Home

document in original format

1. 72551 Glass Run Channel Lower amp Retainer Cate 6 11 Glass Run Channel Upper amp Retainer End Gate s 6 1 Glass Run Channel Rear Door SGS a IN gu Glass Run Channel Rear Door Spr RAM ee eens 2 2 7222 Guide Assembly Rear Quarter Window essen 4 5 Guide Window Cam Front amp Rear Door saa 7117 Grille Shroud Ventilation T TIN 5 cuc aaa aa sana ka eee S RES Handle Door Interior DURO a t Handle End Gate Ju PS CS N Handle Rear Quarter Window Regulator citur RET NARA Headlining Assembly Sedan amp Coupe Headlining Assembly Station Sedan Headlining Description Heater amp Distribution Duct Assembly Hinge Assembly Doors quce ES Hinge Assembly End Gate Hinge Assembly Engine Hood Hood Lacing Shroud Ledge l Qn Os J O OO CO O 1 mi a O O O 1 M Inner Trim Panel Door Interior Handle End Gate Renmei Cantrell m I ON Limit Arm End
2. CO gt O ERUNT I 25 fl A BR N OO CO CO CO p CO Qn O WON a rd ae T Sa TO 1 DATE E laci 24 DEN NOTES AND BULLETIN REFERENCES BU IN 4
3. 4 5 Armrest Rear Quarter 4 6 Trim Rear Seat Parcel AT ASM 4 6 Trim Rear Quarter Side 4 6 Trin 4 7 Quarter Trim Panel Front Lese l c y Cover Quarter Inner Panel 4 8 Weatherstrip Rear Quarter Belt Outer jew Finishing Lace Rear Quarter Window 4 8 Upper Weatherstrip and Retainer 4 9 Seal Lock Pillar Upper Corner 4 9 Relief Valve Body Lock Pillar 4 9 Pressure Relief Valve Rear Quarter Sde Tim 4 9 Description The tear quarter inner and outer panels of HQ coupes accommodate the various rear quarter hardware assemblies illustrated Fig 4 1 Plastic rollers attached to the sash plate of the quarter window roll in a guide assembly attached to the inner panel A single arm window regulator positions the quarter window in the desired location Forward rearward and in and out adjustment of the quarter glass is provided by adjustable studs and slotted holes in the quarter inner panel and by an adjustable bracket attached to the lower section of the window guide assembly and quarter inner panel An optional electrically operated rear quarter window regulator is available on all coupes except 803 437 models REAR QUARTER 4 2 T NO MAO PUR WINDOW REGULATOR INTERIOR HANDLE SPRING WINDOW GUIDE ADJ
4. 2 x o zk e 2 8 BODY MOUNT ASSY N R BODY MOUNT WASHE BODY MOUNT BOLT FIG 1 2 BODY MOUNTING 5 13 0 NOILVOIdILN3dI VLIW L33HS 9 AQOB Gb 3 83 1 4 SISSYHD INOJ ASSV H3MOT 13NVd 8 TANVd 333203 YANNI 8 48043 5 3415 3008 ASSY 48083 j3NVd YANNI 839 33 LNOBNJ j3Nvd 33100 330N34d 4 083 ASSY JHLNAD jaNvd 418043 5 804 0 8 ASSY 1 4 MOS 3008 ASSV 18083 Ne 38 MOS 4004 3015 Aqog 13NYd 48683 LNZWLAYdWOD NV3M Assy 3015 ASSY TANYd 34008 GENERAL INFORMATION 1 6 GENERAL INFORMATION 1 5 11 15 STAGOW NOIL V2IJILN3GI 1V13W L33HS 9 AQOS r a AVILYVd SISSYHO LNOHH 706 ASSV 3415 43100 33204 6l ASSY ONJ 4 ASSV TANVd 1NO d 781 13NYd YANNI 430N34 4 083 ASSV 381 133 Zt TIYA 80343 5 3015 4004 ASSY 33qQN34 1 043791 14044085 HOLVIGvU ASSY AdOSMN3QN SL 13NYd 834 83 334071 13NY d 2 8 1804415 40014 NVANNOL 1NO 4 3008 384 33 4008 5 38 183 8 38
5. 12 MIN VIEW 814 5 6 ONLY View FIG 9 4 BACK WINDOW INSTALLATION MODELS SEDAN amp COUPE 3 With the aid of assistant outside body to support window commence bumping top of window outwards using the palm of the hand Remove and place window assembly on a clean protected surface NOTE As a safety precaution leather or thick cloth gloves should be worn 4 Remove windshield sealer from body opening flange and glass retaining channel 5 Visually check body opening flange and correct any existing irregularities Installation 1 Apply glass retaining channel to rear quarter window 2 Apply 5 16 bead of windshield sealer around complete body opening flange see Section Fig 9 5 SECTION STATIONARY GLASS 9 9 Insert a strong cord inside body opening flange cavity of glass retaining channel leaving ends protruding centrally at inside upper edge of window assembly see B Fig 9 5 Place window and channel assembly in window opening and while pressing assembly fimly from outside body have an assistant inside body slowly pull cord seating lip of rubber retaining channel over complete body opening flange Apply windshield sealer between glass and 110 of retaining channel around complete perimeter of window see C Section Fig 9 5 Use white spirits to clean off any excess wind shield sealer from around windo
6. PLASTICINE OR CAULKING COMPOUND 1 FIG 6 5 LOCK STRIKER ADJUSTMENT CHECK 2 No amp Size of Dimension A Spacers Required ny myb LUE tee coe 7 5 13 ta Wn mo fota Z A6 CB 322 27517 Dimension from centre of lock housing to inside face of striker should not be less than 1 8 in LIMIT ARM Models Station Sedan Removal 1 With end gate open provide support for side from which limit arm is to be removed 2 Remove screws securing limit arm to end gate and bolts securing limit arm to rear end aper ture pillar see Fig 6 1 or 6 2 Installation Apply caulking compound around screw and bolt attaching holes in end gate side and rear body aperture pillar prior to reversing removal operations TORQUE ROD Models Station Sedan Removal 1 Remove rear tonneau floor 2 Remove rear bumper assembly refer pages 14 2 14 3 or 14 4 3 Position end gate vertically to relieve tension from torque rod then remove retainer securing torque rod to body back panel lower see Fig 6 1 or 6 2 4 Remove wear strips and inner trim panel refer page 6 7 5 Raise and support end gate window 6 Remove screws securing torque rod retainer to end gate then remove torque rod Installation Apply caulking compound around screw and bolt attaching hol
7. 2 On drive side lift top of clip and slide clip along actuating link see View A Fig 3 8 3 Position a wide bladed screwdriver between shoulder at base of pivot splines and rod then ptise rod off pivot splines Installation 1 Locate wiper rods on pivot splines so that RH blade is located 1 60 16 and LH blade 1 40 16 above lower section of windshield reveal moulding 2 Install actuating link and securing clip to RH pivot assembly see View A Fig 3 8 SWITCH ASSEMBLY WINDSHIELD WIPER amp WASHER CONTROL Models All Removal 1 Remove facia panel from instrument carrier refer page 3 7 2 Remove screws attaching switch assembly to instrument carrier see View E Fig 3 8 3 From behind instrument carrier disengage harness terminals from switch then remove switch assembly Installation Reverse removal operations FRONT END 3 16 NOTES AND BULLETIN REFERENCES REAR QUARTER 4 1 SECTION 4 REAR QUARTER INDEX Subject Page Rear Quarter Description 4 1 Regulator Rear Quarter Window 21 4 3 Motor Rear Quarter Window Regulator 4 3 Window Rear Quarter 4 3 Guide Assembly Quran 4 5 Handle Rear Quarter Window Regulator 4 5 Trim Panel Rear Quarter Inner
8. 4008 6L ASSV 3015 AGO ASSV 14NVd 4008 34 03 ST3qQoW NOILVIISILNAGI 1V13W L33HS 8 5 1 913 vilsuVd SISSVHD 1NO3MJ Zl ASSY 839 33 TANVd 838308 91 ASSY 3015 AJOS 11 ASSV TANVd LNOwS 61 ASSY 701 e OJ M ASSY TANVd NOVA 6 SSY AINNI LYOddNs 3918 4008 8 1 MOB 3008 1404415 804 0 8 9 YANNI 39433 LNO3J TANYd 33100 YAGNAS LNOAS TANVd LNOYS LN3WIBNVdWOO 8 38 ASSV TANVd 34008 Assy 3915 4009 Body Shell Parts Replacement When replacing or repairing a part or sub assembly care must be taken to ensure that correct alignment and strength of unit as a whole is maintained some instances major damage to the body or frame can be more effectively and economically repaired be replacing a part or sub assembly with a new one rather than repairing the damaged part Spot welding is used extensively for joining panels together particularly around the flanged edges of dash panel windshield and back window opening along edges of rocker panels and lower edge of rear body When replacing a section that is normally attached by this method and spot welding equipment is not available or the location of parts prevents the use of same the part or assembly should be attached by the welding method known as plug welding
9. 7 Disconnect regulator harness connector and thread switch base and motor and switch har nesses through harness aperture on front face of door Installation Reverse removal operations using Neoprene cement to attach window regulator harness seal to leading face of door Door Adjustment In making door adjustments attention should be given to uniform spacing and alignment between door edges and surrounding parts Oversize holes in pillars and doors in addition to floating anchor plates provide horizontal vertical and in and out door adjustment To check door for misalignment and then adjust proceed as follows 1 Pencil scribe around lock striker to facilitate installation 2 Using 5 16 Allen Key in tool recess in head of striker bolt see Fig 7 5 remove striker allowing door to hang freely 3 If the check reveals horizontal or vertical misalignment support door loosen hinge to pillar attaching bolts see Fig 7 4 or 7 5 move door to the desired position then re tighten bolts 4 If the check reveals an in or out misalignment support door loosen hinge to door attaching bolts move door to the desired position then retighten bolts DOORS 7 9 HINGE ASSEMBLY DOORS Models All Removal 1 With door open pencil scribe around hinge to pillar and hinge to door to facilitate install ation 2 With an assistant supporting door remove bolts securing hinge to door and pilla
10. Fig 10 5 HEADLINING REMOVAL AND INSTALLATION trated in Fig 10 5 tuck headlining up between roof rail and retainer to engage on saw teeth 2 Using a small wooden block placed against the headlining and retainer lightly tap retainer towards roof rail Fig 10 7 HEADLINING RETAINER STRAIGHTENING BEND TABS TO RETAIN LISTING WIRES ASSIST STRAP idis VIEW D VIEW E 2 PLACES VIEW K 80335 435 1135 1235 3 PLAIN OR BLACK p PLAIN OR BLACK SEAT BELT 5 STOWAGE HOOK PLAIN OR BLACK kan BROWN 7 BROWN WHITE YELLOW BROWN 5 BODY PILLAR GARNISH PANEL FRONT DOOR APERTURE FINISHING LACE REAR DOOR APERTURE FINISHING LACE ATTACH TO CENTRE PILLAR WITH CEMENT APPLIED TO TRIM OVER ENTIRE SURFACE OF CONTACT N CEMENT HEADLINING OVER THIS AREA ONLY SECTION SECTION C C HEADLINING TO BE COAT HOOK TURNED UNDER FRONT HEADLINING RETAINER LISTING WIRE LISTING POCKET VIEW F MODELS 803 435 amp 811 235 SECTION D D view C WINDSHIELD FINISHING LACE ATTACH HEADLINING TO FRONT RETAINER CLOSE RETAINER AGAINST ROOF AND TO OUTSIDE OF DOOR OP ENINGS AND REAR QUARTER WINDOW OPENING FLANGES INSTALLATION OF SECTIONS C C amp E E WITH CEMENT HEADLINING APPLIED TO HEADLINING FOR ENTIRE LENGTH OF HEADLINING OVER AREAS SHOWN THUS 7 w WE HEADLINING TO BE TUR
11. MOULDING UPP ER MOULD SECTION A A ING MOULDING REAR WINDOW MOULDING REVEAL UPPER WINDSHIELD UPPER REVEAL CLIP WINDSHIELD LOWER REVEAL MOULDING SECTION B B SECTION CLIP END GATE GLASS OPENING MOULDING MOULDING END GATE KR MOULDING WINDSHIELD SIDE REVEAL RETAINER REAR WINDOW REVEAL MOULDING MOULDING REAR WINDOW LOWER REVEAL SECTION F F SECTION D D MOULDING ROOF SIDE REVEAL SECTION WASHER PLATE BELT MOULDING TO GLASS OPENING EXTENSION REAR WINDOW REVEAL MOULDING LOWER SECTION E E lt x MOULDING ROOF A t lt SIDE REVEAL CLIP DOOR BELT MOULDING MOULDING DOOR BELT SECTION 1 1 SECTION J J PLATE BELT CLIP DOOR BELT MOULDING MOULDING WINDSHIELD SIDE REVEAL SECTION G G MOULDING DOOR BELT sECTION K K PLATE BELT MOULDING amp WEATHERSTRIP TO DOOR MOUL DING amp sECTION L L WEATHERSTRIP TO DOOR SECTION M M DENOTES APPLICATION OF SEALING COMPOUND AROUND MOUL DING SCREW ATTACHING HOLES SECTION N N FIG 12 1 BODY EXTERIOR MOULDING INSTALLATION CLIP REAR QUARTER MOULDING MOULDING REAR QUARTER SECTION 0 0 MOULDING EXTERIOR ORNAMENTATION 12 3 CLIP REAR QUARTER MOULDING UPPER MOULDING f MOULDIN
12. Model The model number is a combination of letters and numbers identifying the body model and style The trim numbers represent the interior paint colour and trim combination Paint The paint numbers represent the exterior paint mat erial and colour identification of the basic or lower colour Body The body number is a numerical reference followed hop by a suffix letter which denotes plant at which body was manufactured i e A Adelaide B Brisbane M Melbourne S Sydney and NZ New Zealand The top numbers represent the exterior paint material and colour identification of the roof or upper section of the body when it differs from the basic colour BASIC BODY CONSTRUCTION The Holden HQ Series bodies are of unitised construction The independent front end chassis partial frame which provides attachment for front end sheet metal front suspension engine etc is tubber mounted along both sides of under body to rear of front door openings see Fig 1 2 Identification of major body and sheet metal assemblies are illustrated in Figs 1 3 4 aud i e Since individual body and underbody steel components contribute directly to the overall strength and rigidity of the vehicle as a whole it is essential that correct alignment welding rust proofing and seali service and repair operations ng techniques be observed during body GENERAL INFORMATION 1 5 section
13. NOTE The finishing lace attached to upper flange of end gate inner panel is a press on attach ment GLASS RUN CHANNEL LOWER AND RETAINER Models Station Sedan Removal l Open end gate and remove wear strips and inner trim panel refer page 6 7 2 Raise and support end gate window 3 Remove bolts securing glass run channel lower retainer assembly to side of end gate inner panel and remove assembly see Fig 6 1 or 6 2 4 Carefully ease run channel lower which is attached to retainer with neoprene cement from retainer 5 Remove or smooth out any hardened cement from back of run channel and from inside te tainer Installation l Attach entire length of glass run channel lower to retainer with neoprene cement 2 Apply caulking compound around lower glass run channel retainer assembly to end gate attaching holes prior to reversing removal operations GLASS RUN CHANNEL UPPER AND RETAINER Models Station Sedan Removal l Open end gate and remove inner garnish mould ings from end gate upper aperture see Fig 6 8 2 Carefully ease out upper glass run channel the lower ends of which are attached to the re tainer with neoprene cement for a distance of 7 inches 3 Remove screw attached upper glass run channel retainer from end gate upper aperture 4 Remove or smooth out any hardened cement or plastic sealer from upper glass run channel or retainer END GATE 6 1
14. VIEW FIG 9 2 WINDSHIELD INSTALLATION ELECTRIC CURING METHOD 8 Apply Solbit bead to inner periphery of wind shield commencing with approximately 3 ins of bead protruding above top edge of windshield Continue positioning bead around perimeter of windshield terminating at top centre NOTE During this process care must be taken not to flatten the Solbit bead or indent it with finger marks as this will lead to subsequent leaks CAUTION Avoid touching glass primed surface If this does occur reprime 9 Twist both ends of bead together as illustrated in View D Fig 9 2 gently kneading beads together at the crossover creating amalgamation of the material 10 With the aid of an assistant locate windshield centrally in body opening on spacer blocks WARNING Ensure that windshield does not strike body opening during installation Chip ped edges can cause subsequent break age of windshield Also ensure that windshield is not installed with edges contacting reveal moulding clips 11 Connect ends of copper wire core to a 24 volt 12 amp electric supply for 12 minutes ensuring that electric connectors are insulated to protect paint finish 12 As the Solbit softens apply even pressure over complete windshield to obtain correct com pression of Solbit see View F Fig 9 2 13 Disconnect electric supply and cut off ends of Solbit bead see Section B B View F Fig Q 2 14 Wate
15. 1 The optional electrically operated end gate window regulator can be operated by one of two switches l A switch located to right of steering column at base of instrument panel operable only with ignition switch ON 2 key operated lock cylinder switch located centrally in end gate outer panel escutcheon see Fig 6 2 A safety switch located above the LH end gate lock prevents operation of electrically controlled end gate window regulator when the end gate is not completely closed After lowering window the end gate can be opened by a remote control handle situated cent rally above the end gate inner trim panel The end gate is counter balanced with a single torque rod secured to the RH side of the rear end panel and to the end gate inner panel with retainer plates When the end gate is opened the end of the torque rod secured to the body remains stationary whilst the remainder of the rod moves with the end gate thereby creating an assisting torque for lowering and raising the end gate Ii END GATE 6 2 pc 0 pag Handle Window Regulator Gasket Window Regulator Handle Remote Control Insulator End Gate Remote Control Rod LEGEND Remote Control End Gate Lifter Channel End Gate Window 19 Cam End Gate Window Lifter Channel Rod End Gate Remote Control Lock End Gate
16. 6 NOTES AND BULLETIN REFERENCES DATE SUBJECT 4 oe ICH E LEA E s PW USA END GATE 6 1 SECTION 6 END GATE INDEX Subject Page Subject Page End Gate Description 6 1 Wear Strips amp Trim Panel Inner 2 6 7 Regulator End Gate Window 6 4 Handle Window Regulator G 8 Motor Electrically Operated Window Lock Cylinder 8 Cap Assembly 6 8 Regulator JS A 4 Electric Switch amp Escutcheon Assembly 6 9 Lock Assembly 25 e 6 5 Safety Switch Electrically Operated End Gate 6 5 Window Regulator 6 9 Army 0002 A 6 6 Interior Handle and Remote Control 6 10 Norges Rod me 6 6 Weatherstrip Lower End Gate Aperture 6 10 End Gate Assembly 6 6 Weatherstrip Outer End Gate Belt 61 10 Hinge Assembly CA E 6 7 Glass Run Channel Lower amp Retainer Window Assembly 7 Glass Run Channel Upper amp Retainer LP END GATE Description The manually controlled end gate window regulator is operated by a folding handle loc ated centrally in the end gate outer panel see Fig 6
17. All Removal 1 Raise engine hood 2 From between radiator and grille remove nut securing emblem or nameplate to rear of grille see Fig 13 2 3 Remove emblem or nameplate Installation Reverse removal operations GTS GRILLE NAME PLATE MODELS GTS COUPES NUT INSERT TO GRILLE EMBLEM A i e EMBLEM RADIATOR GRILLE MODELS ALL EXCEPT GTS COUPE AND STATESMAN INSERT GRILLE EMBLEM FIG 13 2 NAME PLATE AND EMBLEM INSTALLATION RADIATOR GRILLE RADIATOR GRILLE 13 4 NOTES AND BULLETIN REFERENCES SE 2 5g cal RET BUMPER BARS 14 1 SECTION 14 Description The one piece front bumper bar fitted to HO models is mounted to front of partial perimeter front end frame see Fig 14 1 It features horizontal tum signal and park lamp apertures located around bottom outer ledge of bumper The one piece rear bumper bar fitted to Station Sedans is mounted to body below rear lamps see Fig 14 2 On all other body styles except Statesman apertures in the one piece rear bumper surround horizontal motif style rear lamps see Fig 14 3 On Statesman models rear lamp clearance cut outs are featured on ends of the one piece bumper Decorative trim panels are attached to either side of number plate on Statesman De Ville models see Fig 14 4 INNER BRACKET FLAT WASHER r 4 BUMPER MOUNTING SPRING WASHER BOLT INNER amp OUTER MOUNTI
18. Installation 1 Install upper glass run channel retainer to upper end gate aperture 2 Apply plastic sealer between leading outer side of retainer and upper aperture for entire length of retainer see Fig 6 8 3 Install upper glass run channel into retainer cementing both ends of channel to retainer for a distance of 7 inches with neoprene cement QUARTER OUTER PANEL APPLYPLASTIC SEALER ALONG ENTIRE LENGTH OF UPPER GLASS RUN CHANNEL RETAINER UPPER GLASS CHANNEL RETAINER END GATE GLASS RUN UPPER CHANNEL END GATE OPENING GARNISH MOULDING END GATE SLIDING GLASS gt FIG 6 8 UPPER GLASS RUN CHANNEL AND RETAINER INSTALLATION END GATE 6 12 NOTES AND BULLETIN REFERENCES 0 SUBJECT 2 EE 4 DOORS 7 1 SECTION 7 INDE X Subject Page Subject Page Description E ua go Division Channel Rear Door Front Door Hardware S Retainer Assembly Front Door Rear Glass Door HardWare YE E A TT UC i Pf Rear Door Hardware 7 6 Guide Window Cam Front and or Rear Door 7 1 Door Assemblies ae Cam Assembly Sliding Glass 7 0 Door Adjustment _ 7 E inner Trim Panel Door 1 008231 Hinge Assembly RONEM Armrest Door rr a Lock Assembly pao Handle Door Interior LL Snib Loc
19. Length of music wire for cutting out old glass The curing of Silicone Sealant is slow at temperatures of 50 F and below therefore it should not be used in cold climates without provision for this condition immediately after installation NASCO stock this material in the following two kits Part No 2823265 Windshield Silicone Caulking Package Styles Part No 2823266 Rear Window Silicone Caulking Package Sedans 8 Coupes These Kits comprise 1 Container of silicone adhesive caulking compound which does not requite refrigerated storage 1 Plastic nozzle for application of caulking material 1 Foam rubber adhesive backed seal for positioning caulking compound around periphery of glass 2 Water soluble spacers for locating glass 2 Emergency water soluble spacers to achieve 28 dimension in Fig 9 3 1 Container of paint finish primer 1 Length of music wire for cutting out old glass CAUTION This silicone caulking adhesive material supplied in the kit starts to cure immediately it is dispensed from the container Any undue pressure on the inside of the glass such as would be exerted when a door is slammed with all windows closed or the vehicle driven with the vent fully open with all windows closed should be avoided for at least twenty four hours after glass installation WINDSHIELD Models All Removal 1 Place protective covering over the paint finish
20. Removal air duct assembly to plenum chamber is water tight 1 From under instrument panel remove screws UPPER LEVEL AIR OUTLET INSTRUMENT securing end of ventilator control cable casing to plenum chamber air duct see View B Fig PANEL 277727 Models All 2 Disengage end of ventilator door control cable Removal to air duct 1 When removing LH upper level air outlet 3 Disengage upper level air outlet duct by com temove instrument panel compartment refer pressing end of outlet duct attached to plenum page 3 5 chamber air duct see Section A A Fig 3 2 2 From behind instrument panel compress top 4 Remove screws securing air duct assembly to and bottom of upper level air outlet see Section plenum chamber C C Fig 3 2 withdrawing outlet into body from instrument panel 5 Ease inner side of essembly down slightly before disengaging outer side which is re Installation tained by two plastic lugs see Section B B Reverse removal operations AIR DUCT ASSY RETAINING LUG 5 PANEL PAD UPPER LEVEL AIR QUTLET DUCT 2 gt SECTION 8 8 SECTION C C 5 5 ry 2 i PLENUM CHAMBER SECTION AIR DUCT VENTILATOR CONTROL amp CABLE VIEW R FIG3 2 VENTILATOR DUCTING amp CONTROLS view B GRILLE SHROUD VENTILATOR Models All Removal 1 Raise engine hood 2 Remove sctews securing
