring to the relevant headings in this
section.
TO RENEW MAIN BEARINGS -
CRANKSHAFT INSTALLED

(1) Remove the automatic transaxle or manual
transaxle as described in the appropriate section.

(2) Remove the flywheel/drive plate as outlined
under the Flywheel/Drive Plate heading. (3) Remove the engine sump and oil pump
pickup pipe as previously described. (4) Ensure that the main bearing caps are num-
bered to ensure correct assembly. (5) Remove the main bearing cap bolts and
remove the bearing cap and half shell of the bearing to
be renewed. Thoroughly clean the bearing cap in
solvent. (6) Where necessary, use the Plastigage method
to measure the bearing clearance.
(7) Position a piece of Plastigage the approxi-
mate length of the bearing width, across the bearing
shell in the cap and tigh ten the cap bolts to the
specified torque. Do not rotate the crankshaft. (8) Remove the bearing cap and measure the
spread width of the Plastigage with the scale on the
packet to determine the main bearing clearance.
Compare the measurement to the Specifications and if
the bearing clearance exceeds the limit, install a new
set of bearing shells.
NOTE: Renew one bearing at a time, leav-
ing the others securely attached.

(9) Install a brass rivet in the crankshaft journal
oil drilling and rotate the crankshaft in a clockwise
direction until the head of the rivet contacts the plain
edge of the upper bearing shell. (10) Continue to rotate the crankshaft to carry
the upper half of the bearing shell out of the crank-
case.
(11) Select a half shell of the required thickness
(standard or undersize), coat it liberally with clean
engine oil and start it, plai n edge first, into position on
the crankshaft. Rotate the crankshaft anti-clockwise so
that the rivet contacts the locating lug edge of the
bearing shell, carrying it into position in the crankcase
above the main bearing journal. Slightly reverse the
rotation of the crankshaft and remove the rivet from
the oil drilling in the crankshaft. (12) Place the other half shell of the selected
bearing shells in the bear ing cap. checking the clear-
ance as detailed in operations (7) and (8).
NOTE: By checking the taper on the plas-
tigage any taper of the bearing journal can
be calculated.

(13) When the bearing has been correctly selected
to give the specified clearance, tighten the cap bolts to
the specified torque. (14) Use the same method to renew the other
main bearings. (15) When renewing the rear main bearings, re-
move and discard the rear crankshaft oil seal. (16) Install the rear main bearing cap into position
and inject KP510-00150 sealant or equivalent into the
grooves in the sides of the rear bearing cap. Fill the
grooves until the sealant a ppears at the inner lower
View showing the numbering and correct location of
the main bearing caps.

Manual Transaxle and Drive Shafts 131

(19) Renew the rear mainshaft bearing outer race
as follows:

(a) Remove the bolts retaining the rear cover to
the transaxle case. (b) Remove the rear cover. O ring, spacer and
adjusting shim from the transaxle case. Discard the O
ring. (c) Using a suitable punch, tap the bearing outer
race out of the transaxle case. (e) Install the adjusting shim, spacer and a new O
ring to the transaxle case. Install the rear cover and
tighten the retain ing bolts securely.

(20) Renew the front mainshaft bearing outer
race as follows:

(a) Using a suitable puller, pull the outer race
out of the clutch housing.
(b) Ensure that the oil groove in the resin oil
channel is facing the oil pocket in the clutch housing. (c) Install the new outer race to the clutch
housing.
(21) Measure the end float of the input shaft fifth
gear using feeler gauges betw een the fifth gear and the
adjacent gear shoulder. Note the measurement for
later reference.
(22) Dismantle the input shaft as follows:
(a) Remove the snap ring and spacer from the
front of the input shaft. (b) Using a suitable puller, remove the bearing
from the front of the input shaft. Remove the bearing
retainer noting the installed direction. (c) Remove the snap ring from the rear of the
input shaft. (d) Remove the shift retainer, fifth gear synchro
assembly, fifth gear and th e split bearing from the rear
of the input shaft.
(23) Measure the end float of the mainshaft first,
second, third and fourth gears using feeler gauges
between the gear and the adjacent shaft shoulder.
Note the measurements for later reference.
(24) Dismantle the mainshaft as follows:
(a) Remove the front and rear bearing cones
using a suitable puller.