21. Windshield Wiper amp Washer i io 3 15 FRONT END 3 2 BODY FLOW THROUGH VENTILATION Description The new ventilation and heating system on all HQ models allows fresh or mixed hot or cold air to flow through the body Fresh air entering the shroud ventilation grille forward of the windshield passes into a full width plenum chamber from where it is directed to the upper and lower air outlets located both on and under both ends of the instrument panel Finger grip controls marked located on each side of the instrument cluster operate flaps within the R amp LH air ducts directing air down on the floor through these ducts With the VENT control pulled fully out maximum lower level air flow is attained with reduced air flow through the upper level outlets With the VENT control fully closed lower level air flow is shut off and maximum upper level air flow is possible Serrated wheels on either end of the rotable vanes are used to direct or shut off air flow from the upper air outlets Balanced air flow through upper and lower level air outlets can be achieved by intermediate setting of the lower vent controls and by opening the upper level air outlet direct ional vanes A heat demist control incorporating an air induction fan switch is attached to the RH side of the instrument carrier Fresh air entering the plenum chamber is drawn into the heater air mix unit via a branch fro
22. remove snib rod knob 2 Remove armrest where fitted and disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel water deflectors refer Fig 7 1 3 From inside door remove nuts securing ex terior handle to door outer panel see View A Figs 7 1 7 2 or 7 3 4 Disengage handle to lock connecting rod from door lock and remove handle from outside door Installation Reverse removal operations Adjustment With door lock in locked position and from inside door turn plastic nut attached to lower end of ex terior handle to door lock connecting rod see Figs 7 1 7 2 or 7 3 in a clockwise direction to relieve connecting rod tension or anti clockwise to increase tension l Using end of weatherstrip removal and inserti Tool No 1A4 see Fig 7 15 between weath strip and door inner panel at clip location carefully prise clips from weatherstrip reta ing holes 2 Check weatherstrip clips for correct shape lt reform if necessary using clip reforming Tv No see Fig 7 16 Installation 1 Ensure that weatherstrip clip attaching ho sealing plugs are correctly installed in holes below door belt line 2 Insert weatherstrip clips into holes aro door inner panel by positioning notched end weatherstrip inserting Tool No 1A4 into c and inserting clip into hole as illustrated Bie dy W
23. see Sections and Figs 10 9 and 10 10 SECTION NOTCH IN CORNER MUST NOT EXTEND BEYOND THIS LINE 2 PLACES ROOF COVER SECTION B B CUT AND REMOVE FOLD TO ELIMINATE 3 THICKNESSES UNDER MOULDING 4 PLACES TO LINE UP WITH EDGE OF MOULDING RETAINER ROOF VIEW PANEL COVER SECTION C C SECTION E E veo ine NOTE ATTACH COVER TO ROOF WITH 3M NITRILE ADHESIVE APPLIED VIEW B TO BOTH CONTACTING SURFACES SECTION D D FIG 10 9 VINYL ROOF COVER INSTALLATION MODEL LUXURY SPORTS COUPE ROOF 10 12 RETAINER ROOF PANEL COVER 7 SECTION C C NOTCH IN CORNER MUST NOT SECTION B B EXTEND BEYOND THIS LINE 2 PLACES SECTION E E 223 COVER FLUSH WITH WELD STUDS CUT AND REMOVE FOLD TO ELIMINATE 3 THICKNESSES UNDER view B MOULDING 4 PLACES TO LINE UP WITH SECTION D D EDGE OF MOULDING NOTE ATTACH COVER TO ROOF WITH 3M NITRILE ADHESIVE APPLIED TO BOTH CONTACTING SURFACES FIG 10 10 VINYL ROOF COVER INSTALLATION MODEL STATESMAN DE VILLE 10 11 123 13 Apply even coat of Nitrile adhesive cement to RH side of roof between centre line of toof and drip gutter Commencing at the fold carefully smooth out cover between centre line of roof panel and drip gutter ensuring that any air pockets or wrinkles in the cover are smoothed out Repeat
24. which is as follows l Remove the damaged part by cutting through the spot welds between the panels with a thin edged chisel or by drilling the spot welds 2 Drill 3 16 in diameter holes in either the new or mating part to correspond with the spacing and location of the original spot welds Parts to be drilled determined by accessibility for following operations 3 Clamp new part in position and gas or arc weld the two parts together through each hole finally dressing off high spots on exposed surfaces When replacing parts such as roof panels rear quarter or rocker panels where a butt or overlap weld is required the join of the panels must be formed below the normal contour This allows for solder loading over the join and eliminates the possible reduction of sheet steel thickness following the necessary buffing or grinding of a normal welding operation IMPORTANT Following replacement or repair of body components it is essential that proper rust proofing techniques be observed Components should be rust proofed whenever body repair operations destroy or damage the original rust proofing GENERAL INFORMATION 1 9 Body Sealing After replacing body panels or assemblies all under body panel joins should be sealed with an under body sealer Where it is necessary to paint over sealer a neutral plastic sealer should be used Considerable attention is given to the sealing of body shells during the process of manu
25. 1 Pencil scribe around striker assembly on lock pillar to facilitate installation 2 Remove screws securing striker assembly to tear end aperture pillar see Fig 6 4 Installation Apply a ribbon of caulking compound around inner face of striker assembly and screw attaching holes ptior to reversing removal operations END GATE 6 8 SPACER AS REQUIRED STRIKER 1 FIG 6 4 LOCK STRIKER ASSEMBLY Adjustment 1 To adjust striker horizontally or vertically loosen screws securing striker assembly to rear body aperture pillar move striker to the desired location then tighten attaching screws 2 To adjust striker away from rear body aperture pillar and to ensure correct engagement of striker and end gate lock emergency Spacers should be installed between striker and lock pillar The end gate should be correctly aligned with rear body aperture before checking end gate lock spacer requirements To determine if end gate lock striker emergency Spacers are required apply plasticine or caulking compound in behind the tooth plate where the rotary lock housing engages then close end gate to form an impression in the plasticine or caulking compound as shown in Fig 6 5 When dimension A in F ig 6 5 from inside face of striker tooth plate to outside of lock housing is less than 11 32 in install emergency spacers in accordance with the following table END GATE 6 6
26. 10 adjacent to windshield Remove windshield wiper rod and blade ass emblies refer Page 3 1 Remove windshield reveal mouldings refer Page 12 1 Remove internal rear vision mirror assembly Remove windshield garnish mouldings refer Page 3 1 Remove front headlining finishing lace refer Page 10 1 From inside body pierce caulking compound bead at top of windshield and insert one end of a 2 approx length of 020 music wire through bead and copper wire core Securely attach wooden handles to both ends of music wire see Fig 9 1 and with the aid of an assistant inside the body work wire around periphery of windshield using a saw like action to cut through caulking compound bead Remove windshield Remove surplus caulking compound bead re maining on flanges of body opening then tho roughly clean flanges with a clean cloth damp ened with an oil free cleaning solvent such as Shell 55 Solvent or equivalent Installation ELECTRIC CURING METHOD Visually check body opening flanges and correct any existing irregularities Prime shaded area of complete body opening flange with the paint finish primer supplied in kit see Views and B Fig 9 2 Position two spacer blocks at locations ill ustrated in View E Fig 9 2 FIG 9 1 WINDSHIELD REMOVAL Centrally position glass in body opening on spacer blocks th
27. 7 2 Remove nuts securing nameplate to instrument facia then remove nameplate Installation Reverse removal operations HEATER amp DISTRIBUTION DUCT ASSEMBLY Models Removal 1 Remove instrument panel compartment refer page 3 5 2 Remove LH air outlet from plenum chamber refer page 3 4 3 Remove instrument facia closing panel see 2 4 From under instrument panel remove screws and butterfly nuts securing demist and heat distribution duct to instrument panel and heat distribution duct assembly see View A Fig 3 00 m FRONT END 3 9 5 Disconnect heat and demist control cables from top of heat distribution duct assembly see Fig 3 5 71 6 From inside engine compartment disconnect body harness connector from heater impellor motor 7 Disconnect inlet and outlet water hoses from heater assembly see Fig 3 7 8 Remove screws and nuts securing blower and air duct assembly to heat distribution duct see Fig 3 6 then remove blower and air duct assembly 9 Remove screw attached retainer securing LH side of heater core to heat distribution duct 10 Slacken off screws securing RH heater core retainer to duct then withdraw heater core into engine compartment LH side first ll From inside vehicle remove heat distribution duct and demist assemblies Installation Reverse removal operations ensuring that the heat distribution duct cover is
28. Compartment 144 mor Pertsa me Trim Panel Rear Quarter Inner ENS SL a u unas en I rima Trim Rear Quarter Side Trim Rear Seat Parcel Shelf Trim Wheelhouse Underbody Alignment Upper Level Air Outlet e e Panel Upper Weatherstrip amp Retainers 0a a asa a A Mentilation Description wawawa RE Vinyl Roof Gover a a EE Water Deflector Door Panel 22 Water Leak Diagnosis amp REEE LM Wear Strips amp Trim Inner Panel End Gate Weatherstrip Assembly Door Weatherstrip Lower End Gate fol e NS Weatherstrip Oute End Oat nme terre Weatherstrip Rear Compartment Lid Weather strip Rear Quarter Belt 2 Wheel Opening Reveal Moulding oo Window Assembly Door PA RC Window Assembly End Gate Windshield Description Windshield Installation sine Windshield Installation Electric bag Method M Windshield Lower Reveal Bai Windshield Side Reveal Moulding Windshield Upper Reveal Moulding Windshield Wiper Motor Linkage amp Washer gs Mn PAGE 7M CO Ur 00 I co 111
29. DIVISI ette oar co SEA Deer Assemblies Sermo E ae Deer een Af ea Doors Description Door Window Glass eon inane GS NC en diis Door Window Glass and or Sash Plate SNS s l Qn 3 O AL tM Electric Switch amp Escutcheon ms Lem OTE Emblem or Nameplate Radiator Grille 4 End Gate Assembly SS End Gate Description End Gate Glass Opening a Deo O ALPHABETICAL INDEX 16 2 SUBJECT PAGE End Gate Outer amp s Belt Moulding unio 192 531 Engine Hood BR SA 12555 Exterior naue rid pesona mi ora AR A 121 Facia Instrument Panel Filler Panel ich co cron Finishing Rear Quarter ee Fixed Glass Rear Door Front amp Rear Door Belt Menace Front amp Rear Door Scalp Moulding Front Bumper wane a ve NAWA OO Front End Panel Zend LEM SOA ami PAL l m c em ec DONWON Garni sh Moulding Windshield aS a 3 12 Glass Run Channel Deer
30. Ensure that frictional surfaces of the quarter window regulator are adequately lubricated with zinc oxide gtease or light oil prior to reversing removal op erations MOTOR QUARTER WINDOW REGULATOR Models Option on all Coupes except 803 437 Removal 1 Remove quarter window regulator assembly refer preceding instructions WARNING Do not loosen motor to window reg ulator attaching bolts prior to per forming operation 2 REAR QUARTER 4 3 2 Lock motor to regulator assembly by using a 1 4 bolt 3 4 long 1 5 8 flat washer and an attaching nut attached through hole in regulator base plate and curved slot in sector plate 3 Remove motor to regulator assembly attaching bolts Installation Reverse removal operations ensuring that frictional surfaces of regulator sector and motor gear are adequately lubricated with zinc oxide grease or light oil REAR QUARTER WINDOW Models Coupe Removal 1 On GTS and luxury sports coupes remove rear quarter armrest and on all coupes rear quarter window regulator handle refer Page 4 5 2 Remove rear seat cushion and seat back refer page 8 1 3 Remove rear quarter inner trim panel refer page 4 5 4 Remove screw attached quarter inner cover panel 5 Remove up travel stop bracket see Fig 4 1 6 Remove quarter belt outer weatherstrip and rear quarter finishing lace refer Page 4 8 7 Loosen bolt securing adj
31. Gate Wa Dee we CERT l ock Assembly Doors T Lock Assembly End Gate Ee E Lock Cylinder amp Cap Assembly Gie wawan Lock Cylinder 8 Housing Instrument Panel Compartment Doa APEI OEE Lock Cylinders Key amp Locks Sen Lock Plate amp Support alise pelvis Engine H Lock Rear Compartment Lid 2 Lock Striker End Gate Bec O Lock Striker Instrument Panel Con C pos SESS Ch Gn xO ALPHABETICAL INDEX 16 3 SUBJECT PAGE Maintenance Appearance 4 1241 Model Identification mos darti em 12 3 Motor amp Impellor e E 3 9 Motor amp Pump Assembly Windshield Wiper Weathers 3 12 Motor Door Window Regulator 7 13 Motor Electrically Operated End 2 Window Regulator TR 6 4 Motor Rear Quarter Window Regulator oe 4 3 Nameplate 3 9 Nameplate Front Fender ee 12 14 Nameplate or Emblem Rear modimeni is de _ Deve ANO 12 14 Nameplate Rear Compartment Lid amp End Gate 2 12 14 Pad Instrument Panel wiam ad dood elena RS POTINS 3 6 Petrol Filler Door sc rome cem 5 5 Pivot amp Link ns Weer
32. QUARTER 4 5 HANDLE REAR QUARTER WINDOW REGULATOR Models Coupe Removal 1 Insert slotted end of door interior handle re moval Tool No 21812X Fig 4 4 between base of handle and bearing plate and in line with arm of handle disengaging horse shoe shaped retaining spring and releasing handle Installation 1 Locate horse shoe shaped retaining spring in handle with open ends of spring towards am of handle and press spring into the engaged position 2 Install handle bearing plate into regulator splines with raised face towards door 3 Press handle onto regulator until retaining spting engages behind splines ensuring that the handle is positioned as illustrated see Fig 4 4 TRIM PANEL REAR QUARTER INNER Models Coupe Removal 1 On GTS and luxury sports coupes remove rear quarter armrest and on all coupes rear quarter window regulator handle refer preceding in structions 2 Remove rear seat cushion and seat back refer Page 8 1 TOOL No 21812X RETAINING SPRING DISENGAGED PUSH TOOL IN DIRECTION OF ARROW INSIDE HANDLE FIG 4 4 WINDOW REGULATOR HANDLE REMOVAL REAR QUARTER 4 6 QUARTER INNER TRIM PANEL RETAINING BRACKET SECTION REAR QUARTER TRIM PANEL REAR QUARTER INNER PANEL _ SECTION FINISHING LACE TRIM PANEL SA RETAINING CLIP FIG 4 5 REAR QUARTER TRIM PANEL REMOVAL MODEL COUPE 3 Loosen
33. RETAINED UNDER SEAT CUSHION FRAME SEAT BACK FRAME WIRE 92 SEAT BACK LOWER RETAINER BEND AS SHOWN VIEW B 69 STYLES SEAT CUSHION FRAME SEAT BACK FRAME WIRE Z SEAT BACK OUTER RETAINER BEND AS SHOWN 1 View B 37 STYLES CUSHION ATTACHING BRACKET view D FIG 8 6 REAR SEAT CUSHION amp BACK INSTALLATION MODELS SEDAN amp COUPE CC 5 REAR SEAT BACK BUMPER REAR SEAT D BACK STOP BRACKET REAR sear 7 BACK STOP section SEAL WITH CAULKING COMPOUND section B B 7 REAR SEAT BACK HINGE ASSEMBLY section C C SEAT CUSHION FRAME CUSHION ATTACHING SEAL WITH CAULKING BRACKET COMPOUND SECTION VIEW C Fig 8 7 REAR SEAT CUSHION AND BACK INSTALLATION MODEL STATION SEDAN SEATS 8 10 REAR SEAT BACK LOCK amp HANDLE ASSEMBLY 4 Disengage lock bar attaching clips from lock plunger assembly and remove lock handle ass Models Station Sedan embly from seat back 5 Withdraw lock plunger assemblies from sides Removal of seat back 1 Lower tear seat back 2 Remove screw attached plate covering seat Installation back lock handle assembly Lubricate frictional surfaces of lock plunger 3 Remove screws securing lock handle assembly and handle assembly prior to teversing removal to seat back see Section A A Fig 8 8 operations HANDLE ASM REAR SEAT BACK RS CLIP REAR SEAT BACK LOCK BA
34. SEDAN SEATS 8 14 SPACER WASHER WASHER REAR QUARTER INNER PANEL BOLT SECTION A A SEAT BACK CUSHION SEAL WITH CAULKING COMP OUND LAP amp SHOULDER SEAT SEAT BACK BELT ASSY 7 BOLT W SEAL WITH SPACER CAULKING COMPOUND SECTION B B CUSHION CENTRE LAP BELT ASSY SECTION C C FIG 8 12 REAR SEAT BELT INSTALLATION MODELS STATION SEDAN STATIONARY GLASS 9 1 SECTION 9 STATIONARY GLASS INDEX Subject Page Windshield Description 9 1 Windshield Electric Curing Method 9 3 Windshield Air Curing Method 9 5 Back Window 9 6 Rear Quarter Window 9 6 Description The windshield is of toughened armour plate glass and includes as a safety feature a modified Zone This Zone covers an area 17 5 in wide by 7 in deep elliptical in shape and is located at eye level directly in front of the driver Should the glass shatter the modified Zone remains comparatively clear due to larger particles of glass in this area thus allowing sufficient vision to stop the vehicle Armour plate glass windshields with a modified Safety Zone can be identified with the work ZONE in the manufacturer s mark etched in the bottom centre of the glass con taining the modified Zone Optional laminated windshields including one featurin
35. SPRING M xi SWITCH BODY LIGHT MUST BE OFF JUST BEFORE LID IS CLOSED BEND BRACKET IF NECESSARY TO ACHIEVE THIS CONDITION FIG 5 2 REAR COMPARTMENT LAMP amp SWITCH INSTALLATION MODELS SEDAN amp COUPE EXC BELMONT amp KINGSWOOD PETROL FILLER DOOR LICENSE NUMBER PLATE SECTION FIG 5 3 PETROL FILLER DOOR INSTALLATION PETROL FILLER DOOR ASSEMBLY Models Sedan amp Coupe Removal 1 Remove screws securing rear license number plate to petrol filler door see Fig 5 3 and remove plate 2 Remove nuts and bolts securing petrol filler door assembly to back panel lower Installation Reverse removal operations WEATHERSTRIP REAR COMPARTMENT LID Models Sedan amp Coupe The rear compartment weatherstrip is a constant rubber section secured in position with wire clips inserted into holes at regular intervals around the rear compartment lid REAR COMPARTMENT 5 TOOL 1A4 FIG 5 4 WEATHERSTRIP CLIP REMOVAL amp INSTALLING TOOL Removal 1 Using weatherstrip clip inserting tool No 144 Fig 5 4 or a similar suitable tool at clip locations carefully prise clips from retaining holes 2 Check weatherstrip clips for correct shape and reform if necessary using clip reforming tool No Fig 5 5 Installation Reverse removal operations TOOL No 1A3 FIG 5 5 WEATHERSTRIP CLIP REFORMING TOOL REAR COMPARTMENT 5
36. So mulo boc La 3 15 Quarter 2 OMSL P O WA 12 9 Quarter Moulding NEUE oet EAC O BEE A RTT 12 Quarter Trim panel 2 6 03 ee 00 a a R Radiator lT Mere 0 OCTET AOR TA Rear BUMP e rec T rm 4 Rear Door Hardware o Rear Compartment Lamp amp Swich s T ER EE Rear Compartment Lid meo m DS 5 Rear Compartment Lid Acres Description copra itera EE 5 Rear Compartment Lid Moulding 25192 EEE OA te Ree RS 12 13 Rear End Moulding ROS UPPER DO 12 13 Rear Quarter Side Upper amp over Reveal Moulding 21 Rear Quarter Upper Moulding CO 12 10 4 Rear Quarter Window 4 3 Rear Quarter Window Station 2414 ME boe Rear Seat Beck tod amp Henele Assembly que yan T N m dp a Rear Window Reveal Moulding nn Ss E ERE 202 Rear Window Upper Reveal Moulding Recliner and or Arm Assembly ei Raa E se Door Window 22 2 S Regulator Gore ITANE Regulai 2222 222 Walkie Relief Valve Rear Quarter Side Trim 2 2222 Remote Control Door Lock 222222 sn enn ith ba 4448 35 49 88 48 498 466 48 9 Remote Control Front Seat Adjuste
37. a clean cloth saturated with cold water However no type of treatment will repair damage to material resulting from the action of the acids par ticularly after the spot has dried Blood Rub the stain with a clean cloth saturated with cold water until the stain is removed Only use clean portions of cloth for rubbing the stain This treatment should remove all of the stain If it does not apply a small mount of household ammonia to the stain with a cloth or brush After a lapse of about one minute continue to rub the stain with a clean cloth dipped in clean water If the stain remains after the use of water and ammonia a thick paste of corn starch and cold water may be applied Allow the paste to remain until it has dried and absorbed the stain then pick off the dry starch Brush the surface to remove starch particles that remain For bad stains several applications of starch paste may be nec essary CAUTION Do not use hot water or soap and water on blood stains as this will set the stain thereby making its removal pract ically impossible Sweets and Chocolate Sweet stains resulting from cream and fruit filled chocolates can be removed more easily by rubbing with a cloth soaked in lukewarm soapsuds mild neutral soap and scraping while wet with a dull knife This treatment is followed with a rinsing by rubbing the spot with a cloth dipped in cold water Stains resulting from chocolate can be removed by rubbi
38. attaching screws NOTE Removal of inner recliner amm assembly necessitates removal of seat separator transmission control console refer Page 2 1 2 Locate seat back in its fully folded position see Fig 8 5 3 Remove screws securing outer or inner amm assembly to seat cushion and back 4 Disengage arm assembly ies from torque tube removing assembly ies Installation Ensure that recliner arm assembly ies are in the fully unloaded position see Fig 8 5 and that the seat is fully folded prior to re versing removal operations IMPORTANT It is essential that the first tooth on each arm assembly sector plate engage simultaneously CAUTION Removal of the spring loaded recliner arm assemblies in any but the fully folded position can cause injury SEATS 8 SCREW amp WASHER ASSEMBLY TORQUE TUBE RECLINER ARM ASSEMBLY ACTUATING LEVER SECTOR PLATE ATTACH WITH NEOPRENE CEMENT APP LIED TO BOTH CONTACTING SURFACES RETAINER WIRE TRIM FASTENER SECTION Fig 8 5 FRONT SEAT RECLINER ASSEMBLY MODELS COUPE SEATS 8 8 SEAT BACK FRAME WIRE SEAT BACK FRAME SEAT BACK HANGER BRACKET SEAL WITH NON HARDENING SEALER VIEW 37 STYLES 4 SEAT BACK FRAME SECTION B B SEAT BACK LOWER RETAINER BEND AS SHOWN VIEW 69 STYLES Us WITH NON HARDENING SEALER SECTION A A REAR SEAT CUSHION CARPET OR MAT TO BE
39. ee 1 10 Body wy aO NUM Al Body Lubrication ee ee NEM Body Sealing oe PE 1 9 Body Shell Parts Ren lt n J 9 Bracket Assembly Hood Lock k Plunger a p N BA OU ee 11 6 Bumper Bar Assemblies em m 19 11 Cn CO C W Gables 222222 2 7 70 Care amp Cleaning of Interior Trim 1 AREN ON Compartment amp Door Instrument Panel 8615671557 liransmissionaGcniroli em Body mnr Control Cable Heat and or Demist Covering Eiller Panel were SuSE hawaka Covering Front Floor Covering Rear Floor eme 29 Covering Tonneau tone t Covering Tonneau Floor Side Sill 22222 Cover Quarter Inner Panel Cylinder Front Door Lock Cylinder Rear Comparten Lid R y l JO MON OS OW LOS cnemo eam 722 TCI 2 2 PEC yel tU
40. effectively sealed see sealing note on Fig 3 6 NOTE Run engine at a fast idling speed for five minutes to ensure full circulation of water through heater core before topping up rad iator MOTOR amp IMPELLOR ASSEMBLY HEATER Models All Removal 1 With engine hood raised disconnect air in duction motor to heater resistor lead see Fig 3 6 2 Remove screws securing earth strap and air induction motor and impellor assembly to air duct cover and withdraw assembly Installation Reverse removal operations NOTE For inspection overhaul and testing of air induction fan motor refer VOL 5 Electrical Instruments and Gauges FRONT END 3 10 DUCT DEMIST amp HEAT DISTRIBUTION BUTTERFLY NUT DEMIST DUCT TO INSTRUMENT PANEL y DUCT ASSY HEAT s DISTRIBUTION g AIR INDUCTION MOTOR amp IMPELLOR ASSY 8 HEATER CORE f WASHER E TIGHTEN MOUNTING ASSY PLATE SCREWS AFTER EATER 1 FITTING RADIATOR RESISTOR 1 1 z APPLY SEALER WITH A CONTINUOUS RUN APPLY A CONTINUOUS RUN FOLLOWING OVER GROOVE OF NON HARDENING SEALER IN GROOVE SECTION EMALCO BLOWER amp AIR DUCT ASSY SCREWS BLOWER amp AIR DUCT TO HEATER DUCT TIGHTEN CLAMP SCREW SECTION AFTER FITTING RADIATOR SMITHS FIG 3 6 MOTORISED HEATER INSTALLATION r FRONT END 3 11 ASSEMBLE CABL
41. flush against switch cam 4 Install switch into lock cylinder case 5 Position lock cylinder and switch assembly into escutcheon and engage retainer NOTE The lock cylinder and switch assembly is serviced as a complete unit SAFETY SWITCH ELECTRICALLY OPERATED END GATE WINDOW REGULATOR Models Optional on Kingswood amp Premier Station Sedans Removal 1 Open end gate and remove wear strips and inner trim panel refer page 6 7 2 Raise and support end gate window 3 Disconnect switch harness from inside end gate see Fig 6 2 4 Remove screws securing safety switch to LH Side of end gate and remove switch END GATE 6 10 Installation 1 Apply PVC adhesive over entire plastic surf e of switch back 2 Apply mastic sealer under lip of switch act uating lever rubber seal prior to reversing removal operations INTERIOR HANDLE AND REMOTE CONTROL Models Station Sedan Removal 1 Open end gate and remove wear strips and inner trim panel refer page 6 7 2 Remove screw attached remote control handle from end gate inner panel 3 Raise and support end gate window 4 Remove screws securing remote control to inside of inner panel see Fig 6 z 1 or 6 2 5 Disengage anti rattle clip and control rods from remote control and remove control Installation 1 Clean and lubricate frictional surfaces of remote control 2 Apply mastic sealer between mating sur
42. hole shield pillars see View B Figs 10 2 to through headlining in rear quarter inner panel upper slitting a cross approximately 1 long in centre of hole 10 4 inclusive c Pull lamp harness through headlining then 11 Clean off any excess cement around head install lamp holders in lamp base see Views lining area using a cloth moistened with white C D or E Fig 10 1 spirit d Install lamp base on roof support by passing roof support tabs through base and firmly CAUTION Do not use petrol or paint thinners twisting tabs see View A Fig 10 1 e Install screws securing rear quarter interior lamp base to rear quarter inner panel upper 12 Install finishing lace around door aperture see Views and F Fig 10 1 flanges and headlining retainers see Section and View A and Figs 10 2 to 10 4 f Install lamp and lens to lamp base inclusive FRONT HEADLINING RETAINER ATTACH HEADLINING TO FRONT amp REAR RETAINERS AS SHOWN AND TO OUTSIDE OF DOOR OPENING FLANGES SECTION WITH CEMENT FOR ENTIRE LENGTH OF HEADLINING WINDSHIELD FINISHING LACE BACK WINDOW FINISHING LACE VIEW F BEND TABS TO RETAIN 2 LISTING WIRES 7 7 50 lt HEADLINING BE TURNED UNDER VIEW B REAR HEADLINING RETAINERS view D VIEW E LISTING WIRE COAT HOOK TRIM QUARTER SIDE LOWER VIEW G 8
43. lifter arms which are under tension from the counter balance spring can cause serious injury if the motor is removed without locking the sector gears in position GARNISH MOULDING WEATHERSTRIP LOCK STRIKER LIMIT ARM REMOTE CONTROL HANDLE ENDGATE ASSEMBLY N LOCK FIG 6 3 REAR END STATION SEDAN Drill a 1 8 in dia hole through regulator sector and back plate DO NOT drill the hole closer than 1 2 in to edge of sector back plate Install a pan head self tapping screw 10 12 x 5 8 in pre viously drilled 1 8 in dia hole to lock regulator sector gear to retain counter balance spring tension NOTE For servicing end gate electrically operated window regulator motor refer Volume 5 Electrical Service Manual LOCK ASSEMBLY Models Station Sedan Removal 1 Open end gate and remove wear strips and inner trim panel refer page 6 7 2 Raise and support end gate window 3 Remove lower glass run channel on side from which lock is to be removed 4 Remove screws securing lock to side of end gate see Fig 6 1 or 6 2 2 Disengage lock from remote control rod and remove lock Installation 21 Ensure frictional surfaces of lock are ade quately lubricated with zinc oxide grease or light oil 2 Apply caulking compound around face of lock frame and rotary bolt prior to reversing removal operations LOCK STRIKER Models Station Sedan Removal
44. moulding 3 Apply sealing compound around outer moulding attaching screw holes prior to installing screws and removing masking tape MOULDING END GATE Models Kingswood amp Premier Station Sedan Removal 1 With end gate open remove screws securing ends of moulding to end gate 2 To protect paint finish apply masking tape below end gate moulding 3 Using a wide bladed screwdriver located between moulding and panel carefully prise end gate moulding off retaining clips see Section Fig 12 2 Installation l Locate upper edge of end gate moulding over top of retaining clips then using the hand or a rubber mallet lightly tap moulding into position 2 Apply sealing compound around moulding att aching screw holes prior to installing screws and removing masking tape LID MOULDING Models Premier Sedan amp L Removal 1 With rear compartment lid open remove screws securing ends of moulding to rear compartment lid see Section V V Fig 12 2 To protect paint finish apply masking tape below moulding to be removed Using a wide bladed screwdriver located between moulding and lid carefully prise moulding off retaining clips Installation 1 Locate upper edge of moulding over top of tetaining clips then using the hand or a rubber mallet lightly tap moulding into position Apply sealing compound ar
45. operations Adjustment Elongated holes in the hinge straps provide forward rearward and side adjustment of the lid Horizontal adjustment of the hinge area of the lid can be achieved as follows a To raise lid at hinge area place a shim be tween lid inner panel and one or both hinge straps at forward attaching bolt locations b To lower lid at hinge area place a shim be tween lid inner panel and one or both hinge straps at rearward attaching bolt locations Adjust lock striker to allow rear compartment lid to seat firmly on rubber bumpers located on each side of compartment lid see View A Fig 5 1 IMPORTANT Following any adjustment of the rear compartment lid it is important that the lid lock striker engages correctly with the lid lock To check correct engagement place a small piece of plasticine or similar material at each side of the lock bolt cover and close lid Open lid and check engagement of lock cover with striker Where required adjust striker so that lock engages cent rally with striker REAR COMPARTMENT 5 3 TORQUE RODS REAR COMPARTMENT LID 4 Models Sedan amp Coupe Removal 1 Raise and support compartment lid 2 Pencil scribe location of torque rod on retainer to facilitate installation 3 Using a length of steel tubing approximately 12 long with an inside diameter of 1 2 place one end of tube over end of totque rod then lever torque rod from retainer 4 Dis
46. rear compartment upper panel see Section Fig 12 1 2 Locate moulding removal tool No 1A6 between moulding and glass until point of tool engages with one of the retaining clips then using the tool in a rocking motion see Fig 12 7 pro gressively disengage moulding from clips see Section C C Fig 12 1 3 Disengage reveal mouldings from upper reveal moulding Installation l Locate top end of reveal moulding into lower end of upper reveal moulding then install moulding onto retaining clips 2 Apply sealing compound around moulding ex tension attaching screw holes prior to install ing extension onto back panel upper NOTE On Statesman models the method of retain ing the rear window reveal mouldings are similar however no moulding extension covering the lower reveal moulding attaching clips are used and the sequence of install ation is lower sides then upper rear window reveal mouldings REAR QUARTER UPPER MOULDING Models Statesman De Ville LS Monaro amp Optional on All Sedans amp Coupes Removal l On Statesman models remove lower reveal moulding refer preceding instructions 2 On Statesman models remove screw securing rear end of moulding to rear quarter panel see Section Fig 12 2 3 On coupes and sedans other than Statesman open tear compartment lid and from within com partment remove sealing nut securing rear end of moulding to rear quar
47. ventilator grille to shroud upper panel then remove grille Installation Reverse removal operations HOOD LACING SHROUD LEDGE Models Removal 1 With engine hood raised remove screws sec uring front ot shroud ventilator grille to shroud upper panel FRONT END 3 5 2 Remove screws securing R amp LH hood lacing retainers to shroud upper panel then remove tetainers and lacing Installation Reverse removal operations COMPARTMENT amp DOOR INSTRUMENT PANEL Models Removal 1 Remove screws securing instrument panel compartment hinges to door see Section A A Fig 3 3 then remove door 2 Remove screws securing upper and lower rear edges of compartment to instrument panel V ESCUTCHEON LOCK CYLINDER DOOR HINGE SECTION SECTION B B SECTION C C FIG 3 3 INSTRUMENT PANEL COMPARTMENT amp DOOR INSTALLATION FRONT END 3 6 3 Remove compartment rearwards into body Installation Reverse removal opetations LOCK CYLINDER amp HOUSING INSTRUMENT PANEL COMPARTMENT DOOR Models All Removal 1 With compartment door open position lock cylinder in locked position key head vertical 2 With key removed and using a paper clip in serted through slot in top rear end of lock cylinder housing depress aluminium coloured retainer in rear end of lock cylinder and with draw cylinder 3 Unscrew lock cylinder retainer whi
48. 03 469 amp 811 269 TURNED UNDER T PLAIN OR BLACK p 1 l C 3 5 5 GREEN WHITE RED SECTION U Z CEMENT OVER THIS lt lt amp F AREA ONLY x BODY PILLAR GARNISH PANEL REAR DOOR APERTURE FINISHING LACE ATTACH TRIM TO CENTRE PILLAR WITH CEMENT APPLIED OVER ENTIRE TRIM CENTRE PILLAR HEADLINING BE TURNED SURFACE OF CONTACT su UNDER emp AM 803 469 amp 811 269 J 2 30 5 4 z PE t m SECTION B B ATTACH HEADLINING TO BODY WITH CEMENT 7425230 AT AREAS SHOWN THUS Fig 10 2 HEADLINING INSTALLATION MODELS ALL SEDANS except STATESMAN ROOF 10 6 FRONT HEADLINING RETAINER BACK WINDOW FINISHING LACE ATTACH HEADLINING TO FRONT amp REAR RETAINERS AS SHOWN AND TO OUTSIDE OF DOOR OPENING FLANGES SECTION A A WITH CEMENT FOR ENTIRE LENGTH 0F WINDSHIELD VIEW FINISHING LACE HEADLINING ab 27 BEND TABS RETAIN LISTING WIRES 150 HEADLINING TURNED UNDER VIEW D LISTING WIRE LISTING POCKETS 5 PLAIN OR BLACK view C RED 4 GREEN WHITE 5 D BLUE BODY PILLER 5 GARNISH PANEL Ey HEADLINING REAR QUARTER FINISHING LACE FRONT BODY PILLAR CEMENT HEADLINING FINISHING LACE OVER THIS AREA ONLY ENP TRIM QUARTER LOWER REAR HEADLINING RETAINERS ATTACH
49. 11 1 Vertical adjustment to front end of engine hood is provided by adjustable engine hood bumpers attached to both sides of radiator support panel and to an adjustable hood lock bolt see View D Fig 11 1 and Fig 11 3 CAUTION Following any adjustment to engine hood it is essential that lock operation be checked for alignment and effectiveness refer engine hood lock and plate adjustment on this page LOCK PLATE and SUPPORT ASSEMBLY ENGINE HOOD Models All Removal 1 Raise engine hood 2 Disconnect hood cable release anchor and retaining clip see View D Fig 11 3 3 Remove screws securing lock plate and support assembly to radiator support and front end panel see View C Fig 11 3 and remove assembly Adjustment Engine Hood Lock 1 With engine hood raised loosen lock plate and support assembly to radiator support and front end panel attaching screws see View C Fig 11 3 2 Carefully lower engine hood sufficient to permit tapered end of lock plunger bolt to enter and position lock plate in its correct location Do not completely close engine hood 3 Raise engine hood without disturbing lock plate then tighten lock plate and support assembly attaching screws 4 Lower engine hood to check engagement tension of lock plunger bolt in relation to lock plate SHEET METAL 11 6 5 To achieve correct engagement between lock plunger bolt and lock plate position an open ended s
50. 1A8 remove roller tee nuts and plastic bushings from bolts see Fig 7 12 3 Lift glass off front and rear sash plate ass emblies 4 Prise rubber glass bearing fastener and cap off glass Assembly Reverse to disassembly FIXED GLASS REAR DOOR Models Sedan and Station Sedan Removal 1 With door open and window raised remove snib rod knob 2 Remove armrest where fitted disconnect electrically operated regulator switch where fitted remove door interior handles inner trim panel door inner panel water deflector and door window refer Page 7 1 3 Ease rear end of upper glass run channel out of top of door 4 Remove screws securing top and bottom of rear door division channel see Fig 7 3 ease channel forward and upwards out of window aperture 5 Holding fixed glass assembly firmly slide assembly fotward and out of door window aperture 6 Remove weatherstrip surrounding fixed glass Installation Reverse removal operations DIVISION CHANNEL REAR DOOR Models Sedan and Station Sedan Removal and Installation Refer preceeding instructions Adjustment To adjust top of door division channel forward or rearward loosen screw securing top of division channel to top of door inner frame see Fig 7 3 move channel to desired location then tighten screw To adjust lower end of division channel in or out loosen screw securing lower end of div ision channel to r
51. 237 ONLY 3 MOULDING ROOF SIDE REVEAL 4 MOULDING QUARTER BEL T 5 MOULDING REAR QUARTER UPPER 811 81237 803 80437 WITH 27 C08 amp CB1 ONLY 6 MOULDING REAR WINDOW REVEAL UPPER 7 MOULDING REAR WINDOW REVEAL L H 8 MOULDING REAR WINDOW REVEAL R H 9 NAMEPLATE TRIMATIC WITH M40 ONLY 10 NAMEPLATE ACCORDING TO MODEL 11 MOULDING FRONT WHEEL OPENING 12 GTS EMBLEM RADIATOR GRILLE 808 81837 ONLY MOULDING DOOR BELT 14 MOULDING ROCKER PANEL 803 80437 ONLY 15 MOULDING ROCKER PANEL 811 81237 ONL Y 16 MOULDING REAR WHEEL OP ENING 17 MOULDING REAR END 811 81237 ONL Y 18 PLATE ENGINE IDENTIFICATION 19 MOULDING REAR COMPARTMENT LID 811 81237 ONLY 20 MOULDING REAR END 811 81237 ONL Y w FIG 12 5 BODY EXTERIOR ORNAMENTATION IDENTIFICATION MODELS COUPE L 4 224 10 11 12 13 14 15 16 17 EXTERIOR ORNAMENTATION 12 7 8 9 10 11 12 13 14 15 16 17 E ew 7 48 7 d n 7 4 222 123 24 2 MOULDING WINDSHIELD SIDE REVEAL R H 18 MOULDING WINDSHIELD LOWER REVEAL R amp LH MOULDING WINDSHIELD UPPER REVEAL R amp LH 19 MOULDING WINDSHIELD SIDE REVEAL L H 20 EMBLEM 81400 ONLY 21 NAMEPLATE STATESMAN 22 MOULDING FRONT DOOR SCALP FRONT 23 L H 81400 ONLY MOULDING FRONT DOOR SCAL
52. 3 13 2 Se 4 SET THESE DIMENSIONS IN PARKED POSITION ACTUATING LINK SLOT RETAINING SPRING RETAINING PIN BLADE ASSY VIEW F ACTUATING LINK INSTRUMENT CARRIER RETAINER ACTUATING LINK WASHER BUTTON VIEW SHROUD GRILLE PIVOT 4 LINK ASSY SS SHROUD PANEL view B PRESLITE LUCAS RETAINER view D INSULATOR MOTOR CRANK MUST BE IN PARK POSITION PRIOR TO INSTALLATION OF BLADES amp RODS EARTH STRAP LINKAGE w RETAINER REFER view D WASHER WASHER PUMP ASSY RETAINER SEAL APPLY MOLYBDENUM DISULPHIDE MOTOR GREASE TO WASHER DURING DASH PANEL APPLICATION TO PARELLEL PIN view C APPLY MOLYBDENUM DISULPHIDE GREASE FIG 3 8 WINDSHIELD WIPER ASSEMBLY INSTALLATION FRONT END 3 14 JETS MUST STRIKE WIND SHIELD WITHIN 5 THIS 4 00 DIA TARGET AREA IF ADJUSTMENT IS NECESSARY BEND OR TWIST TIP OF NOZZLE NOZZLE MUST BE CENTRAL IN VENTILATOR GRILLE SLOT WINDSHIELD CLIP 4 PLACES RETAIN HOSE lt WIRING 5 HARNESS CLIPS X 6 PLACES SENS NOZZLE RH VAN NS 3 GROMMET HOSE RESERVOIR TO PUMP NOTE ARROWS DENOTE WATER FLOW DIRECTION HOSE PUMP RA 22 TO NOZZLE PRESLITE HOSE CONNECTIONS EN NM view B FLAT WASHER SPRING WASHER CLIP HOOD CABLE Pw WATER RESE
53. 3 With an assistant supporting engine hood remove bolts securing hinge assembly to hood inner panel and front fender and remove ass embly see View C Fig 11 1 Installation Reverse removal operations NOTES INDEX Subject Page Subject Exterior Ornamentation Description 12 1 Quarter Moulding E Windshield Upper Reveal Moulding 12 8 End Gate Glass l m 3 Windshield Side Reveal Moulding 12 8 End Gate Outer amp Centre Belt mt AR Windshield Lower Reveal Moulding 12 8 End Gate Moulding Roof Drip Gutter Rear mu 12 8 Rear Compartment Lid 3 an Roof Side Reveal Moulding 12 9 RET EA Mania e Roof Side Reveal Moulding Coupe 12 9 O ba MEM sS Tail Lamp Reveal Moulding 44 42 Quarter Belt Moulding 12 9 4 Front amp Rear Door Belt Mold e secs WCG Rocker Panel Moulding 4 Front amp Rear Door Scalp Muro 9 10 10 Wheel Opening Reveal Moulding Rear Window Upper Reveal Moulding 12 10 Nameplate gt Front Fender naa Rear Window Reveal Moulding Eye om 12 10 Nameplate Rear Compartment Lid and Rear Quarter Upper Moulding 12 10 End Gate on DAE Rear Quarter Side Upper amp Lower 22 07 os 220066 EXTERIOR ORNAMENTATION 12 1 SECTION 12 EXTERIOR ORNAMENT
54. 7 1 3 Remove nuts securing sliding glass cam ass embly to door inner panel see Fig 7 1 7 2 ot 7 3 then remove cam assembly 4 Remove bolts securing window regulator ass embly to door inner panel and from inside door disengage regulator arm lt ollers from glass lifter cams and remove regulator assembly through lower aperture in door inner panel 5 On electrically operated window regulators disengage window regulator harness connector from motor Installation 1 Ensure that frictional surfaces of window reg ulator assembly sliding glass and glass lifter cams are adequately lubricated with zinc oxide gtease or light oil 2 Position window regulator assembly in bottom of door 3 Loosely install sliding glass cam into door inner panel using rear attaching screw only 4 With an assistant supporting top of window position window regulator arm rollers into glass lifter and sliding glass cams 5 With the assistant positioning window in its raised position line up window regulator ass embly and sliding glass cam to door inner panel attaching holes and install bolts and screws NOTE Use washer markings in sealing compound around bolt and screw attaching holes as location guides when replacing door hard ware 6 On electrically operated window regulators connect harness to window regulator motor 7 Check operation of window regulator prior to adequately sealing window regulator assem
55. AR ATTACHING BOLTS TO DOOR ATTACHING BOLTS DOOR HOLD OPEN SPRING DOOR HOLD OPEN LEVER SEAL OPTION LOWER HINGE TO DOOR ATT ACHING BOLTS LOWER HINGE TO PILLAR ATTACHING BOLTS FIG 7 4 FRONT DOOR HINGES NOTE Prior to removing doors exercising the 1 2 3 optional electrically operated window re gulator the following operations must be performed Remove snib rod knob Remove screws securing armrest on all doors except rear doors of station sedan Using a wide bladed screwdriver carefully prise switch assembly out of armrest or on rear doors of station sedan rear door inner trim panel On RH front and rear door armrest mounted regulator switches remove nut securing switch escutcheon to switch base and on all switches prise switch escutcheon off switch base UPPER HINGE TO PILLAR UPPER ATTACHING BOLTS HINGE TO DOOR ATTACHING BOLTS DOOR LOCK SEAL OPTION BOLT STRIKE E DOOR HOLD OPEN SPRING n 7 A DOOR 4 HOLD OPEN 7 LEVER LOWER HINGE V TO PILLAR ee ATTACHING BOLTS TE FIG 7 5 REAR DOOR HINGES MODELS SEDAN amp STATION SEDAN 5 Remove door interior handles inner trim panel and door inner panel water deflectors refer Page 7 1 6 Ease off end of window regulator hamess seal see Fig 7 4 or 7 5 which is attached to leading face of door with Neoprene cement
56. ATION Nameplate or Emblem Rear Compartment EXTERIOR ORNAMENTATION Description Exterior nameplates emblems and mouldings are secured to the body and sheet metal with various plastic and spring steel retaining clips anchor plates screws sealing nuts and tubular lock type clips NOTE During removal and installation of exterior mouldings retained by plastic clips the retaining edges of the clips can become damaged Such damage necessitates replacement of clips Figs 12 1 through to and including 12 6 illustrate these methods of attachment through sections of the mouldings Figs 12 3 to and including 12 6 also identify the various mouldings Exterior omamentation is generally applied over paint finish surfaces therefore it is important that it be protected against damage by the use of masking tape applied adjacent to the part to be removed Where screws or tubular lock type clips are used to secure nameplates or moulding retainers to panels it is essential that a sealing compound be applied around nameplate or moulding holes prior to installation of screws or clips to effect a watertight seal 12 11 Lid Statesman De Ville age 12 12 12 12 12 12 12 12 12 13 12 13 12 13 12 13 12 14 12 14 12 14 12 14 EXTERIOR ORNAMENTATION 12 2 CLIP REAR WINDOW REVEAL CLIP WINDSHIELD MOULDING WINDSHIELD UPPER REVEAL LOWER REVEAL 2