Dismantled view of the mainshaft.
(b) Remove the C ring holder, the C rings and
the thrust washer from the rear of the mainshaft. (c) Using a puller positioned on the fifth gear
rear flange, remove the fifth gear from the mainshaft. (d) Remove the fourth gear , bush and steel ball
from the mainshaft. (e) Remove the third/fourth synchro assembly,
using a suitable puller if necessary. (f) Remove the third gear, bush, steel ball and
second gear from the mainshaft. (g) Remove the first/second synchro assembly,
using a suitable puller if necessary. (h) Remove first gear and the needle roller
bearing from the mainshaft.

(25) Suitably mark the assembled positions of the
synchro assemblies components and remove the
springs from the assemblies.
(26) Slide the sleeves off the hubs and remove the
shift plates.
(27) Arrange the various synchro components
separately to avoid mixing the components on
assembly.
TO CLEAN AND INSPECT

(1) Clean all the components in cleaning solvent
and allow to dry.
(2) Inspect the teeth on all the gears for wear,
pitting and damage. (3) Push each synchro ring onto its respective
gear cone and measure the distance between the
synchro ring and the synchro teeth on the gear. Renew
the synchro ring and/or the gear if the distance is less
than 0.7 mm.
(4) Inspect the shift forks for excessive clearance
in the synchro sleeves and the control fingers. Renew
the forks as necessary if the clearance is excessive. (5) Inspect the components of the control
bracket for wear and damage. Inspect the shift caps
for wear. Renew the control bracket and/or the shift
caps as necessary.
218/680 INPUTSHAFT M AI N B E AF I N G SPACER
Dismantled view of the input shaft.

136 Manual Transaxle and Drive Shafts
right hand side gear and the adjacent spacer in an area
where there is no oil groove in the differential case.
(d) Insert another 0.03 mm feeler gauge diago-
nally opposite the first feeler gauge to avoid tilting the
side gear.

(e) Insert a splined adaptor into the right hand
side gear and attempt to rotate the gear by hand.
(f) If the gear cannot be rotated, change the
thickness of the left hand side gear spacer, repeating
the test until the gear can be rotated.
NOTE: Spacers are available in thicknesses
from 0.8 mm to 1.5 mm in increments of
0.1 mm.

(g) Remove the 0.03 mm feel er gauges and insert
0.09 mm feeler gauges to the same position. The gear
should lock.

(h) The spacer selection is correct when the right
hand side gear can be rotated with 0.03 mm feeler
gauges inserted but locks when 0.09 mm feeler gauges
are inserted.

(18) Install the ring gear to the differential case
with the chamfered edge of the ring gear inwards. (19) Install and tighten the retaining bolts in
a
diagonal sequence to the specified torque.
(20) Install a new speedometer drive gear to
the
differential case. Install the stopper adjacent to the
drive gear.
(21) Install the differentia] carrier bearing
cones
and roller assemblies to the differential case.
(22) Remove the adjusting shim from behind the
carrier bearing outer race in the transaxle case and
replace the outer race in the transaxle case.
(23) Install the differential assembly to the clutch
housing. (24) Install the transaxle case to the clutch housing
and tighten the retaining bolts to the specified torque.
(25) Mount a dial gauge to the clutch housing so
that the contact point is resting on the differential
case. (26) Insert a bar through the opposite side gear
and, contacting the pinion shaft, raise and lower the
differential case and measure the end float in the
carrier bearings. (27) Using the following table, select a shim to
correspond to the relevant end float.
END FLOAT SHIM THICKNESS

0.30-0.34 mm....................................................0.64 mm
0.34-0.38 mm................................................... 0.68 mm
0.38-0.42 mm................................................... 0.72 mm
0.42-0.46 mm................................................... 0.76 mm
0.46-0.50 mm................................................... 0.80 mm
0.50-0.54 mm................................................... 0.84 mm
0.54-0.58 mm................................................... 0.88 mm
0.58-0.62 mm................................................... 0.92 mm
0.62-0.66 mm................................................... 0.96 mm
0.66-0.70 mm................................................... 1.00 mm
0.70-0.74 mm................................................... 1.04 mm
0.74-0.78 mm ................................................... 1.08 mm
0.78-0.82 mm ................................................... 1.12 mm
0.82-0.86 mm ................................................... 1.16 mm
0.86-0.90 mm ................................................... 1.20 mm
0.90-0.94 mm ................................................... 1.24 mm
0.94-0.98 mm ................................................... 1.28 mm
0.98-1.02 mm ................................................... 1.32 mm
1.02-1.06 mm ................................................... 1.36 mm
1.06-1.10 mm ................................................... 1.40 mm
1.10-1.14 mm ................................................... 1.44 mm
1.14-1.18 mm ................................................... 1.48 mm
1.18-1.22 mm ................................................... 1.52 mm
1.22-1.26 mm ................................................... 1.56 mm
1.26-1.30 mm ................................................... 1.60 mm
1.30-1.34 mm ................................................... 1.64 mm
1.34-1.38 mm ................................................... 1.68 mm
1.38-1.42 mm ................................................... 1.72 mm
1.42-1.46 mm ................................................... 1.76 mm
The thickest shim available is 0.88 mm. Multiple
shims are required above this thickness.