57. D ASSEMBLY LOWER SPRING AND FRAME ASSEMBLY CUSHION SPRING INSULATORS CUSHION SPRING INSULATORS SEAT ADJUSTER ASSEMBLY Fig 8 1 FRONT SEAT FRONT SEAT 4 With the aid of assistant remove front seat fom body and place on a clean protected Models All surface Removal 1 Loosen sill plate attaching screws and ease floor covering away from seat adjuster to floor Installation attaching bolts 1 Ensure that frictional surfaces of the seat adjusters are adequately lubricated with zinc oxide grease or light oil 2 Position seat fully rearward and using a thin ratchet spanner with a 5 16 female hexagon insert remove bolts securing front end of seat adjusters to floor see Section Fig 8 2 2 Apply caulking compound around seat adjuster to floor attaching bolt holes prior to reversing 3 Position seat fully forward and remove bolts removal operations see Section A A Fig securing rear end of seat adjuster to floor 8 2 SEATS 8 3 BOLT SEAT ADJUSTER TO FLOOR TORQUE TO 10 15FT 185 APPLY 18DIA BEAD OF CAULKING COMPOUND AROUND TOP EDGE OF HOLES IN FLOOR PAN BEFORE INSTALLATION OF SEAT ASSEMBLY Fig 8 2 FRONT SEAT INSTALLATION REAR SEAT REAR SEAT Models All except Station Sedan Models Station Sedan Removal Removal 1 Remove screws securing seat cushion frame l Lower rear seat back and remove hinge to brackets to rear floor crossbar see View D Fig 8 6 sea
58. D LEAD ASSY FROM DOME LAMP ORANGE LAMP REAR QUARTER LAMP LEAD ASSY LAMP LENS RH REAR DOOR JAMB SWITCH LEAD WHITE REAR QUARTER LAMP AND WIRING RH SIDE 814 VIEW B REAR QUARTER LAMP FEED LEAD ASSY ORANGE DOME LAMP WIRING FOR 814 view D REAR COMPT LAMP LEAD ASSY BROWN RH SIDE ONLY m LAMP BASE LAMP REAR QUARTER LAMP HARNESS ASSY 4 LAMP LENS REAR QUARTER LAMP amp WIRING COUPES View F ROOF 10 4 8 Install headlining around tear quarter back 13 Install rear parcel shelf rear seat back and window and tear body pillars nicking radii cushion refer pages 4 1 and 8 1 to obtain wrinkle free installation 14 Install interior rear vision mirror sun visors 9 On sedans fold part of headlining to be and coat hooks attached to centre pillar back on itself suff icient to align folded edge of headlining with original cement mark on pillar then cem nt this part of headlining to centre pillar see 15 Install roof interior lamps see Fig 10 1 by Section B B Figs 10 2 and 10 4 a Pushing roof support lamp base retaining tabs through headlining and splitting head lining in centre of tabs sufficient to allow 10 Install edges of headlining to roof side rails lamp to pass through headlining repeating No 9 installation instruction for installing front comers of headlining to wind b On rear quarter interior lamps locate
59. EAR Models Sedans amp Station Sedans except Belmont Removal 1 With rear door open remove screws securing drip gutter to quarter panel then remove gutter Installation Reverse removal operations ROOF SIDE REVEAL MOULDING Models All except Coupe amp Belmont Removal 1 Position U shaped section of moulding removal tool No 1A7 under rear lower edge of moulding raising tool and disengaging moulding from toof side rail see Fig 12 8 2 Continue this operation progressively along the moulding disengaging front end of moulding from under windshield upper reveal moulding NOTE On Station Sedans a front and rear roof side reveal moulding is fitted Installation 1 Locate front end of roof side reveal moulding under upper windshield reveal moulding and over top of roof side rail then using the hand or a rubber mallet lightly tap moulding into position ROOF SIDE REVEAL MOULDING Models Coupe Removal 1 Open door and lower quarter windows on side from which moulding is to be removed 2 Remove rear roof drip gutter refer Page 12 8 3 Ease out upper weatherstrip adjacent to mould ing from retainer 4 Loosen screws securing weatherstrp retainer to roof side rail then slide moulding out from between roof side rail and weatherstrip retainer see Section I I Fig 12 1 Installation Apply sealing compound between roof side rail and weatherstrip retainer prio
60. EATHERSTRIP ASSEMBLY DOORS Models Coupe Removal l Carefully ease off front and rear upper ends weatherstrip which are attached to the d inner panel with Neoprene cement 2 Using end of weatherstrip removal and inse ing Tool No 1A4 see Fig 7 15 betwe weatherstrip and door inner panel at clip 1 ations carefully prise clips from weatherst retaining holes 3 Clean or smooth off any hardened cement fr front and rear upper section of door inner pan 4 Check weatherstrip clips for correct shape a reform if necessary using clip reforming T No 1A3 see Fig 7 16 DOORS 7 20 TOOL No 1A4 FIG 7 15 WEATHERSTRIP CLIP REMOVAL AND INSTALLATION TOOL Installation 1 Ensure that weatherstrip clip attaching hole sealing plugs are correctly installed in all weatherstrip clip holes 2 Insert weatherstrip clips into holes around sides and bottom of door inner panel by pos itioning notched end of weatherstrip inserting Tool No 1A4 into clip and inserting clip into hole as illustrated in Fig 7 15 3 Attach upper ends of weatherstrip between attaching clips and ends of weatherstrip to door inner panel with Neoprene cement TOOL No 1A3 FIG 7 16 WEATHERSTRIP CLIP REFORMING TOOL BELT WEATHERSTRiP FRONT and REAR DOOR OUTER Models All except Coupe Removal 1 With door window lowered position a wide bladed screwdriver between belt weatherstrip and inner f
61. EE 2 z ee BR GA HOLDEN _ HQ HOLDEN service manual CONTENTS BODY AND SHEET METAL GENERAL MOTORS HOLDEN S SALES PTY LTD SERVICE DIVISION HCLDEN PUBLICATION 2 54 4 L 5 MES RR SERVICE MANUAL FOREWORD VOLUME 1 Designed as a reference book for the competent mechanic and a step by step procedure for the less experienced this Manual provides complete descriptive CONTENTS information maintenance and repair data on the HO Holden To use the index bend the manual back to expose the black section marks on the pages Locate the 1 GENERAL INFORMATION corresponding black section mark on the pages of the section you desire to find Where warranted a more detailed table of contents 2 UNDERBODY preceeds each section and an alphabetical index is in cluded in the back of the manual 3 FRONT END Space is provided at the back of each section for noting any additional service information received sub 4 REAR QUARTER sequent to the publication of the Manual through the Q medium of Service Bulletins The special tools illustrated are essential for the efficient servicing of the HQ Holden and are available through major tool distributors 6 END GATE The terms used in the description of operations are REMOVAL AND INSTALLATION meaning 7 DOORS simply to remove or take out a unit or parts of a unit and to put back the same unit or part
62. ES WITH HEAT AND DEMIST CONTROL LEVERS IN OFF AND COLD POSITIONS RESPECTIVELY POSITION JAY 2 M CABLE HEAT CONTROL CABLE DEMIST CONTROL CONTROL ASSY HEAT amp DEMIST NOTE ARROWS ON INLET amp OUTLET WATER NIPPLES DENOTE WATER FLOW DIRECTION FIG 3 7 HEATER amp DEMIST CONTROL INSTALLATION FRONT END 3 12 CONTROL CABLE HEAT and or DEMIST Models All Removal 1 Remove instrument facia closing panel see Fig 3 5 2 From behind instrument carrier disconnect heat and or demist control cable s from control lever s see View B Fig 3 7 3 Remove instrument panel compartment refer page 3 5 4 Disconnect heat and or demist control cable s Installation Reverse removal operations WINDSHIELD GARNISH MOULDING Models All Removal 1 Remove screws securing windshield garnish moulding to inside of windshield aperture pillar see Fig 3 4 Installation from control lever s on top of heat distribution duct assembly see Fig 3 7 Reverse removal operation WINDSHIELD WIPER MOTOR LINKAGE and WASHER ASSEMBLY Description The electrically operated windshield wiper assembly illustrated Fig 3 8 con sists of a two speed wiper motor attached to links and pivot assemblies that op erate wiper blades in a parallel wipe action An actuating link attached to the drive sid
63. G ANCHOR REAR PLATE ASSY SEALING WASHER 2 amp NUT ASSY SECTION Q Q SECTION P P CLIP END GATE MOULDING MOULDING END GATE BELT MOULDING REAR QUARTER SIDE LOWER REVEAL 7 MOULDING SECTION R R CLIP REAR QUARTER SIDE UPPER REVEAL MOULDING MOULDING REAR QUARTER SIDE UPPER REVEAL SECTION U U CLIP ROCKER PANEL MOULDING MOULDING REAR WHEEL OPENING MOULDING ROCKER PANEL SECTION X X DENOTES APPLICATION OF SEALING COMP OUND AROUND MOULDING SCREW ATTACHING HOLES e MOULDING REAR COMP ARTMENT LID END GATE E gt CLIP REAR 4 QUARTER SIDE CLIP END GATE LOWER REVEAL y MOUL DING MOULDING sECTION S S SECTION T T CLIP REAR COMP ARTMENT LID MOULDING MOULDING FRONT WHEEL OPENING SECTION V V MPR SECTION W W SEALING WASHER amp NUT ASSY TUBULAR LOCK TYPE CLIP NAMEPLATE amp EMBLEM ATTACHMENTS MOULDING FRONT WHEEL OPENING MOULDING ROCKER PANEL SECTION Y Y SECTION 7 1 FIG 12 2 BODY EXTERIOR MOULDING INSTALLATION EXTERIOR ORNAMENTATION 12 4 13 O l O Q GO N 8 108 8 Qu eks E 25 14 215 46 47 48 i 49 20 422423 MOULDING WINDSHIELD SIDE REVEAL R H MOULDING WINDSHIELD L
64. G WINDSHIELD Models All Removal 1 Locate moulding removal tool No 1A6 between moulding and glass until point of tool engages with one of the retaining clips then using the tool in a rocking motion see Fig 12 7 pro gressively disengage moulding from clips see Section Fig 12 1 Installation Ensure that moulding retaining flanges and attaching clips are not damaged prior to installing moulding onto clips SIDE REVEAL MOULDINGS WiNDSHIELD Models All Removal 1 With door open remove screws securing side reveal mouldings to front body pillar see Section F F Fig 12 1 On coupes it is ne cessary to remove the upper weatherstrip and retainer see Section G G Fig 12 1 2 Lift off moulding Installation Reverse removal operations LOWER REVEAL MOULDING WINDSHIELD Models All Removal 1 Remove windshield wiper rods refer Page 3 1 2 Remove screws securing ends of moulding to front body pillar 3 Locate moulding removal tool No 1A6 between moulding and glass until point of tool engages with one of the retaining clips then using the tool in a rocking motion see Fig 12 7 pro gressively disengage moulding from clips see Section B B Fig 12 1 Installation 1 Ensure that moulding retaining flanges and retaining clips are not damaged prior to in stalling moulding onto clips FIG 12 8 ROOF SIDE REVEAL MOULDING REMOVAL ROOF DRIP GUTTER R
65. HEADLINING TO BODY WITH COAT HOOK CEMENT 7425230 AT AREAS SHOWN VIEW E THUS Fig 10 3 HEADLINING INSTALLATION MODELS COUPE FRONT HEADLINING RETAINER WINDSHIELD FINISHING LACE HEADLINING TO BE TURNED UNDER VIEW B BEND TABS TO RETAIN LISTING WIRES LISTING POCKET VIEW VIEW D ASSIST STRAP RETAINING SCREW BODY PILLAR GARNISH PANEL ASSIST STRAP 1 32 VIEW J 81400 ONLY PAD CENTRE PILLAR CENTRE PILLAR TRIM ATTACH WITH CEMENT SECTION D D 81400 ONLY SECTION 0 0 815 600 ONLY ATTACH HEADLINING TO BODY WITH CEMENT 7425230D AT AREAS SHOWN THUS ATTACH HEADLINING TO FRONT amp REAR RETAINERS AS SHOWN AND TO OUTSIDE OF DOOR OPENING FLANGES SECTION A A WITH CEMENT FOR ENTIRE LENGTH OF HEADLINING HEADLINING TO BE TURNED UNDER SECTION B B FRONT DOOR APERTURE FINISHING LACE TRIM CENTRE PILLAR ATTACH TO CENTRE WITH CEMENT APPLIED TO TRIM OVER ENTIRE SURFAC OF CONTACT BACK WINDOW FINISHING LACE VIEW F COAT HOOK CEMENT HEADLINING SEAT BELT OVER THIS AREA ONLY STOWAGE HOOK SECTION VIEW K fons PLAIN OR BLACK REAR DOOR APERTURE FINISHING LACE HEADLINING TRIM QUARTER SIDE LOWER ATTACH TRIM TO BODY WITH CEMENT APPLIED TO METAL AND TRIM OVER ENTIRE CONTACT AREA HEADLINING TO BE TURNED UNDER Fig 10 4 HEADLINING MODEL IN
66. I Removal 1 On R amp LH control remove screws securing finger grip control bracket to instrument carrier see View A Fig 3 2 2 From under instrument panel slacken off screw attaching control cable casing clip to side of plenum chamber air duct see View B Fig FRONT END 3 8 NAMEPLATE INSTRUMENT 77 CARRIER SURROUND 7 FACIA 7 BUMPER INSTRUMENT CARRIER SECTION NUT NAMEPLATE INSTRUMENT VIEW A INSTRUMENT FACIA ASSY LIGHT SWITCH CONTROL KNOB 4 ENGINE HOOD CONTROL CABLE SPEED NUT PANEL INSTRUMENT FACIA CLOSING COVER FUSE PANEL FIG 3 5 INSTRUMENT FACIA 8 CLOSING PANEL INSTALLATION 3 Disengage end of cable attached to plenum chamber air duct see View B Fig 3 2 and on LH control cable ease back clinch over tabs securing centre of cable to base of plenum chamber prior to removing control cable ass embly Installation Reverse removal operations CLOSING PANEL INSTRUMENT FACIA Models All Removal 1 Remove screws securing closing panel to base of instrument panel instrument carrier and engine hood control cable bracket see Fig 3 5 Installation Reverse removal operations NAMEPLATE INSTRUMENT FACIA Models Premier Monaro Luxury Sports amp Statesman Removal 1 Remove instrument facia panel refer Page 3
67. K RETURN SPRING BACK PLATE SU REMOTE LEVER ACTUATING LEVER SPRING ACTUATING LEVER FIG 7 7 REAR DOOR LOCK DOORS 7 1 4 Disengage lock cylinder pawl from lock con REMOTE CONTROL DOOR LOCK necting rod and remove cylinder assembly from door outer panel Models All Removal Installation Install and check operation of door lock cylinder pror to reversing removal operations Disassembly Front Door Lock Cylinder l With lock cylinder assembly removed from door prise off clip securing pawl to lock cylinder see Fig 7 8 2 Remove lock cylinder housing scalp by prising folded over edge of scalp from lock cylinder assembly then removing lock cylinder from housing CAUTION When removing scalp hold down spring loaded cylinder cap Reassembly 1 With door open and window raised remove snib rod knob Remove armrest where fitted and disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel water deflector refer Page 7 1 Remove screws securing remote control to inner panel see Figs 7 1 7 2 or 7 33 and from inside door disengage control from remote control rod then remove control through aperture in door inner panel Installation Install and check operation of remote control prio to adequately sealing remote control to door innei panel attaching screw
68. Limit Arm End Gate 15 Torque Rod End Gate Hinge Assembly RH End Gate 16 Retainer End Gate Glass Run Channel Retainer RH End Gate Torque Rod 17 Regulator End Gate Window Bumper End Gate Glass Stop 18 Hinge Assembly LH End Gate Bumper End Gate Limit Arm Stop 19 Retainer LH End Gate Torque Rod FIG 6 1 END GATE HARDWARE INSTALLATION 2 LEGEND Escutcheon End Gate Switch Lock Cylinder Case amp Switch Assembly Gasket End Gate Switch Escutcheon Cover Plate Window Regulator Motor Cam End Gate Window Lifter Channel Handle Remote Control Connector Window Regulator Control Switch Lifter Channel End Gate Window Remote Control End Gate Harness Window Regulator Safety Switch Safety Switch End Gate Retainer End Gate Glass Run Channel Rod End Gate Remote Control Insulator End Gate Remote Control Rod Lock End Gate FIG 23 Limit Arm gt Seal Window Regulator Hamess to Body Hamess Electric Window Regulator Seal Window Regulator Hamess to End Gate Bumper End Gate Limit Arm Stop Motor Electric Window Regulator Torque Rod End Gate Regulator End Gate Window Bumper End Gate Glass Stop Hinge Assembly End Gate Retainer End Gate Torque Rod END GATE HARDWARE INSTALLATION MODELS OPTICNAL ON KINGSWOOD 8 PREMIER STATION SEDAN END GATE 6 4 REGULATOR ASSEMBLY E
69. N one SUBJECT z FRONT END 3 1 SECTION 3 INDEX Subject Page Ventilation Description SETA or nnde C T 3 2 Air Duet Assemb Plenum 3 7 Upper Level Air Outlet Instrument Panel 3 4 Grilles Shroud MEM s 3 5 Hood thm oe Y Compartment amp Door Instrument Panel 3 5 Lock Cylinder amp Housing Instrument Panel Compartment Door 3 6 Lock Striker Instrument Panel Compartment Door 3 6 Panel ato 2 0 2200 3 6 rena 60 0 cot 3 6 Page lansirana 3 7 Control Cable Body Vomit UU Uu ae e 3 7 Clasing Penal 3 9 Nameplate Instrument Facia 1 3 9 Heater amp Distribution Duct Assembly 2 3 9 Motor amp Impellor Assembly Heater 3 9 Control Cable Heat andion 3 12 Garnish Moulding Windshield P Sens A 3 12 Windshield Wiper Motor Linkage amp Assy Description 3 Motor 8 Pump Assembly Windshield Wiper amp Washer 3 12 Pivot amp Link Assemblies Windshield Wiper 3 15 Blade Assembly Windshield Wiper csse 3 15 Rod Assembly Windshield Wiper JANE m 3 15 Switch Assembly
70. ND GATE WINDOW MANUAL OR ELECTRIC Models Station Sedan Removal 1 Open end gate and remove wear strips and inner trim panel refer page 6 7 2 Raise and support end gate window 3 On electrically operated window regulators disconnect regulator motor hamess 4 Remove bolts securing window regulator to end gate see Fig 6 1 or 6 2 5 Disengage regulator arm rollers from lifter cams and remove regulator assembly through aperture in end gate inner panel CAUTION Do not operate regulator motor after regulator is removed from end gate Operation of the motor with load r moved may damage unit Installation Clean and lubricate regulator sector teeth with zinc oxide grease or light oil prior to reversing removal operations MOTOR ELECTRICALL Y OPERATED WINDOW REGULATOR Models Optional on Kingswood amp Premier Station Sedans Removal 1 Open end gate and remove wear strips and inner trim panel refer page 6 7 2 Raise and support end gate window 3 Disconnect regulator motor harness 4 Remove screws securing motor to window reg ulator and remove motor see Fig 6 2 Installation Clean and lubricate regulator motor gear teeth spar ingly with zinc oxide grease or light oil prior to reversing removal operations CAUTION The following operation MUST be per formed if the motor is disengaged from the regulator in any but the fully raised position The regulator
71. NED UNDER ATTACH HEADLINING TO BODY WITH VIEW G CEMENT 7425230 AT AREAS SHOWN THUS Fig 10 8 HEADLINING INSTALLATION MODEL STATION SEDAN ROOF 10 10 VINYL ROOF COVER Models Luxury Sports Coupe Statesman De Ville and option on all other Sedans and Coupes except Belmont Removal 1 23 Protect painted surfaces by masking over all doors rear end of engine hood and front fenders back panel upper and front end of rear quarter panels Remove windshield and back window reveal moulding and retaining clips refer page 12 1 Remove roof side reveal and rear quarter upper mouldings and retaining clips Remove roof panel cover retainers see Section C C Figs 10 9 and 10 10 by inserting tip of thin wide bladed screwdriver under inside against cover end of cover retainet and care fully easing retainer upwards disengaging it from drip gutter NOTE Application of heat to cover will soften adhesive and assist removal of cover CAUTION Heat may be applied by lamps held no 5 closer then 18 from cover until cover is warm Lamps held too close or cover heated over 200 can cause the cover to lose its grain blister or become objectionally shiny Loosen cemented edges of roof cover at wind shield drip gutter back window and rear quarter area then carefully ease cover from remaining cemented areas of roof panel Remove or smooth down any ex
72. NG BRACKET TO FRAME e FRONT BUMPER BAR NUT BUMPER BAR TO OUTER MOUNTING SPRING WASHER EXTENSION FLAT WASHER EXTENSION OUTER BUMPER BAR MOUNTING BOLT BUMPER BAR TO OUTER MOUNTING BRACKET OUTER BRACKET BUMPER BAR MOUNTING Fig 14 1 FRONT BUMPER BAR ASSEMBLY BUMPER BARS 14 2 FRONT BUMPER BAR outer mounting brackets to partial perimeter front end frame see Fig 14 1 and place Models All assembly on a clean protected surface Removal 2 Remove inner and outer mounting brackets from front bumper 1 With an assistant to support front bumper bar Installation assembly remove bolts securing inner and Reverse removal operations BOLT BACK PANEL LOWER TO MOUNTING BRACKET APPLY NON HARDENING SEALER TO AREAS MARKED THUS ERES TO EFFECT A WATER TIGHT SEAL NUT REAR BUMPER BAR TO MOUNTING BRACKET SPRING WASHER FLAT WASHER C I I gt if REAR BUMPER BAR lt MOUNTING BRACKET Af 2 5 22 i p x LR Z Se on SPACER BUMPER BAR MOUNTING BOLT MOUNTING BRACKET TO BACK PANEL LOWER CREE 2 MODELS STATION SEDAN Fig 14 2 REAR BUMPER BAR ASSEMBLY MODELS STATION SEDAN REAR BUMPER BAR 14 3 REAR BUMPER BAR 14 4 and place assembly on a clean protected surface Models 3 Remove bumper bar mounting brackets rear Removal licence plate lamp assemblies and on all coupes and sed
73. OLLER RUBBER 11 WASHER QUARTER WINDOW GUIDE LOWER ROLLER METAL 12 ROLLER ASSY QUARTER WINDOW GUIDE LOWER Disassembly 1 With quarter window assembly positioned face down on a clean protected surface disengage tension spring from front roller see Fig 4 2 Turn window over and using Tool No 1A8 see Fig 4 3 remove roller tee nuts and plastic bushings fron bolts Lift glass and weatherstrip assembly off sash plate and roller assemblies and remove sash plate filler Slide out weatherstrip from retainer on leading edge of glass Holding glass face down on an insulated sur face tap weatherstrip retainer off glass sliding a hammer across glass WARNING Ensure that hammer head is smooth 6 and free from burrs which can dam age glass Remove and discard old filler strip from inside of weather retainer Assembly Ik Apply a film of liquid soap to rear inner surface of weatherstrip retainer Position glass on its rear edge and place a new filler strip evenly over leading edge of quarter window glass Locate glass channel of weatherstrip retainer over filler strip with end of retainer in line with top corner of leading edge of glass Using a steel strip 6 x 1 x 1 8 positioned in weatherstrip channel of retainer carefully tap retainer onto glass Apply a film of liquid soap to weatherstrip channel of retainer prior to sliding weatherstrip into
74. OWER REVEAL R amp LH MOULDING WINDSHIELD UPPER REVEAL R amp LH MOULDING WINDSHIELD SIDE REVEAL L H PLATE MODEL NAME ACCORDING TO MODEL MOULDING ROOF SIDE REVEAL 803 804 811 81269 ONLY GUTTER ROOF DRIP REAR MOULDING REAR QUARTER UPPER WITH TWO TONE PAINT amp VINYL ROOF MOULDING REAR WINDOW REVEAL L H MOULDING REAR WINDOW REVEAL UPPER MOULDING REAR WINDOW REVEAL R H PLATE TRIMATIC NAME WITH TRIMATIC TRANSMISSION ONLY MOULDING FRONT WHEEL OPENING 803 804 811 81269 ONLY MOULDING FRONT DOOR BEL T 803 804 811 81269 ONLY MOULDING ROCKER PANEL 803 80469 ONLY MOULDING REAR DOOR BELT 803 804 811 81269 ONLY MOULDING ROCKER PANEL 811 81269 ONLY MOULDING REAR WHEEL OPENING 803 804 811 81269 ONL Y MOULDING REAR END 811 81269 ONLY PLATE ENGINE IDENTIFICATION ACCORDING TO ENGINE FITTED MOULDING REAR COMPARTMENT LID 811 81269 ONLY PLATE MODEL NAME ACCORDING TO MODEL MOULDING REAR END 811 81269 ONLY EMBLEM RADIATOR GRILLE ALL EXCEPT 81400 500 600 808 81837 G T S EMBLEM RADIATOR GRILLE 808 81837 ONLY FIG 12 3 BODY EXTERIOR ORNAMENTATION IDENTIFICATION MODELS SEDAN EXCEPT STATESMAN EXTERIOR ORNAMENTATION 12 5 12 m m 21 22 24 25 44 45 46 Iq lig MOULDING WINDSHIELD SIDE REVEAL R H MO
75. P UPPER 24 L H 81400 ONL Y 25 MOULDING REAR DOOR SCALP FRONT L H 26 81400 ONL Y MOULDING REAR DOOR SCALP UPPER L H 27 81400 ONLY 28 MOULDING ROOF SIDE REVEAL GUTTER ROOF DRIP REAR EMBLEM 81400 ONLY 29 MOULDING REAR WINDOW REVEAL L H 30 MOULDING REAR WINDOW REVEAL UPPER 31 MOULDING REAR WINDOW REVEAL LOWER 32 MOULDING REAR WINDOW REVEAL R H P N R 25 26 27 28 29 33 FIG 12 6 BODY EXTERIOR ORNAMENTATION IDENTIFICATION MODELS STATESMAN gt gt Pe a w 40 41 J 42 433 NAMEPLATE TRIMATIC 815 600 WITH 40 ONL Y NAMEPLATE STATESMAN NAMEPLATE DEVILLE 81400 ONLY MOULDING FRONT WHEEL OPENING MOULDING FRONT DOOR BELT MOULDING FRONT DOOR SCALP REAR L H 81400 ONLY MOULDING ROCKER PANEL 815 600 ONLY MOULDING REAR DOOR BELT MOULDING REAR DOOR SCALP REAR 81400 ONL Y MOULDING ROCKER PANEL 81400 ONLY MOULDING REAR QUARTER UPPER 81400 815 600 WITH C27 CO8 amp CBI ONLY MOULDING REAR WHEEL OPENING MOULDING TAIL LAMP REVEAL PLATE ENGINE IDENTIFICATION EMBLEM 81400 ONLY NAMEPLATE DE VILLE 81400 ONLY EXTERIOR ORNAMENTATION 12 8 KEEP THIS SURFACE OF TOOL FLAT ON GLASS AA 4 TOOL NO Z ROCK TOOL SLIGHTLY FIG 12 7 WINDSHIELD REVEAL MOULDING REMOVAL UPPER REVEAL MOULDIN
76. R Models Station Sedan Removal l Open end gate and remove screws securing wear strips and trim panel to end gate inner panel Installation l Ensure that inner trim panel to end gate inner panel seal is seating correctly and apply caulk ing compound around screw attaching holes prior to reversing removal operations END GATE 6 8 HANDLE WINDOW REGULATOR Models Station Sedan Removal l Open gate and remove wear strips and inner trim panel refer preceeding instructions 2 Raise and support end gate window 3 From inside end gate remove nuts securing outside handle assembly to outer panel then remove assembly see Fig 6 1 or 6 2 Installation 1 Ensure that handle assembly gasket effectively seals handle aperture in outer panel 2 Check operation of regulator handle prior to replacing inner trim panel Disassembly ul 1 Remove clutch retaining spring and slide clutch D off shaft of handle driver see Fig 6 6 n 2 Using a snap ring removal tool remove handle retaining spring and spring washer from shaft of handle driver and remove handle assembly from escutcheon 3 Remove screws securing handle driver hinge pin to handle and knob assembly ESCUTCHEON HANDLE RETAINING SPRING 178 220 CLUTCH HANDLE SPRING CLUTCH RETAINING Q HANDLE Pa Assembly Clean and lubricate frictional surfaces of handle
77. R gt PLUNGER ASM ZAM SPRING PLUNGER ASM LUBRICATE FRICTIONAL SURFACES mw ZINC OXIDE GREASE OR LIGHT OIL REAR SEAT BACK SCREW LOCK HANDLE ASM TO REAR SEAT 4 PANEL REAR SEAT BACK T FLAT WASHER 144 SECTION A A REAR SEAT BACK LOCK AND HANDLE ASSEMBLY LOCK WASHER WASHER WASHER SPACER CENTRE BELT LOCK WASHER SEAL WITH CAULKIN COMPOUND SECTION LOCK d BOLT I WASHER lt BELT ADJUSTME section B B ad section D D SEAT BELT ASSEMBLY Fig 8 9 FRONT BENCH SEAT BELT INSTALLATION MODELS ALL EXCEPT COUPE SEATS 8 12 BOLT WASHER PRING WASHER SECTION A A BELT ADJUSTMENT Ses 2 y 3 BOLT 2 VEN j LOCK WASHER gt AA BELT 9 4 SEAL WITH CAULKING SN KJ COMPOUND 2 SECTION C BOLT LOCK WASHER SPRING WASHER section Fig 8 10 FRONT SEAT BELT INSTALLATION MODELS COUPE SEATS 8 13 LAP amp SHOULDER SEAT BELT ASSY WASHER 1 Fe SEAT BACK 1 SEAL WITH CAULKING COMPOUND CENTRE LAP BELT ASSY SECTION A A SEAT BACK REAR PARCEL SHELF TRIM CUSHION BOLT WASHER SEAL WITH CAULKING COMPOUND BOLT SPACER SECTION C C SECTION B B FIG 8 11 REAR SEAT BELT INSTALLATION MODELS COUPE 8
78. RVIOR SCREWS LUCAS HOSE CONNECTIONS RES ERVOIR TO FENDER view HOSE PUMP TO RESERVOIR FIG 3 9 WINDSHIELD WASHER ASSEMBLY INSTALLATION PIVOT amp LINK ASSEMBLIES WINDSHIELD WIPER Models All Removal 1 Remove rodand blade assembly refer this page 2 Remove shroud ventilator grille 3 From within plenum chamber remove screws secuting LH pivot and link assembly to shroud panel see View B Fig 3 8 4 Remove clip securing wiper linkage to wind shield wiper motor crank see View C Fig 3 8 then disengage inner end of linkage 5 For removal of RH pivot and link assembly remove RH plenum chamber air outlet see Fig 3 2 6 From within RH side of plenum chamber via air outlet aperture remove screws securing pivot and link assembly to shroud panel see View A Fig 3 8 Installation Reverse removal operations BLADE ASSEMBLY WINDSHIELD WIPER Models All Removal 1 Insert tip of narrow bladed screwdriver in slot View Fig 3 8 and lever wiper blade assembly retaining spring downwards to clear groove in retaining pin allowing removal of blade assembly from rod Installation 1 Firmly press blade assembly over retaining pin until blade retaining spring correctly engages in retaining pin groove FRONT END 3 15 ROD ASSEMBLY WINDSHIELD WIPER Models All Removal 1 Remove blade assembly refer preceding in structions
79. Reverse removal operations DOORS 7 22 GLASS RUN CHANNEL REAR DOOR DIVISION Models Sedan and Station Sedan Removal 12 27 With door open and window lowered remove snib rod knob Remove armrest where fitted disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel upper water deflector refer Page 7 1 Loosen off bolts securing top of front guide window cam to door inner panel see Fig 7 3 Holding top of window ease window forward to relieve pressure from glass run channel Ease out re r end of reardoor glass run channel Ease door division glass run channel out of division channel and out through window ap erture Installation mah Holding top of window ease window forward allowing channel to be fed down into door division channel Raising and lowering window and working inside door locate lower end of run channel into lower end of door division channel NOTES AND BULLETIN REFERENCES BULLETIN PAGE NO NO DATE 3 install upper end of glass run channel into division channel prior to reversing removal operation WATER DEFLECTOR DOOR INNER PANEL Models All Removal 1 With door open remove snib rod knob 2 Remove armrest where fitted disconnect electrically operated window regulator switch where fitted remove door interior handles and inner tr
80. STALLATION STATESMAN ROOF 10 8 Station Sedan for station sedan body are basically the same as those specified for the passenger sedan except for the additional operation of removing the side quarter windows and the use of special tools associated with the saw tooth attachment of headlining to rear roof header bar see View H Fig 10 8 I The headlining removal and installation instructions Removal 1 Remove rear side quarter windows refer page 9 1 15 LEAD ae Pese MATERIAL f DIA SPRING STEEL SECTION A A R H de ks HARDEN AND TEMPER END Fig 10 6 HEADLINING RETAINER STRAIGHTENING TOOL 2 Using a putty knife or special tool see F ig 10 5 fabricated from 16 gauge sheetmetal ease the headlining retainer out from the roof rail by inserting the tool between rail and retainer as shown the special tool fabricated to conform with details as shown in Fig 10 6 For location and method for operating setting tool see Fig 10 7 3 Using the same tool similarly inserted lift 1 Usi tty knif ial tool illus the headlining from the teeth of the retainer RPM s o Installation NOTE Prior to the installation of the headlining examine the condition of the saw tooth retainer for damage or off set teeth Teeth that require straightening can be set using TOOL DETAIL l d w MATERIAL I6GA M S PLATE REMOVE SHARP EDGES
81. ULDING WINDSHIELD LOWER REVEAL RA LH MOULDING WINDSHIELD UPPER REVEAL R amp LH MOULDING WINDSHIELD SIDE REVEAL L H MOULDING ROOF SIDE REVEAL FRONT L H 803 804 811 81235 ONL Y MOULDING QUARTER FRONT L H 803 804 811 81235 ONLY MOULDING ROOF SIDE REVEAL REAR L H 803 804 811 81235 ONLY MOULDING QUARTER SIDE UPPER REVEAL L H MOULDING ASSY END GATE GLASS OPEN PLATE TRIMATIC NAME WITH TRIMATIC TRANSMISSION ONLY PLATE MODEL NAME ACCORDING TO MODEL PLATE MODEL NAME ACCORDING TO MODEL MOULDING FRONT WHEEL OPENING L H 803 804 811 81235 ONL Y MOUL DING FRONT DOOR BELT L H 803 804 811 81235 ONLY MOULDING ROCKER PANEL L H 803 80435 ONLY MOULDING REAR DOOR BELT L H 803 804 811 81235 ONLY MOULDING ROCKER PANELL H 811 81235 ONLY MOULDING REAR WHEEL OPENING L H 803 804 811 81235 ONL Y MOULDING QUARTER SIDE LOWER REVEAL L H MOUL DING QUARTER L H WITH D99 ONL Y PLATE ENGINE IDENTIFICATION ACCORDING TO ENGINE FITTED MOULDING ASSY END GATE BELT MOULD END GATE MOULD END GATE LOWER EMBLEM RADIATOR GRILLE ALL EXCEPT 81400 500 600 808 81837 FIG 12 4 BODY EXTERIOR ORNAMENTATION IDENTIFICATION MODELS STATION SEDAN EXTERIOR ORNAMENTATION 12 6 m m 11 12 13 14 15 16 17 18 19 20 1 NAMEPLATE MONARO 803 80437 ONLY 2 NAMEPLATE MONARO LS 811 81
82. USTING STUD UPPER WINDOW UP TRAVEL STOP INTERIOR HANDLE BEARING PLATE DOOR ARMREST MODELS 808 811 812 818 WINDOW GUIDE WINDOW DOWN TRAVEL STOP 16 SECTION SECTION B B FIG 4 1 REAR QUARTER HARDWARE INSTALLATION MODEL COUPE Ds 10 11 12 13 14 15 16 DOOR INTERIOR HANDLE WINDOW GUIDE ADJUSTING BRACKET LOWER ELECTRIC WINDOW REGULATOR MOTOR OPTION REAR QUARTER TRIM PANEL WINDOW GUIDE IN amp OUT ADJUSTMENT LOWER ELECTRIC WINDOW REGULATOR SWITCH SEAL OPTION ELECTRIC WINDOW REGULATOR SWITCH OPTION WINDOW GUIDE FORWARD amp REARWARD ADJUSTMENT LOWER REAR QUARTER WINDOW REGULATOR Models Coupe Removal 1 On GTS and Luxury sports and coupes remove rear quarter armrest and on all coupes rear quarter window regulator handle refer page 4 5 Remove rear seat cushion and seat back refer page 8 1 Remove rear quarter inner trim panel refer page 4 5 Remove screw attached quarter inner cover panel On models exercising the optional electrically operated window regulator disconnect electric harness at motor With quarter window supported in the raised position remove screws securing window ulator to quarter inner panel see Fig 4 1 Disengage window assembly roller from reg ulator arm cam and remove regulator assembly out through quarter inner panel aperture Installation
83. Y BOLT BUMPER BAR TO OUTER MOUNTING BRACKET OUTER BRACKET BUMPER BAR MOUNTING Fig 14 4 REAR BUMPER BAR ASSEMBLY MODELS STATESMAN SECTION 15 TOOL No 1A4 TOOL No 1A3 TOOL 1A3 TOOL 1A4 WEATHERSTRIP CLIP REFORMING TOOL WEATHERSTRIP CLIP INSERTING TOOL TOOL No A6 TOOL No lA7 TOOL 1A6 WINDSHIELD BACK WINDOW AND REAR QUARTER SIDE MOULDING REMOVAL TOOL ROLLER TEE NUT 72 LBS TOOL 147 ROOF SIDE MOULDING REMOVAL TOOL TOOL NO 148 TORQUE WRENCH TOOL 1A8 ROLLER TEE NUT INSTALLING TOOL TOOL NO 21812X DOOR INTERIOR HANDLE REMOVAL TOOL SUBJECT NOTES AND BULLETIN REFERENCES z BULLETIN DATE 1 w 7 O O J lt U 9 3 3 ALPHABETICAL INDEX 16 1 SECTION 16 ALPHABETICAL INDEX SUBJECT PAGE Air Duet Assem bln SZ ma Alphabetical tonite ater OR ERU sie NANI E TEC Armie AAAS oxen EE ES T ae es nic M 138 Armrest Rear ES 22 Basic Body ao co eee oe sa 1 4 Bellum esters 7 21 Belt Weatherstrip Door Outer mai MA SOA 7 20 Belt Weatherstrip Front amp Rear Deen Ouest du oue 7 20 Blade Assembly Windshield Wiper setne Bs v 3 15 Body Cements Sealers amp Adhesive e Compounds gi E
84. ad approx imately 3 in diameter and 2 thick c Powdered Ceric Oxide mixed with water as an abrasive compound d A wide mouth container to hold the compound Glass Scratch and Abrasion Removal Procedure 1 Place a sufficient amount of powdered Ceric Oxide in the bottom of the container and mix in sufficient water to obtain a creamy consist ency NOTE If the compound is too thick it cakes on the felt pad too quickly and if too thin the operation time is extended 2 Place a protective cover over paintwork ad jacent to area where the operation is to be carried out 3 Agitate the compound occasionally to maintain a creamy consistency Powdered Ceric Oxide is insoluble in water and tends to separate 4 Draw a circle around the scratches or abrasions on the inside of the glass using a marking crayon Also draw lines directly behind scratches or abrations to assist in locating the rotary polisher as illustrated in Fig 1 6 E GENERAL INFORMATION 1 17 5 Dip the pad into the mixture at 15 second inter vals to ensure that the pad and glass are always wet during the operation dry pad causes excessive heat to develop NOTE Never fully submerge or allow pad to remain in compound as this may loosen the bond between pad and metal plate 6 Using a moderate but steady pressure hold the pad flat against the scratched area of the glass and using a feathering out motion to prevent the po
85. ans except Statesman rear 1 On all coupes and sedans except Statesman lamp assemblies models disconnect rear lamp wiring hamess 2 On all models and with an assistant to support Installation bumper bar assembly remove bolts Apply non hardening sealer around mounting securing bumper bar mounting bracket to body bracket to body attaching holes prior to re back panel lower see Figs 14 2 14 3 or versing removal operations APPLY NON HARDENING SEALER TO AREAS MARKED THUS Ko EFFECT WATER TIGHT SEAL BOLT BACK PANEL LOWER TO 2 MOUNTING BRACKET 222 A A Ny A STAR SPRING WASHER NUT BUMPER BAR TO MOUNTING BRACKET SPRING WASHER FLAT WASHER STAR SPRING WASHER N BRACKET BUMPER BAR MOUNTING FEED CONNECTOR BODY OF REAR LAMP HARNESS THROUGH HOLE AND INSTALL GROMMET BOLT BUMPER BAR TO MOUNTING BRACKET REAR BUMPER BAR Fig 14 3 REAR BUMPER BAR ASSEMBLY MODELS ALL EXCEPT STATION SEDAN 8 STATESMAN BUMPER BARS 14 4 BEND TABS AS SHOWN 16 PLACES BOLT INNER MOUNTING BRACKET TO BACK PANEL LOWER APPLY NON HARDENING SEALER TO AREAS MARKED THUS TO EFFECT A WATER TIGHT SEAL 4 NUT BUMPER BAR TO INNER BRACKET m X ine SPRING WASHER FLAT WASHER INNER BRACKET BUMPER CA BAR MOUNTING BOLT BUMPER BAR TO INNER MOUNTING BRACKET REAR BUMPER BAR TRIM PANEL REAR BUMPER BAR STATESMAN DE VILLE ONL
86. are steel stampings which include door check and hold open devices on the front door upper hinge and the rear door lower hinge Double arm window regulators operate door sliding windows in guides and cams attached to door inner panels bar type outside door handles and lever type remote control handles operate fork type door locks in conjunction with a free wheeling door lock bolt striker Door snib rods control the locking of door locks from inside the vehicle A Square headed key operates the five bitting depth lock cylinders installed on front doors The door weatherstrip incorporates wire clips which retain the weatherstrip in holes located around the side of the door inner panel DOORS 7 2 SECTION D D SIDE ONLY WITH A31 EU FIG 7 1 FRONT DOOR HARDWARE INSTALLATION MODELS ALL except COUPE 811 225 23 Soo O A FRONT DOOR HARDWARE Models All except Coupe Adjusting Stud Front Guide Window Cam Knob Door Lock Snib Rod Adjusting Bolt Sliding Glass Cam Assembly Lifter Channel Front Door Glass Glass Run Channel amp Retainer Assembly Rear Connecting Rod Front Door Lock to Outside Handle Assembly Retainer Door Lock Cylinder Cylinder Door Lock Lock Front Door Cam Glass Lifter Armrest Front Door Models All except Belmont Regulator Front Door Window Re
87. ary locking wites attached to the remote control activate locking bars on the seat adjusters The correct tension required to operate the bench seat adjuster mechanism is provided by the LH auxiliary locking wire passing through a bracket attached to one of a series of adjustment holes in the seat cushion frame see Fig 8 3 SEAT ADJUSTER ASSEMBLY RH BOLT ASSEMBLY ADJUSTER TO SPRING amp FRAME ATTACHING SCREWS LEVER SUPPORT LEVER SEAT ADJUSTER CONTROL SUPPORT SEAT ADJUSTER LEVER SPRING SEAT ADJUSTER REMER SPRING amp FRAME ASSEMBL Y WIRE TENSIONER BRACKET WIRE ASSY ADJUSTER AUXILIARY LOCKING LH N WIRE ASSY ADJUSTER AUXILIARY LOCKING 1101 BOLT ASSY ADJUSTER FRAME ASSY SPRING RELEASE LEVER i SEAT ADJUSTER ASSY LH ASSIST SPRING SEAT ADJUSTER LH WASHER REMOTE CONTROL HANDLE WIRE RETAINING SPRING BOLT FRONT SEAT REMOTE CONTROL HANDLE SPRING RELEASE LEVER ASSIST SPRING SEAT ADJUSTER LH WASHER REMOTE CONTROL HANDLE SECTION Fig 8 3 FRONT BENCH SEAT ADJUSTER ASSEMBLY SEATS 8 5 FRONT SEAT ADJUSTER adjuster to be removed slide spring retainer over end and disengage wire from adjuster see Models All View A Fig 8 3 Removal 3 Remove adjuster assembly to seat frame attach 1 Remove front seat refer page 8 2 and place ing bolts and temove assembly face down on a clea
88. ashtray assembly 4 Remove screws securing rear end of console and transmission cover facia to console 5 On vehicles fitted with automatic transmission disconnect transmission indicator illuminative harness then remove facia 6 Remove screws securing front end of console to transmission tunnel then remove console Installation Apply caulking compound around console to trans mission tunnel attaching holes prior to reversing removal operations TONNEAU FLOOR _ FRONT Models Station Sedan Removal 1 Lower rear seat squab 2 Remove spare wheel cover 3 Remove screws securing outer edges of tonneau floor to underbody assembly 4 Lift out front tonneau floor Installation Reverse removal operations DIDI FIG 2 5 TRANSMISSION CONTROL CONSOLE MODEL GTS COUPE COVERING _ TONNEAU FLOOR FRONT or REAR Models Station Sedan exc Belmont Removal 1 Remove tonneau floor refer preceding in structions 2 Remove wear strips 3 Remove staples securing edges of covering to base of tonneau floor 4 Carefully remove covering the edges of which are attached to the tonneau floor with vinyl trim adhesive 2 Remove or smooth down any hardened adhesive from edges of tonneau floor and covering Installation T Apply an even coat of vinyl trim adhesive to ed es of tonneau floor and to inside outer edges of covering Apply covering to tonneau floor ensuring that coverin
89. assembly see Fig 5 1 is operated by torsion rods attached to each hinge These assist as a counter balance when raising the lid and hold lid in the taised position when lid is open Retaining notches are provided at each hinge for torsion rod adjustment see View D Fig 5 1 The lid lock which is operated by the lock cylinder and key releases when the key is turned When the lid is closed the spring loaded lock bolt engages with and locks behind the striker Lid adjustments are provided for at hinge attachments and lock striker REAR COMPARTMENT 5 1 LUBRICATE REAR COMPARTMENT LID LOCK STRIKER WITH ZINC OXIDE GREASE OR LIGHT OIL STRIKER REAR COMPARTMENT LID LOCK View C REAR COMPARTMENT LID LUBRICATE HINGE PINS amp BEARING SURFACES WITH GRAPHITE GREASE GASKET LOCK CYLINDER ASSY TORSION RODS RETAINER TORQUE ROD GASKET LOCK CYLINDER RETAINER RETAINER LOCK CYLINDER ASSY LOCK ASSY view B FIG 5 1 REAR COMPARTMENT LID REAR COMPARTMENT LID Models Sedan amp Coupe Removal 1 Raise rear compartment lid and place a pro tective cover over adjacent paint finish surface 2 Pencil scribe location of hinge strap on lid inner panel to facilitate installation 3 With the aid of an assistant to support lid remove hinge to lid attaching bolts see View D Fig 5 1 then remove lid assembly Installation Reverse removal
90. assembly with zinc oxide grease or light oil prior to reversing removal operations LOCK CYLINDER AND CAP ASSEMBLY Models Station Sedan Removal 1 Remove window regulator handle refer pre ceeding instructions 2 Remove clutch retaining spring and slide clutch off shaft of handle driver see Fig 6 6 3 Insert key in lock cylinder and turn key to lock position 4 Depress locking pawl turn key lock cylinder approximately a quarter turn counter clockwise and remove lock cylinder assembly locking pawl and spring from handle driver Installation Clean and lubricate frictional surfaces of clutch escutcheon and handle driver sparingly with zinc oxide grease or light oil prior to reversing removal operations LOCK PAWL AND SPRING 977 HANDLE DRIVER LOCK CYLINDER HANDLE HINGE WASHER HINGE PIN PIN SCREWS HANDLE AND KNOB ASSEMBLY FIG 6 END GATE WINDOW REGULATOR HANDLE ASSEMBLY LOCK CYLINDER CASE AND CAP ASSEMBLY LOCK CYLINDER SWITCH CASE RETAINER RETAINERS SWITCH Cos mx SWITCH SWITCH CAM PIN CAM ESCUTCHEON FIG 6 7 END GATE LOCK CYLINDER and SWITCH ASSEMBLY ELECTRIC SWITCH amp ESCUTCHEON ASSEMBLY Models Optional on Kingswood amp Premier Station Sedans Removal 1 Open end gate and remove wear strips and inner trim panel refer page 6 7 2 Raise and support end gate window NOTE To operate window with end gate open it is nec
91. bly and sliding glass cam attaching bolts and screws then reverse removal operations MOTOR WINDOW REGULATOR Models Option on Premier amp Statesman Removal 1 Remove window regulator assembly refer pre ceeding instructions 2 Measure distance between window regulator sector plate stop and end of cut out in sector plate to facilitate installation 3 Remove bolt securing window regulator motor to window regulator see Figs 7 1 7 2 or 7 3 removing motor Installation 1 Correctly locate and fasten window regulator motor to window regulator using measurement taken prior to removal of motor 2 Adequately lubricate frictional surfaces of motor and window regulator with zinc oxide gtease or light oil and adequately seal window tegulator attaching bolts prior to reversing removal operations NOTE For inspection overhaul and testing of window regulator motor refer Vol 5 HQ Electrical Instruments and Gauges DOORS 7 13 SWITCH DOOR JAMB Front Door Models All except Rear Door Models Premier amp Statesman Removal mu 1 Disconnect battery ground strap 2 Apply masking tape adjacent to jamb switch to protect paint finish 3 Using a thin bladed screwdriver carefully prse switch assembly from pillar 4 Depress plunger and remove switch lead from base of plunger disassembling jamb switch see Fig 7 10 Installation Reverse re
92. can be effected by the inclusion or deletion of these shims ENGINE SKIRT ASSEMBLY FENDER ASSEMBL Y NUT FENDER Ss TO SKIRT i 3D NA 4 ea B 7 gt BOLT SKIRT TO FENDER M 221 FRONT WHEEL section OPENING MOULDING MODELS ALL EXCEPT BELMONT Fig 11 2 FRONT FENDER ILLUSTRATION FRONT FENDER ASSEMBLY 4 From inside body remove bolts securing rear end of fender to cowl upper panel front body Models All pillar and rocker panel see View A Fig 11 1 5 Remove bolts securing front end of fender to tadiator support and front end panels see View D Fig 11 1 es Removal 1 Raise engine hood 2 Remove front bumper bar assembly refer page 6 When removing RH amp ont fender remove shield washer reservoir and disconnect washer i 3 Remove shroud trim inner panel refer page hoses and hood lock release cable attached t zl inside of fender SHEET METAL 11 4 PLATE amp SUPPORT ASSEMBLY HOOD LOCK ENGINE HOOD ASSEMBLY LOCK NUT HOOD PLUNGER BOLT es 23 Z BRACKET ASSEMBLY HOOD LOCK PLUNGER SPRING HOOD LOCK RETAINER HOOD LOCK SPRING PLUNGER BOLT HOOD LOCK SAFETY CATCH ENGINE HOOD LOCK RETAINER HOOD CABLE RELEASE HOOD LOCK CONTROL WIRE TO BE BENT AROUNT ANCHOR Fig 11 3 HOOD LOCK INSTALLATION 7 From inside front wheelhouse rem