(28) Install the shim behind the carrier
bearing
outer race in the transaxle case and assemble the unit
once more. (29) Using a suitable slotted adaptor engage the
pinion shaft and using a to rque gauge, measure the
differential turning torque. The turning torque when new carrier bearings
have been installed should be 3.9-7.8 Nm or slightly
lower if the original carrier bearings have been
replaced.

(30) Assemble the transaxle and measure the total
turning torque of the diff erential assembly and the
mainshaft. The total turning torque should be 5.9 to
13.7 Nm with new bearings or slightly lower if the
original bearings have been replaced.

5. GEAR LEVER ASSEMBLY
TO DISMANTLE AND ASSEMBLE
(1) Remove the gear lever knob and remove the
centre console as described in the Body section. If not
previously removed, remove the rubber boot sur-
rounding the gear lever. (2) Raise the front of the vehicle and support it
on chassis stands. Remove the catalytic converter and
heat shield as described in the Engine section.
(3) Remove the bolt and disconnect the control
rod from the bottom of the gear lever, noting the
position of the return spring and bracket.
(4) Remove the nuts retaining the gear lever
socket to the support rod. (5) Working inside the vehicle, lift the gear lever
out of the floor bracket. (6) Separate the lower rubber boot, socket,
spring seat, spring, upper ball seat and lower ball seat
from the gear lever, noting the location of each
component to aid assembly.

Rear Suspension 171
Installation is a reversal of the removal procedure
with attention to the following points:

(1) When installing the stabilizer bar to the
knuckle assembly bushes, ensu re that the thicker bush
is installed to the front of the knuckle assembly. Install
the rear bush, washers and nut but do not tighten at
this stage. (2) Install the stabil izer bar mounting
brackets,
ensuring that the end with the large bevel is facing the
front of the vehicle. Tighte n the retaining bolts to the
specified torque. (3) Using a new gasket, install the intermediate
exhaust pipe to the catalytic converter, ensuring that
the earth wire terminal is installed, and tighten the
bolts securely. Install the exhaust mounting
retaining
bolt. (4) Install the rear wheels and lower the
vehicle
to the ground. With the wei ght of the vehicle on the
road wheels, tighten the stabilizer bar retaining nuts to
the specified torque.
8. REAR WHEEL ALIGNMENT
Specialized equipment is required to measure the
rear wheel alignment. It is therefore recommended
that the vehicle be referred to a specialist suspension
workshop or an authorized dealer for measurement
and adjustment. The suspension components should
be inspected and renewed as necessary prior to having
the wheel alignment checked. If any suspension com-
ponents are renewed, the re ar wheel toe out may be
temporarily adjusted as described below.

TO INSPECT
Examine the tread of the tires. Excessive or
uneven wear will indicate misalignment or damaged
or worn components. Refer to the Tire Wear Trouble
Shooting Chart in the Wheels and Tires section for
possible causes and renew the faulty components.

Badly worn tires should be renewed prior to
having the wheel alignment checked.

TO CHECK AND ADJUST TOE OUT
NOTE: The following procedures are only a
temporary measure. Th e vehicle should be
referred to a specialis t suspension work-
shop or authorized dealer for accurate
measurement and adjustment.

(1) Position the vehicle on a level floor and
bounce the vehicle several tim es to settle the suspen-
sion. (2) Move the vehicle forward approximately 5
meters, with the front wheels straight ahead, to settle
the tires and suspension to the normal running
position.
(3) Place a chalk line across both tire treads at a
point equivalent to the stub axle height and to the rear
of the suspension. Place a vertical mark at the chalk line in the
centre of each tire.