93. cement Body Sealing mmn Water Leak Diagnosis and Rectification Body Cements Sealers and Adhesive Compounds Body Lubrication Maintenance Appearance Care and Cleaning of Interior Trim ss Lock Cylinders Keys and Locks Safety Glass A Glass Polishing GENERAL INFORMATION Page 1 1 1 1 1 2 1 3 1 3 1 4 1 4 1 9 1 9 GENERAL INFORMATION 1 3 MANUAL DESCRIPTION Index Page 1 1 contains a Manual Index which lists the section number and subject title of each body section The first page in the major sections has an index to the subjects included in that section An alphabetical index covering the entire manual is located in the back of the manual Page and Figure Numbers All page and figure numbers consist of two sets of digits separated by a dash The digits preceding the dash identify the main body area section The digits following the dash represent the consecutive page number or figure number within the particular body section Text Unless otherwise specified each service procedure covets all body styles Procedures covering specific styles are identified by the model number or style Model names with their corresponding numbers are covered on this page under Model Identification 7 lllustrat
94. ch is se cured to compartment door with an escutcheon see Fig 3 3 nstallation Reverse removal operations CODING OF INSTRUMENT PANEL COMPARTMENT DOOR LOCK CYLINDER l With the key inserted in the uncoded lock cylinder cut or file off both ends of tumblers flush with body of lock cylinder Remove all burrs from tumblers to ensure free movement NOTE The aluminium coloured tumbler nearest the head key entrance is a locking device and must not be removed or filed LOCK STRIKER INSTRUMENT PANEL COMPARTMENT DOOR Models All Removal 1 Remove instrument panel compartment refer page 3 5 2 Remove screws securing lock striker to instru ment panel see Section C C Fig 3 3 and remove striker Installation Reverse removal operations Adjustment Elongated holes in lock striker provide forward and rearward adjustment TRIM PANEL SHROUD LOWER Models Removal 1 Remove front lower half of front door finishing lace which secures rear end of trim panel to shroud lower panel 2 Remove screw securing front lower comer of trim panel to shroud lower panel 3 Position a wide blade screwdriver between trim panel and shroud lower panel prising under fasteners until trim panel is released Installation Reverse removal operations PAD INSTRUMENT PANEL Models All Removal 1 Remove instrument panel compartment refer page 3 5 2 From behind to
95. channel With glass face down position sash plate filler metal washers sash plate and roller assemblies over attaching holes in glass Install plastic bushings and roller tee nuts on reverse side of glass torquing tee nuts to 72 in lbs see Fig 4 3 ROLLER TEE NUT 72 LBS TOOL NO 1A8 TORQUE WRENCH FIG 4 3 ROLLER TEE NUT INSTALLATION GUIDE ASSEMBLY REAR QUARTER WIND W Models Coupe Removal On GTS and Premier coupes remove teat quarter armrest and on all coupes rear quarter window regulator handle refer this Page Remove rear seat cushion and seat back refer Page 8 1 Remove rear quarter inner trim panel refer this Page Remove screw attached quarter inner cover panel Remove bolt securing lower section of guide assembly adjusting bracket to quarter inner panel see Section A A Fig 4 1 Remove lock nuts locking quarter window guide assembly upper adjusting studs to inner panel Tum adjusting studs anti clockwise until they become disengaged from guide assembly Loosen window regulator attaching sctews and slide regulator arm cam off quarter window roller Disengage guide assembly from quarter window rollers and remove assembly out through quarter inner panel aperture Installation Reverse removal operations NOTE Refer to quarter window adjustment page 4 4 for adjustment of guide assembly REAR
96. compartment door and rear compartment lid lock cylinders Key code numbers of the ignition and instrument panel compattment lid locks are stamped on the side of the lock cylinders Key identification code numbers are stamped on the KNOCK OUT section of the keys New fork type door locks with bolt type lock strikers incorporating a free wheel action are also featured on these models GENERAL INFORMATION 1 16 SAFETY GLASS With the exception of the optional laminated safety glass windshield all glass surrounding the vehicles occupants is armour plate safety glass This type of glass when struck by a stone thrown up by a passing vehicle can become opaque in a spider web pattern Toughened safety glass windshields incorporate an additional safety feature in the form of a modified zone This zone covers an oval area approximately 17 5 wide by 7 deep and is located at eye level directly in front of the driver Should the glass shatter larger particles of glass in the modified zone allow adequate vision although vision surrounding the zone can be completely obscure due to smaller particles of glass in the remainder of the wind shield All safety glass in the vehicle is insulated against shock either by adhesive caulking compound rubber retainers or rubber and felt glass run channels NOTE It is possible for the safety glass to be struck by an object thrown up by a passing vehicle without the owner being aware a
97. compound Figs 7 1 7 2 or 7 3 atound bolt and screw attaching holes as location guides when replacing door hard ware 6 Turn front and or rear guide window cam lower adjusting stud s anti clockwise positioning 5 Set adjusting stud s securing bottom of guide top of window inboard and lift window assembly window cam s to door inner panel to effect out through top of door smooth operation of door window assembly FRONT DOOR GLASS LIFTER CHANNEL REAR DOOR GLASS LIFTER CHANNEL GLASS FILLER STRIP SUPPORT CHANNEL LIFTER CHANNEL SECTION FIG 7 11 FRONT amp REAR DOOR GLASS ASSEMBLY MODELS SEDAN amp STATION SEDAN 6 On coupe doors install and set window travel stops and window anti rattle brackets see Fig 7 2 7 Adequately lubricate frictional surfaces of window guide and lifter cams with zinc oxide grease or light oil 8 Check operation of window prior to adequately sealing window guide cam bolts and adjusting stud s then reverse removal operations Adjustment Oversize holes in top and bottom of door inner panel together with an adjusting stud provide forward rearward and in and out adjustment of guide window cam on all models except coupe Two adjusting studs on coupe doors provide a similar adjustment On coupe door adjustable window travel stops govern height to which window can be raised Adjustable window anti rattle brackets assist in overcoming wi
98. conditions Alternatively the water test should be carried out using a medium pressure hose giving a good de livery of water in the form of a spray to the upper parts of the body 1 windshield doors drain channels etc A high pressure hose should be used on the underbody in the manner previously described Having established the exact location of a leak the area must be thoroughly cleaned and dried out The affected area should if necessary be de oxidized primed and then sealed GENERAL INFORMATION I 10 Body Cements Sealers and Adhesive Compounds The following list of body cements sealers and adhesive compounds which are the same as those used during manufacture of the vehicle are available from NASCO Part No 7425227 Mastic sealer for back window of States man models and rear quarter windows of Station Sedans 1 Ib 3 oz cylindrical carton To be used with applicator available from G M Skinner Pty Ltd 42 Pine Street Chippendale N S W 7425228 Plastic adhesive for cementing door inner panel seals and shock absorber mounting hole seals 1 pint tin 7425230 P V C adhesive for cementing P V C headlining into position 1 pint tin 7425231 Prestik grey sealing strip for sealing around tail lights 7425233 Neutral plastic sealer for sealing body joins where it is necessary to paint over sealer 1 pint tin 7425330 Prestik black sealing strip for steering column opening cov
99. cting Rod Rear Door Lock to Pivot Lever Lock Rear Door Connecting Rod Rear Door Lock to Remote Control Adjusting Stud Front Guide Window Cam Adjusting Bolt Sliding Glass Cam Assembly Cam Assembly Sliding Glass Regulator Rear Door Window Guide Window Cam Front Bandle Remote Control Models Belmont Kingswood and Station Sedan Handle Remote Control Models Premier amp Statesman Sedan Handle Window Regulator Annrest Rear Door Models Premier amp Statesman Sedan Armmtest Rear Door Option on Premier amp Statesman Sedan Motor Rear Door Window Regulator Option on Premier amp Statesman Regulator Electrically Operated Rear Door Window Option on Premier amp Statesman Switch Electrically Operated Rear Door Window Regulator Option on Premier amp Statesman Sedan DOORS 7 8 FRONT and or REAR DOOR ASSEMBLY Models Removal l With door open pencil scribe hinge locations on pillar to facilitate installation 2 With an assistant supporting door remove bolts securing hinge to pillar see Fig 7 4 ot 7 5 and r move door Installation 1 Apply plastic sealer on hinge to pillar attaching face 2 With an assistant supporting door install hinge to pillar attaching bolts loosely prior to align ing hinges within pencil scribe marks on pillars and torquing bolts to 14 17 ft lbs UPPER HINGE TO PILL
100. d open tap out parcel shelf plastic fasteners which protrude through rear parcel shelf into rear compartment 3 Lift out rear parcel shelf Installation Reverse removal operations using new plastic fasteners to secure trim panel to rear parcel shelf TRIM REAR QUARTER SIDE Models Station Sedan Removal 1 Remove rear seat cushion and lower rear seat back refer Page 8 1 2 Loosen screws securing rear sill plate to rocker panel 3 Ease finishing lace covering leading edge of trim panel off rear body lock pillar 4 Remove screw securing rearlower corner of trim panel to rear lamp access aperture 5 Ease off leading edge of rear quarter side trim which is attached to flange of rear body lock pillar with trim adhesive Z Using a 3 8 sharp wood chisel positioned between trim panel and head of fastener tap end of chisel sharply to pare off head of fastener Alternatively a special tool fab ricated to dimensions illustrated in Fig 4 6 can be used to punch centre of fastener through trim panel taking care to centralize punch with centre of fastener 7 On Kingswood and Belmont models ease base of trim panel inboard disengaging top edge of panel from trim retainer Premier models position a wide bladed screwdriver between 18 and quarter panels prising under each fastener until trim panel is disengaged 8 Remove or smooth out any hardened adhesive cement from flange of r
101. der operation it is advisable whenever the lock cylinder is removed to wash it with petrol dry it with an air hose and lubricate it with powdered graphite DO NOT USE OIL LOCK REAR COMPARTMENT LID Models Sedan amp Coupe Removal 1 Remove rear compartment lid lock cylinder refer preceding instructions 2 Remove bolts securing lock to rear compartment lid inner panel see View B Fig 5 1 then temove lock Installation Reverse removal operations and check operation of lock PRZ STRIKER REAR COMPARTMENT LID LOCK Models Sedan amp Coupe Removal 1 Pencil scribe location of lock striker on rear end inner panel to facilitate installation 2 Remove bolts securing lock striker to rear end inner panel see View C Fig 5 1 then remove striker Installation Position lock striker within scribe marks and install attaching bolts Adjustment Slots inrear face of lock striker provide adjustment for striker LAMP SWITCH REAR COMPARTMENT Models Sedan amp Coupe exc Belmont amp Kingswood Removal 1 Disconnect battery ground cable 2 Withrear compartment lid raised depress switch plunger from bracket attached to RH front of reat compartment gutter then remove harness terminal from base of plunger disassembling switch see Fig 5 2 3 Using a thin bladed screwdriver carefully prise switch body from bracket Installation Reverse removal operations UNS
102. door remove bolt and adjusting stud securing rear guide window cam to door inner panel see Fig 7 2 6 Disengage and remove cams from door window rollers Installation Reverse removal operations ensuring that window roller bearing surfaces of cams are adequately lub ricated with zinc oxide grease or light oil and that cam bolts and adjusting stud s are adequately sealed NOTE Use washer markings in sealing compound around cam bolts and adjusting stud s attaching holes as location guides when replacing door hardware DOORS 7 CAM ASSEMBLY SLIDING GLASS Models All Removal 1 With door open and window raised remove sn tod knob 2 Remove armrest where fitted disconne electrically operated window regulator swit where fitted remove door interior handle inner trim panel and door inner panel wat deflectors refer Page 7 1 3 Remove bolts securing sliding glass a embly to door inner panel see Figs 7 _ 7 2017 3 lag 4 From inside door disengage cam from 8 92 regulator arm roller and remove cam throu aperture in door inner panel Installation Reverse removal operations ensuring that regulat roler bearing surfaces of cam are adequately lul ricated with zinc oxide grease or light oil and th cam attaching bolts are adequately sealed INNER TRIM PANEL DOOR Models Removal 1 With door open and window lowered remov snib rod knob 2 Re
103. e shroud lower trim panels refer page D Reverse removal operations see Fig 2 4 UNDERBODY 2 6 COVERING REAR FLOOR Models All Removal 1 Position front seat s fully forward 2 Remove handbrake cover 3 Remove front seat belt to tunnel attaching bolts 4 Where fitted remove seat separator or trans mission control console refer this page 5 Remove rear seat cushion frame bracket to rear floor crossbar attaching screws see View D Fig 8 6 6 Loosen sill plate attaching screws 7 Remove rear floor covering Installation Apply caulking compound around front seat belt bolt to tunnel attaching holes prior to reversing removal operations see Fig 2 4 SEAT SEPARATOR Models Coupe amp Optional Removal 1 Raise lid of seat separator and ease away carpet which is attached to base of seat separator with neoprene cement 2 Remove ashtray assembly from seat separator 3 Remove screws securing base of seat separator to transmission tunnel then temove separator Installation Apply caulking compound around seat separator to transmission tunnel attaching holes prior to re versing removal operations CONSOLE TRANSMISSION CONTROL Models GTS Coupe amp Optional Removal 1 Raise lid of vanity box section of console and ease away carpet which is attached to base of console with neoprene cement 2 Remove gear lever control knob see Fig 2 5 3 Remove
104. e wiper rod permits the drive blade to complete its upward travel in a perpendicular plane adjacent to the windshield pillar The automatic type washer pump attached to the windshield wiper motor see View B Fig 3 9 is controlled by a switch mounted button located on the right hand side of the instrument carrier see View E Fig 3 8 Depressing this button activates the windshield wiper motor and washer pump simultaneously The knob below this button operates the windshield wiper motor independently MOTOR amp PUMP ASSEMBLY WINDSHIELD WIPER amp WASHER Models All Removal 1 Disconnect battery ground cable 2 Remove shroud ventilator grille refer page ER De 3 Using ignition key stop motor crank clear of motor mounting screws to permit removal of screws 4 From within plenum chamber remove clip se curing wiper linkage to windshield wiper motor crank see View C Fig 3 8 5 Remove screws securing earth strap to wind shield wiper motor and motor to dash panel then remove motor NOTE Do not remove motor crank attaching nut as windshield washer operation may be affected Installation Reverse removal operations ensuring that motor crank is in the park position prior to installation of wiper rods and blades see View C Fig 3 8 NOTE For inspection overhaul and testing of windshield wiper motor refer VOL 5 HQ Electrical Instruments and Gauges FRONT END
105. ear body lock pillar Installation Reverse removal operations attaching leading edge of rear quarter side trim to flange of rear body lock pillar with PVC adhesive cement and using new trim fasteners install lower section of trim panel to rear quarter inner panel MATERIAL Bright round mild steel lly x 45 RAD FIG 4 6 TRIM FASTENER REMOVAL TOOL TRIM WHEELHOUSE Models Station Sedan except Belmont Removal 1 seat cushion and back refer Page 8 1 2 Remove spare wheel cover and front tonneau floor refer Page 2 1 REAR QUARTER 4 7 3 Remove rear seat back stop 4 Remove outer seat belt lower attaching bolt 5 Remove rear quarter trim panel and quarter trim panel front refer Page 4 5 and following instructions 6 Remove screw securing front end tonneau floor sill panel covering to sill panel easing back covering sufficient to remove wheelhouse cover 7 Ease off edges of wheelhouse cover which are attached to rear quarter and floor panels with trim adhesive 8 Clean or smooth off any hardened adhesive from rear quarter and floor panels Installation Reverse removal operations ensuring that during installation of the rear seat back stop and outer seat belt lower attaching bolt caulking compound is used to seal around attaching holes QUARTER TRIM PANEL FRONT Models Station Sedan Removal 1 Lift out r
106. ear lower section of door inner panel move channel to desired location then tighten screw RETAINER ASSEMBLY FRONT DOOR REAR GLASS RUN CHANNEL Models Sedan and Station Sedan Removal 1 With door open and window raised remove snib rod knob 2 Remove armrest where fitted disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel water deflectors refer Page 7 1 3 Remove screw securing glass run channel retainer assembly to rear face of door inner panel see Fig 7 1 4 From inside door disengage glass run channel from retainer then remove retainer out through aperture in door inner panel Installation Reverse removal operations nn nn __ GUIDE WINDOW CAM FRONT and or REAR DOOR Models All Removal I With door open and window raised remove snib tod knob 2 Remove armrest where fitted disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel water deflectors refer Page 7 1 Remove bolts adjusting stud secuting front guide window cam to door inner panel see Figs 7 1 7 2 and 7 3 and on all doors except coupe disengage and remove cam from door window rollers 4 On coupe door remove bolts securing front and rear guide window up travel stops to door inner pariel 5 On coupe
107. ear seat cushion 2 Remove rear sill plate refer Page 2 1 3 Remove finishing lace covering leading edge of quarter trim panel front 4 Ease leading edge of trim panel which is attached to the rear door aperture flange with trim adhesive 5 Using a wide bladed screwdriver positioned between trim panel and rear quarter panel prise plastic fasteners from rear quarter panel 6 Clean or smooth off any hardened adhesive from rear door aperture flange Installation Reverse removal operations REAR QUARTER 4 8 COVER QUARTER INNER PANEL Models Coupe Removal 1 On GTS and luxury sports coupes remove rear quarter armrest and on all coupes rear quarter window regulator handle refer Page 4 5 2 Remove rear seat cushion and seat back refer Page 8 1 3 Remove rear quarter inner trim panel refer Page 4 5 4 Remove screws securing quarter inner cover panel to rear quarter inner panel and remove cover panel Installation 1 Apply a continuous bead of caulking compound around aperture in rear quarter inner panel prior to reversing removal operations BELT WEATHERSTRIP OUTER LACE REAR QUARTER BELT MOULDING INNER TRIM PANEL FIG 4 7 OUTER BELT WEATHERSTRIP INSTALLATION WEATHERSTRIP REAR QUARTER BELT OUTER Models Coupe Removal 1 Remove quarter belt moulding and attaching clips refer Page 12 1 2 With rea
108. en apply a piece of masking tape over each side edge of glass and adjacent front body pillar Slit tape vertically at edge of glass During installation tape on glass and pillar can be aligned ensuring correct location of glass Place glass on a clean protected surface then apply a thin coating of glass primer around the entire perimeter of the glass contacting area to dimensions illustrated in View C Fig 9 2 CAUTION Avoid touching primed areas of glass and body opening flanges Also avoid spillage of glass primer onto glass as this is extremely difficult to remove When applying solvents to the optional laminated windshield avoid contacting edge of windshield with solvents as such contact can create a wick action dis colouring the plastic laminate between sheets of glass With Solbit bead still in its plastic container bare ends of bead to copper wire core for app roximately 1 Pre heat Solbit by connecting copper ends of bead to a 24 volt 12 amp electric supply for approximately 15 to 30 seconds depending on ambient temperature allowing Solbit to become pliable then blow off any moisture existing on the Solbit coil using an air hose STATIONARY GLASS 9 4 METAL PRIMER 17 WINDSHIELD SEALER FOR WATER LEAK CORRECTION SOLBIT BEAD CUT OFF ENDS OF SOLBIT BEAD AS SHOWN SOLBIT A A BEAD TO BE CLEAN LINE FOR APPEARANCE SPACER BLOCK
109. ene cement 3 Remove or smooth out any hardened cement remaining on lock pillar Installation Reverse removal operations RELIEF VALVE BODY LOCK PILLAR Models Removal 1 Remove screw securing lower end of telief valve to body lock pillar see Fig 4 8 REAR QUARTER 4 9 BODY LOCK PILLAR SEAL RELIEF VALVE RELIEF VALVE FIG 4 8 LOCK RELIEF VALVE INSTALLATION 2 Ease out bottom of valve then disengage re mainder of valve from lock pillar Installation Reverse removal operations PRESSURE RELIEF VALVE REAR QUARTER SIDE TRIM Models Station Sedan Removal Remove screws securing pressure relief valve to rear quarter side trim then ease out valve Installation Reverse removal operations REAR QUARTER 4 10 NOTES AND BULLETIN REFERENCES BULLETIN z DATE SUBJECT ESEE SECTION 5 INDEX Subject Page Rear Compartment Lid Assembly Description 5 1 Rear 2 222053 Torque Rods Rear Compartment Lid 9 3 Cylinder Rear Compartment Lid Lock 5 3 Lock Rear Compartment Lid 5 4 Striker Rear Compartment Lid Lock 5 4 Rear Compartment Lamp Switch 5 4 Petrol Filler Door Sls 5 5 Weatherstrip Rear Compartment Lid 5 5 LID ASSEMBLY REAR COMPARTMENT Description The rear compartment lid
110. engage opposite end of torque rod from hinge assembly see View D Fig 5 1 then remove rod Installation Reverse removal operations Adjustment The position of the torque rods in notches of the retainer determine the amount of effort required to open and close the rear compartment lid If the torque rod is located in the lowest notch of the retainer a greater amount of effort is required to open the lid and less effort required to close it If the torque rod is located in the top notch of the retainer the effect is opposite To adjust the torque rods position a length of tubing approx imately 12 long with an inside diameter of 1 2 over end of torque rod then lever torque rod from retainer CYLINDER REAR COMPARTMENT LID LOCK Models Sedan amp Coupe Description The lid cylinder is attached to the rear compartment lid with a screw attached retainer see View B Fig 5 1 rubber gasket between the retainer and rear compartment lid seals against dust and water entry into the body REAR COMPARTMENT 5 4 Removal 1 Remove lock cylinder retainer attaching screws 2 Apply masking tape adjacent to retainer to pro tect paint finish 3 With a wide bladed screwdriver inserted between flange of retainer and lid inner panel partly prise retainer out approximately 1 2 then withdraw lock cylinder Installation Reverse removal operations NOTE Due to the adverse effect of dust on lock cylin
111. er five strips per unit 7425347 Elastite caulking compound for sealing sheet metal panel joins 2 tin 7425360 Underbody sealer for sealing underbody panel joins and holes 2 Ib tin 2823265 Windshield Silicone Caulking Package 2823266 Rear window Silicone Caulking Package The successful application of sealing and adhesive compounds depends upon absolute cleanliness of the areas to be treated therefore it is important to remove all dust water grease or rust before applying the compounds Inflammable adhesives and solvents should be used in well ventilated areas Adhesive compounds are normally applied to both surfaces to be joined allowed to dry until tacky then pressed firmly together over the whole area to provide maximum adhesion adhesive is allowed to dry it can usually be te activated by wiping with a diluent recommended for the particular material being used If a coating of For removing any excess sealer from paintwork or backlight glasses etc use a cloth moistened with white spirit NOTE Petrol or paint thinner must not be used GENERAL INFORMATION 1 11 BODY LUBRICATION The moving mechanical parts of the body which have metal to metal contact are lubricated at assembly Operating conditions whether normal or otherwise determine the effective life of of the lubricant and for this reason lubrication in service is important Equally important is the type of lubricant to be
112. er and apply adjustable clamps at ends of bar one jaw located below drip gutter and the other on top of bar Tighten clamps until retainer fingers click under lip of drip gutter Continue moving bar and clamps progress ively forward until both retainers are correctly installed see Section C C Figs 10 9 and 10 10 Install windshield and back window reveal moulding clips and mouldings refer page 12 1 Install rear quarter upper panel and roof side reveal moulding retaining clips and mouldings refer page 12 1 3 ROOF 10 14 NOTES AND BULLETIN REFERENCES SUBJ 5 SECTION 11 INDEX Subject Page Subject Page Front Fender Assembly 11 3 Bracket Assembly Hood Lock Front End Panel 11 5 Uu 1 6 Engine Hood 11 5 Cable Engine Hood Release 11 6 Lock Plate 8 Support Assembly 11 5 Hinge Assembly Engine Hood 11 6 SHEET METAL Description The front end sheet metalis attached to the body and front end partial frame and comprises the engine hood front fender engine skirt radiator support and front end panel assemblies see Figs 11 1 11 2 and 11 3 The engine hood assembly is of double skin construction 11 is attached to spring loaded hinges which in turn are attached to the engine skirt panels The engine hood hinge springs are positioned so they assist in raising the engine hood and support it in the fully open position A cont
113. es in body back panel lower and in end gate prior to reversing removal operations END GATE ASSEMBLY Models Station Sedan Removal 1 Remove rear tonneau floor 2 Remove rear bumber assembly refer pages 14 2 14 3 or 14 4 3 Position end gate vertically to relieve tension from torque rod then remove retainer securing torque rod to body back panel lower see Figs 6 1 or 6 2 4 Fully open and support end gate 5 Remove screws and bolts securing hinges and limit arms to end gate then remove end gate NOTE On end gate exercising the optional electric window regulator disconnect wiring harness inside spare wheel compartment remove wiring sleeve from body back panel lower and remove harness Installation Apply plastic sealer between hinge and limit arm to end gate mounting surfaces prior to reversing removal operations NOTE On end gates exercising the optional electric window regulator ensure that end gate wiring harness sleeve is effectively bonded to body back panel lower with neoprene cement Adjusiment Horizontal and or vertical adjustment of the end gate can be achieved by 1 Loosen end gate hinge to body attaching bolts 2 Position end gate in the desired location 3 Tighten end gate hinge to body attaching bolts CAUTION Any end gate adjustments necessitate correct radial relationship between end gate window and upper and lower glass run channels This can require ad
114. essary to depress arm of safety switch adjacent to LH end gate lock Fig 6 2 3 Remove nuts securing switch escutcheon to end gate outer panel 4 Disconnect harness connector from switch and remove escutcheon Installation l Ensure that escutcheon assembly gasket effect ively seals escutcheoh aperture in outer panel 2 Check operation of switch prior to replacing inner trim panel Disassembly l Disengage lock cylinder case retainer see Fig 6 7 and remove lock cylinder and switch assembly from escutcheon 2 Using a pointed tool inserted through hole in lock cylinder case depress tab of both switch retainers and remove retainers and switch END GATE 6 9 3 Using suitable pliers grasp pin of switch cam firmly and pull switch cam straight out from lock cylinder Pin is pressed into lock cylinder and may require a firm pull to release Assembly 1 Insert key in lock cylinder and turn key to off position straight up and down 2 Insert switch into lock cylinder ensuring that ends of spring housed in base of switch cam engage in recess opposite major slot in lock cylinder housing 3 Holding switch cam in position check operation of key lock cylinder If lock cylinder operates correctly apply a small amount of cement on serated end of switch cam pin to ensure secure retention of pin to lock cylinder then install pin Press or tap pin in until shoulder of pin is
115. ey will probably set the stain and cause a permanent dis colouration Grease and Oil As much grease as possible should be removed by scraping with a dull knife Grease and oil stains may be removed by rubbing lightly with a clean cloth saturated in a volatile cleaner Be sure all motions are towards the centre of the stained area to decrease the poss ibility of spreading the stain Ice Cream The same procedure is recommended for the removal of ice cream stains as that used for removing fruit stains If the stain is persistant rub the spot with a cloth wet with warm soap suds mild neutral soap Use a clean cloth to apply a cold water tinse to the area When dry rub area lightly with a cloth wet with a volatile cleaner Nausea Sponge with a clean cloth dipped in clear cold water After most of the stain has been removed in this way wash lightly with soap mild neutral using a clean cloth and lukewarm water then rub with another clean cloth dipped in cold water If any of the stain remains after this treatment gently rub with a clean cloth moistened with a volatile cleaner Shoe Polish and Dressings For shoe dressings containing starch or dextrine ot some water soluble vehicle sponge with a clean cloth dipped in clear cold water Paste ot wax type shoe polishes may require using a volatile cleaner Rub the stain gently with a cloth wet with a volatile cleaner until the polish is removed Use a clean portio
116. faces of remote control and end gate inner panel and around screw attaching holes prior to reversing removal operations WEATHERSTRIP LOWER END GATE APERTURE Models Station Sedan Removal 1 Open end gate and ease out lower ends of glass run channel upper which are attached to upper run channel retainer with neoprene cement 2 Remove screws securing lower section of upper glass run channel retainer to upper aperture 3 Ease outer flange of lower weatherstrip retainer outwards 4 Ease upper run channel retainers to one side and ease lower weatherstrip from retainer surrounding lower end gate aperture 5 Remove or smooth out any hardened cement from ends of weatherstrip and retainer Installation Reverse removal operations installing lower ends of glass run channel upper to retainer with neoprene cement WEATHERSTRIP OUTER _ END GATE BELT Models Station Sedan Removal 1 Open end gate and remove screws securing ends of belt moulding to end gate 2 Close endgate and apply masking tape adjacent to belt moulding to protect paint finish 3 Using a wide bladed screwdriver carefully prise moulding from end gate 4 Remove screw attached belt moulding retaining clips from end gate 5 Remove belt weatherstrip outer Installation When reversing removal operations ensure that one edge of belt moulding is located completely over retaining clips prior to lightly tapping moulding into position
117. facture to ensure against the entry of water and dust For various reasons however leaks may ultimately develop in service Accidental damage for example disturb the sealing of joint If new body panels or members are required various manufacturing holes must be plugged and spot welded flanges coated with sealer Water Leak Diagnosis and Rectification As with all welded type body shells it is extremely difficult to identify all the potential points where leaks may occut The following information is therefore given as a general guide to the procedure to be followed for diagnosing and rectifying leak locations Diagnosis of leaks is complicated by the fact that the appearance of water at one point can be caused by seepage through any one or more of many possible locations As an example of this indirect entry the cause of wet front floor coverings may be due to water entering past the door weatherstrip through the door inner panel between the windshield and its glazing compound or through any one of the joints in the floor panel ventilator or dash panels therefore point or points of water or dust entry must be established before effective resealing can be carried out Where automatic type washing equipment is avail able the vehicle should be subjected to a water spray for a minimum period of four minutes At the end of this period the underbody should be sprayed with a high pressure hose to simulate wet weather
118. fitted disconnect electrically operated window regulator switch where fitted remove door interior handles and inner trim panel refer Page 7 Remove door belt inner weatherstrip which on all doors except coupe is screwed to the top outer flange of inner trim panel On coupe door lift door belt inner weatherstrip off door inner panel flange Installation Reverse removal operations DOORS 7 GLASS RUN CHANNEL FRONT DOOR Models All except Coupe Removal 1 With door open and window lowered remo snib rod knob 2 Remove armrest where fitted disconne electrically operated window regulator switc where fitted remove door interior handle innertrim panel and rear end of door inner pan water deflector refer Page 7 1 3 Loosen off bolts securing top of front guic window cam to door inner panel see Fig 7 1 4 Holding top of window ease window forwa to relieve pressure from rear lower end of n channel 5 Ease glass run channel out of upper door fran and retainer inside trailing edge of door Installation l Feed rear lower end of glass run channel int retainer inside trailing edge of door throug window aperture 2 Install remainder of glass run channel int upper door frame prior to reversing remova operations GLASS RUN CHANNEL REAR DOOR Models Sedan and Station Sedan Removal 1 With window lowered ease glass run channe out of upper door frame Installation
119. g a tinted band across the top of the windshield are available on all models Installation of windshield and back window of all HQ models involves a telatively new concept in the bonding of glass to metal It comprises a 5 16 in bead of caulking compound approximately 15 feet long incorporating a centralized Copper wire which is placed around the inner periphery of the glass The ends of the bead are crossed at a point along the top edge of the glass between weld studs with ends of copper wire protruding see View D Fig 9 2 The ends of the wire are then con nected to a 24 volt 12 amp electric supply for 12 minutes This electric current softens the Solbit allowing the glass to be pressed into the body opening effecting a watertight seal and simultaneously starting the curing process Two different types of material for replacement of windshields and back windows in Service are available The first an electric curing type similar to that used during production of the vehicle is available from BOSTIK PTY LTD or their Agencies This kit comprises STATIONARY GLASS 9 2 1 Coil of SOLBIT caulking compound bead which requires refrigerated storage at 30 F or below 1 Container of paint finish primer 1 Container of glass primer 2 Water soluble spacers for locating glass 2 Emergency water soluble spacers to achieve 28 dimension in Fig 9 2 1
120. g is wrinkle free Staple edges of covering to base of tonneau floor Install tonneau floor UNDERBODY 2 8 COVERING TONNEAU FLOOR SIDE SILL Models Station Sedan exc Belmont Removal 1 2 Lower rear seat squab Remove rear quarter trim panels see page 4 4 3 Remove rear tonneau floor 4 Remove screws securing front and rear inner edge of covering to rear side floor 5 Carefully remove covering which is attached to the side sill with vinyl trim adhesive 6 Remove or smooth down any hardened adhesive from the side sill or covering Installation 1 Spray or brush on an even coat of vinyl trim adhesive to side sill and inside of covering 2 Apply covering to side sill ensuring that covering is wrinkle free 3 Install sctews to front and rear inner edge of covering 4 Install rear tonneau floor and rear quarter trim panels refer page 4 1 FILLER PANEL Models Station Sedan Removal 1 Lower rear seat squab 2 Remove screws securing filler panel hinge to rear floor riser panel 3 Remove filler panel Installation Reverse removal operations COVERING FILLER PANEL Models Station Sedan exc Belmont Removal l Remove filler panel refer preceding instruct ions 2 Remove wear strips 3 Remove cover strips surrounding outer edge of filler panel 4 Carefully remove covering which is attached to the filler panel with vinyl trim adhesive 5 Remove or smo
121. he cover should be washed frequently with neutral soap suds lukewarm water and a soft bristle brush Rinse cover with fresh water until all traces of soap are removed Tar Tar stains can be removed with Holt s Tar Remover or Shellite providing the stain is not allowed to remain on the paint finish for an indefinite period Petrol Wash off with water immediately CAUTION Prolonged contact of petrol with paint finish will result in permanent staining of the paint Insect Spots Insect spots on the paint finished parts of the veh icle can be easily washed off by using a solution containing two quarts of water in which half a pound of baking soda Bicarbonate of Soda has been dis solved Flush the washed parts with clean water After washing and drying park the vehicle in shaded area 2 Polishing Over a period of time foreign matter road scum may build up on the paint surface to the detriment of its overall appearance In these circumstances the use of Delco General Cleaner and Polish is recommended Do not attempt to polish without first washing the vehicle to remove existing loose grit or surface dirt Delco General Cleaner and Polish should be applied with a damp clean soft cloth stockingnet or cheese cloth allowed to dry and the final clean up obtained by polishing with a dry soft cloth Inspection Regular inspection of the vehicle should be made for scratch marks cracks or damaged areas all of w
122. hich could develop rust and thus affect paint finish Any deep scratches cracks or breakdown in the finish should be repaired without delay Care should be taken to ensure that any rusting is counteracted immediately otherwise rust will extend beyond the damaged area This applies particularly in sub tropical areas or coastal districts where the moist or salt laden atmosphere accelerates rusting if it is allowed to develop through neglect The paint finish of the vehicle gives a very high degree of protection against the weather but it should be realised that wear and deterioration occur when the car is exposed to elements for prolonged periods The vehicle therefore should be garaged whenever possible Protection of Bright Metal Parts The destructive forces of salt air and corrosive atmosphere can be eliminated if bright metal parts are thoroughly washed regularly in the same manner as the paint finish of the vehicle NOTE Never scour or use abrasive polishes GENERAL INFORMATION 1 13 CARE AND CLEANING OF INTERIOR TRIM Loose dust and dirt particles that accumulate on the surface of interior trims should be removed every few weeks more often with constant hard driving This can be readily achieved using a vacuum cleaner or soft brush IMPORTANT Before attempting to remove spots and stains from trim material it is necessary to determine as accurately as possible 1 The nature and age of
123. im panel refer Page 7 1 3 Using a sharp knife carefully peel deflector s away from door inner panel 4 Clean or smooth off any hardened adhesive from surface to which deflector is to be att ached Installation 1 Apply PVC trim adhesive around edge of door inner panel aperture Cover aperture with deflector ensuring edge of deflector is wrinkle free and bonded firmly to door inner panel prior to reversing removal operations SUBJECT SEATS 8 1 SECTION 8 INDEX Subject Page Subject Page Seats Description 8 1 Recliner and or Arm Assembly 8 6 binont Sedt zad DS Rear Seat a T 8 3 Rear Seat Back Lock and Front Seat Adjuster 5 8 4 Handle AssemBlys 97 Remote Control Front Seat Adiuster 5 a e wl 8 6 Sear 9 9 SEATS Description The general construction and method of upholstering the front bench bucket reclining and rear seats are similar and comprise basic steel frames accommodating ZIG ZAG type springs over which upholstery is applied The upholstery is attached to the seat springs and frames with a combination of rings clinch over tabs retaining wires trim clips and Neoprene cement Fig 8 1 illustrates the front bench seat assembly and shows typical construction through a cut away section of the upholstery The front seats can be adjusted forwards and tearwards by means of sliding seat adjuste
124. ing ROCKER PANEL MOULDING Models All except Belmont Removal 1 On Kingswood and Statesman models and from inside rear wheelhouse remove nut securing rear end of moulding to rocker panel On Premier Monaro LS and Statesman De Ville models remove screws securing base of mould ing to rocker panel see Section Fig 2 2 then lift moulding off upper retaining clips On Kingswood and Statesman models apply masking tape below moulding to protect paint finish Using a wide bladed screwdriver located be tween moulding and panel carefully prise moulding off retaining clips and disengage front end of moulding from under front wheel opening moulding see Section Z Z Fig 12 2 Oo goa c a 5 k EXTERIOR ORNAMENTATION 12 14 Installation 1 On Kingswood and Statesman models locate front end of moulding under front wheel opening moulding see Section Z Z Fig 12 2 and the upper edge over top of retaining clips 2 Using the hand or a rubber mallet lightly tap moulding into position 3 From inside front of rear wheelhouse install nut securing rear end of moulding to rocker panel then remove masking tape 4 On Premier Monaro LS and Statesman De Ville models locate upper edge of moulding over top of retaining clips and install screws along bottom of moulding see Section Y Y F ig 12 2 WHEEL OPENING REVEAL MOULDING Models All except Belmont Removal 1 Rem
125. ions Where possible illustrations are placed in close proximity to the accompanying text and should be used as part of the text MODEL IDENTIFICATION Right Hand Drive Only ENGINE L 6 8 HQ80135 080235 030169 080269 HQ80170 HQ80270 080180 080280 80335 80435 80337 HQ80437 030369 080459 HQ80380 HQ80480 HQ80837 081135 081235 HQ81169 HQ81269 HQ81137 HQ81237 HQ81469 HQ81569 HQ81669 HQ81837 DESCRIP TION Belmont Station Sedan Belmont Sedan Belmont Panel Van Belmont Coupe Utility Kingswood Station Sedan Monaro Coupe Kingswood Sedan Kingswood Coupe Utility Monaro GTS Coupe Premier Station Sedan Premier Sedan Luxury Sports Coupe Statesman De Ville Sedan Statesman Sedan Monaro GTS 350 Coupe GENERAL INFORMATION 4 BODY IDENTIFICATION Complete identification of each body is provided by a body identification plate illustrated Fig 1 1 attached to the upper left hand side of the shroud panel and is accessible when engine hood is raised This plate must not be destroyed and if removed during body repairs must be re installed in its original location CICER SY GENERAL MOTORS HOLDENS PTY LTD DY IDENTIFICATION CORRESPONDENCE MUST BEAR THESE NUMBERS MODEL HQ 80369 7 BODY No No 1 4 e TRIM 1198 11E Q PAINT 568 12203 TOP 568 13134 MADE IN AUSTRALIA HOLDEN FIG 1 1 BODY IDENTIFICATION PLATE Trim