(4) Using a telescopic gauge or tape measure,
measure the distance between both vertical marks and
record the measurement. (5) Move the vehicle forward until the marks are
to the front of the suspen sion, with the horizontal
marks at the same height as in operation (3). (6) Measure the distance between both vertical
marks. (7) The difference between the two measure-
ments will be the amount of toe out of the rear wheels. (8) If the toe out is not as specified, adjust the
rear control arm cams as follows: (9) Measure the distance between the inner
wheel rim and the adjusting flange on the rear
crossmember. Measure the distance on the other side
of the vehicle in the corresponding positions. (10) If the measurements are equal, loosen the
cam nut and turn the cam bolt to move the rear
control arm half the distance required to bring the
rear wheel toe out to specifications. Repeat this
operation on the other side of the vehicle.
(11) If the measurements obtained in operation
(9) are not equal, proceed as follows:
(a) If the toe out is less than specifications,
decrease the length of the shorter arm.
(b) If the toe out is greater than specifications,
increase the length of the longer arm.
NOTE: The toe out will alter approximately
2 mm with each graduation of the adjusting
cam.

Diagram indicating rear wheel toe out. B should be less than A. Refer to Specifications.

200 Electrical System


Using an ohmmeter to test for bridging or internal shorting of the rotor fields.

internally, while a high reading indicates an open
circuit or high resistance in the windings. In both
cases a new rotor assembly will have to be installed.

Stator Windings
The stator test is carried out using a test lamp.
The stator leads must be detached from the
diode pack.
Connect a jumper lead from the negative
terminal of a charged 12 volt battery to the stator
winding frame. Connect one en d of a test lamp to the
battery positive terminal, the other end of the test
lamp to the stator lead, one at a time. Should the test lamp illuminate, however
dimly, a short circuit is indicated and the stator
assembly must be renewed.
Diodes
On some models the diod es may be tested after
disconnection. Testing can be done by using a 12 volt
battery and a 1.5 watt bulb in series with a jumper
lead.

Connect a jumper lead from the negative
terminal of a charged battery to the carrier/bracket
holding the diode to be tested. Connect one end of a test lamp to the battery
positive terminal and the other end of the lamp to the
diode lead. Note whether the lamp is illuminated and
then reverse the connections on the battery. If the lamp was illuminated in both direc-
tions or was not illuminated at all, the diode is faulty
and the diode pack/heat sink must be renewed.
Brush Springs and Brushes
Check the brush spring s for overheating and
distortion, check for binding in the brush holder.

Check the brush length and renew as neces-
sary. Refer to Specifications for the correct dimen-
sions. TO ASSEMBLE

Bosch Alternator
Assembly is a reversal of the dismantling proce-
dure with attention to the following points:

Using a hot soldering iron and a pair of long
nosed pliers as a heat sink, solder the stator leads to
their respective terminals on the diode pack. Install the insulating washer and spacer to the
(B +) terminal post and position the diode pack and
stator assembly onto the slip ring end bracket. Install
the diode pack retaining screws and tighten securely. Working on the exterior of the slip ring end
bracket, install the output terminal components to
the
(B + ) terminal and secure the retaining nut.
Position the bearing retainer, bearing and
spacer on the rotor shaft. Using a suitable press and press plates,
support the rotor sh aft on the front face of the spacer
and carefully press the rotor shaft fully into the
bearing and spacer. Position the rotor shaft assembly into the
rear of the drive end bracket and install and tighten the
bearing retainer plate screws. Install the fan, plate, spacer and split
drive
pulley to the rotor shaft and secure them with the
retaining washer and nut. If necessary, using a suitable press and press
plates, support the rotor shaft rear bearing and
carefully press the rotor shaft fully into the bearing.
NOTE: Ensure that pressure is applied only
to the inner race of the bearing.

Ensure that the rotor shaft bearing wave
washer is located in the slip ring end bracket and
insert the rotor in the stator and slip ring end bracket
assembly. Align the marks made on dismantling and
install and tighten the long securing screws.
Position the regulator and brush holder as-
sembly to the slip ring end bracket and install
and
tighten the retaining screws. Install the alternator to the vehicle and
test
the operation as prev iously described.
Hitachi Alternator
If necessary, position the new brush termi-
nals in the brush assembly and install the
brush
assembly and terminal plate to the diode pack.
Carefully solder the terminal plate to the diode pack
and secure the brush assembly by installing and
staking new rivets.

If necessary, solder the diode pack and
regulator to the stator and install the fan guide
and
retaining nuts. Tighten the retaining nuts securely.
NOTE: When soldering or unsoldering the
stator leads or bridges from the diodes or
regulator, grip the leads with a pair of long

Electrical System 211
When using an aiming board, position the
vehicle five meters from and square to the aiming
board. Gently rock the vehi cle and allow the suspen-
sion to stabilize. Mark a reference line on the board to
correspond with the horizontal centre line of the
headlamp low beam bulbs. Mark two reference lines on the board to
correspond with the vertical centre lines of
the
headlamp low beam bulbs. Switch on the headlamps and select low
beam. Adjust the headlamps by turning the adjust-
ing screws located at the rear of the headlamp
assemblies. Adjust the headlamps to comply with local
regulations. As a guide, adjust the lamps so that the
low beam pattern strikes the aiming board with the
horizontal cut off point 50 mm below the headlamp
bulb horizontal centre line and the point where the
beam raises from the horizontal is on the headlamp
low beam bulb vertical centre line.
To Renew Low Beam Bulb (Pulsar)
Remove the dust cover from the rear of the
headlamp assembly.
Disconnect the wiring from the end of the
bulb.
Remove the cover from the rear of the
headlamp housing. Release the retaining clip from the bulb
holder and withdraw the bulb from the headlamp. Installation is a reversal of the removal procedure
ensuring that the new bulb is correctly located in the
bulb holder.
NOTE: Care must be taken not to handle
the glass portion of the bulb as this will
shorten the life of the bulb. Accidental
fingerprints can be removed by applying
methylated spirits to the bulb and drying
with clean tissue or cloth.

To Renew High Beam Bulb (Pulsar) or
High/Low Beam Bulb (Astra) Disconnect the wiring connector and re-
move the dust cover from the rear of the headlamp. Release the retaining clip and remove the
bulb from the bulb holder. Install the new bulb to the headlamp ensur-
ing that the metal plate is correctly located in the
bulb holder.
NOTE: Care must be taken not to handle
the glass portion of the bulb as this will
shorten the life of the bulb.
Accidental fingerprints can be re-
moved by applying methylated spirits to
the bulb and drying with clean tissue or
cloth.
(4) Secure the retaining clip, install the cover to
the headlamp and connect the wiring to the end of the
bulb.
FRONT COMBINATION LAMP (PULSAR)
OR TURN SIGNAL LAMP (ASTRA)
To Renew Bulb
(1) Remove the retaining screws from the front
combination lamp and remove the lens.

Renewing the front combination lamp bulb. Pulsar models.
(2) Push the bulb inwards, turn it anti-clock-
wise and remove it from the holder. Installation is a reversal of the removal procedure.
SIDE INDICATOR LAMP (PULSAR) OR
FRONT COMBINATION LAMP (ASTRA)
To Renew Bulb
(1) Remove the retaining screws and remove
the lens cover.
Renewing the low beam bulb.

226 Body

Remove the screws retaining the speaker to
the trim panel, withdraw the speaker slightly and
disconnect the wiring connector at the rear. Place the
speaker to one side clear of the work area.
On models with a step lamp located in the
door trim panel, remove the screws, withdraw the step
lamp and disconnect the wiring connector. Using a broad bladed screwdriver, carefully
lever the trim panel outwa rds and disengage all the
retaining clips. When all the clips have been disen-
gaged maneuver the trim panel from the door. Remove the screw retaining the speaker
water deflector to the inner door panel and withdraw
the water deflector.
Carefully remove the plastic sealing sheet from
the inner door panel.

Installation is a reversal of the removal procedure
with attention to the following points:

Ensure that the plastic sealing sheet is cor-
rectly installed and not torn or damaged.
Check the trim panel retaining clips and
renew any damaged clips as necessary. On models with manual windows, wind the
door glass to the closed position, install the
retaining
clip to the regulator handle and install the regulator
handle to correspond with the regulator handle on the
opposite door.
DOOR GLASS AND REGULATOR

To Remove and Install
Remove the interior trim panel and handles
as previously described. Lower the door glass to align the lift channel
with the lower aperture. Support the door glass and remove the
retaining screws from the lift channel and door glass. Tilt the door glass to disengage it from the
run channel, then lift the door glass out through the
door glass opening. Remove the retaining bolts securing the
regulator assembly to the door panel. On models with
power windows, disconnect the wiring connector.
Maneuver the regulator assembly from the door
through the lower aperture. Installation is a reversal of the removal procedure
with attention to the following points:

Ensure that the sliding surfaces are ade-
quately lubricated with a zinc oxide grease.
Loosely install the regulator assembly to the
inner door panel. Install the doo r glass through the door glass
opening, engage the door glass in the run channel and
loosely install the retaining screws.
Tighten the regulator retaining bolts and
operate the door glass a few times up and down to
ensure that the glass is centralized. Tighten the lift
channel screws and check the operation of the door
glass. Adjust as required.

Dismantled view of the manually operated front door

window regulator and glass components.
(5) Install the plastic sealing sheet, the trim panel
and the interior handles as previously described.

REMOTE CONTROL AND DOOR LOCK
To Remove and Install
Remove the interior handles, the trim panel
and the plastic sealing sheet as previously described.
Remove the screws retaining the door lock to
the door frame. Disconnect the operating links at the door
lock from the snipper button and the lock cylinder.
The remote control link can be left connected. On
models with central locking, disconnect the link from
the lock actuator.
Remove the screws securing the remote con-
trol to the inner door panel, release the link from the
inner door panel clip and w ithdraw the remote control
and door lock assembly from the door. Installation is a reversal of the removal procedure
with attention to the following points:

Ensure that the exterior handle operates
correctly and has 0.5-2.0 mm free play at the stepped
adjuster holder. Adjust the stepped adjuster holder if
necessary. Check the operation of the door lock assem-
bly before installing the plastic sealing sheet, the trim
panel and the interior handles as previously described.

Body 229
trol assembly escutcheon to the door and remove the
escutcheon.

(4) On models with manual windows, lever back
the regulator handle escutcheon and using a suitable
wire hook, withdraw the handle retaining clip and
remove the handle and escutcheon.

Alternatively, a piece of sturdy cloth can be used
to remove the regulator handle by sliding the cloth
behind the handle and pulling on each end of the cloth
in a see-saw action to release the retaining clip.

On models with a step lamp located in the
door trim panel, remove the screws, withdraw the
lamp and disconnect the wiring connector. Using a broad bladed screwdriver, carefully
lever the trim panel outwa rds and disengage all the
retaining clips. When all the clips have been disen-
gaged maneuver the trim panel from the door. Carefully remove the plastic sealing sheet
from the inner door panel. Installation is a reversal of the removal procedure
with attention to the following points:

Ensure that the plastic sealing sheet is cor-
rectly installed and not torn or damaged. Check the trim panel retaining clips and
renew any damaged clips as necessary. On models with manual windows, wind the
door glass to the closed position, install the
retaining
clip to the regulator handle and install the regulator
handle to correspond with the regulator handle on the
opposite door.
DOOR GLASS, REGULATOR AND QUARTER
GLASS

To Remove and Install
Remove the interior handles, the trim panel
and the plastic scaling sheet as previously described. Lower the door glass to align the lift channel
with the lower aperture.
Support the door glass and remove the
retaining screws from the lift channel.
Remove the screws retaining the rear run
channel to the door.
NOTE: To gain a ccess to the upper screw
carefully ease a small section of the door
rubber from the upper door flange.

Maneuver the run channel from the door
using care not to chip the d oor paintwork or the glass.
Withdraw the door glass through the door
glass aperture. Slide the quarter glass and seal assembly
towards the front top corner of the door and withdraw
the quarter glass from the vehicle. Remove the regulator retaining bolts and
withdraw the regulator from the door through the
lower aperture. Installation is a reversal of the removal procedure
with attention to the following points:


Dismantled view of the manually operated rear window
regulator and glass components.
Ensure that the regulator sliding surfaces are
adequately lubricated with a zinc oxide grease. Ensure that the door glass slides freely in the
run channels. The rear channe l lower bolts and the lift
channel screw are adjustable in slotted holes to
achieve this. Install the plastic sealing sheet, the trim panel
and the interior handles as previously described.
REMOTE CONTROL AND DOOR LOCK
To Remove and Install

Remove the interior handles, the trim panel
and the plastic sealing sheet as previously described. Remove the retaining screws from the re-
mote control assembly.
Remove the retaining screws from the door
lock assembly. On models with central door locking, discon-
nect the lock actuator li nk from the lock assembly by
releasing the snap clip. Withdraw the door lock assembly from the
door at the same time turning the snipper button
pivot holder to release the pivot from the door. Installation is a reversal of the removal procedure
with attention to the following points:

(1) Ensure that the exterior handle link enters
the door lock stepped adjuster when maneuvering the
door lock into position.