126. isting hardened cement from roof panel or inside of cover NOTE xylol solvent such as adhesive cleaner or equivalent should be used to remove old cement Exercise care to avoid excessive softening of roof panel acrylic sealer Manufacturers directions must be followed when using cement remover Installation To enable easier fitting and removal of air pockets from roof cover install cover at room temperature approximately 72 F 1 Determine centre line of roof and mark with chalk 2 Place cover face down on roof panel and apply an even coat of 3M Nitrile adhesive cement to the complete inner surface of cover Allow cover to completely dry which usually takes between fifteen and twenty minutes IMPORTANT Application of Nitrile adhesive cement shouldbe as thin as possible as an excess amount of cement may result in trapped solvents blisters or highlights cement build up be tween roof panel and cover 3 Reverse cover so that grain is on the outside 4 Loosely fold cover lengthwise to determine centre line of cover marking front and rear locations with chalk CAUTION It is essential that when folding cover no pressure is brought to bear on the actual fold as the crease mark that can result is extremely difficult to remove 5 Align front and rear markings of folded cover with centre line of roof ensuring adequate over hang of material at windshield and back window reveal moulding weld studs
127. isting wires in their correct listing pockets NOTE Listing wires are identified by a daub of coloured paint on end of wires see Figs 10 2 10 3 10 4 and 10 8 2 Apply a 2 band of adhesive cement around outer edge of headlining 3 Apply adhesive cement to roof side rails and front and rear headlining retainers 4 Install ends of No 3 listing wire into roof side rails NOTE If a new headlining is being installed it may be necessary to trim listing pockets away from ends of listing wires sufficient to clear roof side rails 5 Pierce No 3 listing pocket in line with roof support clinch over tabs locate tabs under listing wire and bend tabs over securing wire to roof support see View D Figs 10 2 to 10 4 inclusive 6 Install ends of Nos 2 1 4 and 5 listing wires into roof side rails 7 Locate front and rear ends of headlining centrally into headlining retainers NOTE When positioning headlining it is important that the stitched seams remain straight and aligned with each other across the roof BEND TANGS TO RETAIN BASE REAR DOOR JAMB SWITCH LEAD ASSY WHITE LAMP BASE DOME LAMP amp WIRING FOR 811 812 815 816 VIEW A LH REAR DOOR JAMB SWITCH LEAD WHITE REAR QUARTER LAMP REAR QUARTER LAMP WIRING LH SIDE 814 view C DOME LAMP WIRING FOR 801 802 803 804 VIEW Fig 10 1 ROOF INTERIOR LAMP INSTALLATION ROOF 10 3 REAR QUARTER LAMP FEE
128. justment of end gate striker plate and or hinges Incorrect adjustment will result in stiff end gate window operation and subsequent damage to run channels HINGE ASSEMBLY Models Station Sedan Removal 1 Open and support end gate on side from which hinge is to be removed 2 Pencil scribe around hinge assembly to fac ilitate installation 3 Remove hinge to body and hinge to end gate attaching screws and bolts see Fig 6 lor 6 2 then remove hinge Installation Apply plastic sealer between mating surfaces of hinge to body and hinge to end gate prior to reversing removal operations END GATE 6 7 WINDOW ASSEMBL Y Models Station Sedan Removal 1 Open end gate and remove wear strips inner trim panel and inner belt lacing refer page 6 1 2 Partly raise and support end gate window to gain access to glass lifter channel cam attach ing bolts see Fig 6 1 or 6 2 3 Remove glass lifter channel cam attaching bolts and cams from lifter channel 4 Remove window through top of end gate and place on a clean protected surface CAUTION On models fitted with electrically operated window regulator do not operate regulator motor after regulator is removed from end gate Operation of the motor with load temoved may damage the unit Installation Lubricate regulator sector teeth with zinc oxide gtease or light oil prior to reversing removal oper ations WEAR STRIPS AND TRIM PANEL INNE
129. k Red man ME Handle Door Exterior 7 1 Cylinder Front Door Lock Weatherstrip Assembly Door 7 15 Remote Control Door Lock 7 Striker Bolt Assembly Door Lock 7 12 WK S 7 4 Regulator Door Wigdew s pms 01112177 Window Regulator 956 Belt Weatherstrip Door Outer 7 2 Switch Door Pales Belt Weatherstrip Door Inner 7 21 Window Assembly 7 13 Glass Run Channel Front Door 7 2 Door Window Glass and or Lifter Channel 7 15 Glass Run Channel Rear 7 2 Door Window Glass and or Sash Plate 7 16 Glass Run Channel Rear Door Division 7 2 Fixed Glass Rear Door leg 4 7 6 Water Deflector Door Inner Panel 7 22 Description All doors of HQ Sedans and Station Sedans consist of inner and outer panels welded together at surrounding door flanges An upper frame rolled section reinforcement provides retention for glass run channels Doors on HQ Coupes consist of half inner and outer panels welded together at leading bottom and trailing door flanges All doors feature separate hinge pillar facings and floating anchor plates for upper and lower hinge mountings Concealed door hinges mounted on leading faces of the doors
130. k to Inside Locking Lever Lock Front Door Cam Assembly Sliding Glass Armrest Door Connecting Rod Door Lock to Remote Control Remote Control Door Lock Handle Remote Control Guide Window Cam Rear Guide Window Cam Front Handle Window Regulator Adjusting Stud Front and Rear Guide Window Cams Regulator Electrically Operated Door Window Option on GTS Monaro amp Luxury Sports Coupe Adjusting Stud Sliding Glass Cam Assembly Switch Electrically Operated Door Window Regulator Option on GTS Monaro amp Luxury Sports Coupe Armrest Door Option on GTS Monaro amp Luxury Sports Coupe Motor Door Window Regulator Option on GTS Monaro amp Luxury Sports Coupe DOORS 7 6 a SECTION D D Y SECTION B B SECTION C C FIG 7 3 REAR DOOR HARDWARE INSTALLATION MODELS ALL except COUPE 152 P O ES 10 11 125 13 14 15 16 17 18 19 20 21 22 23 DOORS 7 7 REAR DOOR HARDWARE INSTALLATION Models All except Coupe Knob Door Lock Snib Rod Seal Electrically Operated Rear Door Window Regulator Switch Option on Premier amp Statesman Connecting Rod Rear Door Lock to Outside Handle Assembly Channel Assembly Rear Door Division Lifter Channel Rear Door Glass Switch Electrically Operated Rear Door Window Regulator Option on Premier amp Statesman Cam Glass Lifter Conne
131. k type clip see Fig 12 2 Installation 1 Apply sealing compound around emblem or nameplate attaching stud prior to inserting stud into clip and lightly tapping emblem or nameplate into position using the hand or a rubber mallet 2 From hetween inner and outer panels of lid install sealing nut then remove masking tape SECTION 13 Description The radiator grille on all models is of moulded plastic two piece on Statesman and one piece on all other models see Fig 13 1 Special paint treatment employed on the radiator grille of GTS and GTS 350 models is distinct from that of other models RADIATOR GRILLE 13 2 NUT GRILLE TO FRONT PANEL UPPER BOLT GRILLE TO FRONT PANEL UPPER BOLT TAN FRONT PANEL LOWER RADIATOR GRILLE MODELS STATESMAN MODELS ALL 5 5 BOLT GRILLE TO RADIATOR GRILLE FRONT PANEL LOWER BOLT GRILLE TO FRONT PANEL UPPER FIG 13 1 RADIATOR GRILLE INSTALLATION RADIATOR GRILLE Models All Removal 1 Raise engine hood 2 Remove bolts securing top and bottom of radiator grille to front end panel see Sections and Fig 13 1 Installation Reverse removal operations NUT EMBLEM TO GRILLE WASHER EMBLEM TO GRILLE 22 4 22 s N RADIATORIGRILLE 13 3 EMBLEM OR NAMEPLATE RADIATOR GRILLE Models
132. lange of door outer panel then care fully prise weatherstrip retaining clips out of slots in door outer panel Installation Reverse removal operations BELT WEATHERSTRIP DOOR OUTER Models Coupe Removal 1 With door open and window lowered remove snib rod knob DOOR INNER BELT WEATHERSTRIP RETAINING CLIP DOOR INNER TRIM PANEL RETAINING CLIP BELT WEATHERSTRIP OUTER FEZ E 7 BELT WEATHERSTRIPS FRONT amp REAR DOORS MODEL SEDAN amp STATION SEDAN 2 Remove armrest where fitted disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door belt inner weather strip refer Page 7 1 Loosen bolts securing window anti rattie brackets to door inner panel see Fig 7 2 4 Remove screw securing rear end of door belt moulding to door Apply masking tape adjacent to door belt moulding and using a wide bladed screwdriver carefully prise moulding off retaining clips Remove screw attached door belt moulding retaining clips from door outer panel ease top of window inboard then remove screws sec uring outer belt weatherstrip to inner flange of door outer panel releasing weatherstrip Installation Reverse removal operations BELT WEATHERSTRIP DOOR INNER Models All Removal 1 With door open and window lowered remove w snib rod knob Remove armrest where
133. m the LH air duct This forced air has alternative routing either through or by passing the heater core Control is achieved by selecting the control knob setting on the RH side of the instrumeat carrier proportioning the hot and cold air mixture thus achieving the desired dis charge temperature This air flow can be directed to foot seat level or demist outlets in varying proportions or completely shut off dependent on control knob setting Bowden cables attached to the control knobs operate air deflector doors within the heater unit With all windows in the vehicle closed air flowing through the body exhausts through pressure relief valves fitted to the rear body lock pillars see Fig 3 1 This partial pressurization of the body reduces wind noise and dust entry into the vehicle An optional air conditioning unit available on all models except GTS 250 manual incorporates a heater core four speed air induction fan attached to the air conditioner induces hot cold or mixed air to be ducted into the body via air outlets located centrally and on both ends of the instrument panel through the windshield demist ducts or onto the floor dependent on control knob setting FRONT END 3 3 69 STYLES 35 STYLES 37 STYLES FLOW THROUGH VENTILATION BODY FRONT END 3 4 AIR DUCT ASSEMBLY PLENUM CHAMBER Installation Models Reverse removal operations ensuring that seal of
134. mote Control Front Door Lock Cam Assembly Sliding Glass Connecting Rod Remote Control to Pivot Lever Guide Window Cam Front Handle Remote Control Models Belmont Handle Remote Control Models All except Belmont Handle Window Regulator Regulator Electrically Operated F ront Door Window Option on Premier amp Statesman Armrest Front Door Option on Premier amp Statesman Motor Front Door Window Regulator Option on Premier amp Statesman Switch Electrically Operated Front Door Window Regulator Option on Premier amp Statesman DOORS 7 4 THRU WEATHERSTRIP SECTION D D ATTACHMENT U A 2 4 1 T R CRON J Os SECTION A A SECTION SECTION 8 8 WITH 1 PL SECTION RH SIDE ONLY DOOR HARDWARE INSTALLATION MODELS COUPE ee 66 U BW c Ma 29 24 253 DOOR HARDWARE INSTALLATION Models Coupe Weatherstrip Door Belt Outer Moulding Door Belt Weatherstrip Door Belt Inner Knob Door Lock Snib Rod Strip Assembly Door Window Anti Rattle Cylinder Door Lock Connecting Rod Door Lock to Outside Handle Assembly Strip Assembly Door Window Anti Rattle Front Lifter Channel Door Glass Connecting Rod Door Loc
135. moval operations WINDOW ASSEMBLY DOOR Models All Removal 1 With door open and window lowered remove door belt outer weatherstrip refer Page 7 20 2 Raise and support window and remove rod knob 7 R w SWITCH LEAD PILLAR BODY L SPRING Nz PLUNGER FIG 7 10 DOOR JAMB SWITCH INSTALLATION FRONT DOOR MODELS ALL except BELMONT REAR DOOR MODELS PREMIER 8 STATESMAN DOORS 7 14 3 Remove armrest where fitted and disconnect Installation electrically operated window regulator switch where fitted remove door interior handles 1 With an assistant supporting top of window inner trim panel door inner panel water de position window rollers in top of front and on flectors and door window regulator assembly coupe door rear guide window cams refer Page 7 1 2 Loosely install bolts securing top of front and or rear guide window cam to door inner 4 On coupe doors remove bolts securing window panel see Figs 7 1 7 2 or 7 3 travel stops and window anti rattle brackets to door inner panel removing stops and bra ckets from inside door see Fig 7 2 3 Install door window regulator assembly refer Page 7 12 4 With window in the raised position tighten cam to door inner panel attaching bolts 5 Remove bolts securing top of front and or rear guide window cam to door inner panel see NOTE Use washer markings in sealing
136. move armrest where fitted disconnec electrically operated window regulator switcl where fitted and remove door interior handle refer Page 7 1 3 Using a wide bladed screwdriver positioned between rear lower corner of trim and door inne panel carefully prise rear bottom and fron edges of trim from door inner panel see Fig 7 13 DOORS 7 18 4 Lift trim panel inwards and upwards disen gaging nibs of inner trim panel from slots in top of door inner panel installation Reverse removal operations ARMREST DOOR Front Door All except Belmont Rear Door Premier amp Statesman Sedan 1 On models fitted with the optional electrically operated window regulator carefully prise switch assembly out of armrest and on RH front and rear doors remove nut securing switch base to switch escutcheon see Figs 7 1 2 Remove screws securing armrest to door inner panel then remove armrest DOOR PANEL TRIM ASSY n DOOR TRIM PANEL L 29 L RETAINING g 29 SECTION ILE DOOR TRIM PANEL RETAINING CLIP DOOR TRIM PANEL SEALING PLUG FIG 7 13 DOOR INNER TRIM PANEL REMOVAL Installation Reverse removal operations HANDLE DOOR INTERIOR Front Door Model Belmont Rear Door Models Belmont Kingswood and Premier Station Sedan Removal 1 Insert interior handle remo
137. mpound around moulding att aching screw holes prior to installing screw s and removing masking tape SCALP MOULDINGS FRONT amp REAR DOOR Models Statesman De Ville Removal 1 Remove door belt moulding refer preceding instructions 2 Unclinch retaining tabs at inside ends of upper scalp moulding 3 With window lowered partly remove upper glass run channel 4 Position a wide bladed screwdriver against end of lower edge of upper scalp moulding and using inner wall of door upper frame as a fulcrum catefully prise scalp moulding from door upper frame 5 Using the same procedure remove the front and reat scalp moulding from the door upper frame Installation Ensure that flanges of scalp mouldings are not damaged prior to reversing removal operations UPPER REVEAL MOULDING REAR WINDOW Models Sedan amp Coupe Removal 1 Locate moulding removal tool No 1A6 between moulding and glass until point of tool engages with one of the retaining clips then using the tool in a rocking motion see Fig 12 7 pro gressively disengage moulding from clips see Section Fig 12 1 Installation Ensure that moulding retaining flanges and attaching clips are not damaged prior to installing moulding onto clips REVEAL MOULDINGS REAR WINDOW Models Coupe amp Sedan except Statesman Removal l Raise rear compartment lid then remove screws securing rear window reveal moulding extension to
138. n of the cloth for each rubbing operation and rub the stained area from out side to centre GENERAL INFORMATION 1 15 Tar Moistea the spot slightly with a volatile cleaner then remove as much of the tar as possible with a dull knife Follow this operation by rubbing the spot lightly with a cloth wet with the cleaner until the stain is removed Urine Sponge the stain with a clean cloth saturated with lukewarm soapsuds mild neutral soap then rinse well by rubbing the stain with a clean cloth dipped in cold water Saturate a clean cloth with a sol ution of one part household ammonia and five parts water Apply the cloth to the stain and allow the solution to remain on the affected area for one minute then rinse by rubbing with a clean cloth and cold water Lipstick The compositions of different brands of lipstick vary making stains very difficult to remove In some instances a volatile cleaner may remove the stain If some stain remains after repeated application of volatile cleaner further treatment is not recomm ended as this may damage the material LOCK CYLINDERS KEYS AND LOCKS All models are equipped with new five bitting depths lock cylinders Two non interchangeable keyways are used in these lock cylinders square headed key operates the primary keyway of ignition doors and on station sedans endgate lock cylinders n oval headed key operates the secondary keyway of instru ment panel
139. n protected surface Installation 2 Depress end of locking wire attached to seat Reverse removal operations BOLT ASSY SEAT ADJUSTER TO FRAME ASSY LEVER SEAT ADJUSTER GONTROL SEAT ADJUSTER ASS Y RH ASSIST SPRING SEAT ADJUSTER RH SPRING RELEASE LEVER ASSIST SPRING SEAT ADJUSTER LH SPRING RELEASE LEVER WIRE ASSY ADJUSTER AUXILIARY LOCKING SPRING amp FRAME ASSEMBLY WASHER REMOTE CONTROL HANDLE SEAT ADJUSTER ASSEMBLY LH BOLT FRONT SEAT REMOTE CONTROL HANDLE WASHER REMOTE CONTROL HANDLE SECTION Fig 8 4 BUCKET SEAT ADJUSTER ASSEMBLY SEATS 8 6 REMOTE CONTROL FRONT SEAT ADJUSTER Models Removal 1 Remove front seat refer Page 8 2 and place face down on a clean protected surface Remove bolt securing remote control handle to seat cushion frame see Section A A Fig 8 3 3 Depress end of locking wires attached to remote control slide spring retainer over end and disengage wires from remote control see Fig 8 3 4 On bench type seats remove screw attached seat adjuster lever support and on all front seats remove control assembly Installation Reverse removal operations RECLINER ARM ASSEMBLY Models Coupe Statesman De Ville and Optional on other Models Removal l Position bucket seat fully forward to allow access to outer recliner am assembly to seat
140. n underbody alignment check place vehicle on a level surface with the weight of the body supported at wheel locations NVWSALVLS Ld30X3 NYGAS S13qQoW SNOISN3WIG UNDERBODY 2 2 NVQ3S NOLLVLS 13409 r SNOISNAWIG 2 020914 UNDERBODY 3 48 NVWSALVLS 13409 SNOISN3WIG 20914 UNDERBODY 2 4 UNDERBODY 9 48 9203 FASTENER S z ATTACH WITH Pvc ADHESIVE SECTION SECTION teni 5 81400 ONL Y SECTION SECTION Pi 2 TRIM PANEL SHROUD LOWER 7277 222 PA FEC CARPET MUST FIT TUNNEL NEATLY T SEAL WITH CAULKING s SKA COMPOUND vH oae RETAIN FLOOR COVERING UNDER TRIM FASTENER FRONT FLOOR COVERING REAR FLOOR COVERING TO FIT UNDER FRONT FLOOR A COVERING SECTION D D 2 PLACES REAR FLOOR FILLER MAT MODELS FITTED WITH BUCKET SEATS WITHOUT SEPARATOR REAR FLOOR MAT COVERING SECTION MODELS FITTED WITH 4 SPEED FLOOR CONTROL TRANSMISSION FIG 2 4 FLOOR COVERING INSTALLATION COVERING FRONT FLOOR 3 Where fitted remove seat separator or trans mission control console refer page 2 6 Models All 4 Loosen sill plate attaching screws Removal 5 Remove front floor covering 1 Position front seat s fully rearward Installation 2 Remov
141. nd Gate Remote Control MAINTENANCE APPEARANCE To preserve the original paint finish of the vehicle it is essential that it is kept clean by frequent washing Washing not only removes dirt and road grime that settles on the vehicle but also dilutes acids which accompany such grime in particular salt from air or sea spray encountered in coastal areas which often become trapped in crevices Tree sap road tar excretion from insects and industrial fall out often contain harmful chemicals and other foreign matter that may permanently damage the paint finish of the car These should be removed without delay using an effective removal agent GENERAL INFORMATION 1 12 1 Regular Washing If the vehicle is in continuous use it should be washed at least once a week with either cold or warm water preferably running water using clean chamois leathers sponges or rags free from dirt or grit likely to scratch the paint finish It is good practice to first hose the vehicle to remove as much of the grit and grime as possible before swabbing the surface When hosing it is important to hose under the front fenders rear wheelhouses and along any underbody ledges to remove any dirt or mud which can collect in these areas and can if neg lected cause corrosion Do not wash the vehicle under bright sunlight when high temperatures are being experienced as this will result in a streaky watermarked finish Vinyl Roof Cover T
142. nd without the immediate shattering of the glass The actual shattering of the glass can occur some time after the impact and is due to the effect of the impact onto the stresses of the glass together with variations in temperature Our ex perience is that safety glass shattering from causes other than being struck by an object is remote MINOR GLASS SCRATCHES and ABRASION REMOVAL Description Minor glass scratches and abrasions can be effectively removed or substantially reduced by utilizing a felt padded low speed rotary polisher in accordance with the following procedure and precautions Removal of minor scratches and abrasions from glass is an operation that requires teasonable care When removing minor windshield glass scratches and abrasions double vision must be prevented from developing in areas that will distort the drivers vision Glass distortion is most likely to result when attempting to remove deep scratches Avoid using excessive pressure when using the rotary polisher as this may over heat the glass The polisher must never be held in any one spot for longer than 40 seconds at a time If the glass becomes hot to touch allow the glass to air cool prior to proceeding with the operation Avoid cooling with cold water as this may crack the glass The following equipment is recommended for minor glass and abrasion removal a low speed 600 1300R P M rotary pol isher b A wool felt rotary type polishing p
143. ndow vibration when the window is not fully raised DOOR WINDOW GLASS or LIFTER CHANNEL Models All except Coupe Disassembly l Place window assembly on a clean protected surface SLIDING GLASS LOWER SASH PLATE REAR GLASS LIFTER CHANNEL DOORS 7 1 2 Holding window with concave side uppermo carefully tap off support channel see Secti Fig 7 11 by sliding a smooth head hammer across glass against upper edge support channel CAUTION Ensure that hammer head is smoc and free from burrs so as to preve damage to glass 3 When replacing broken glass prise broke fragments from support channel 4 Remove and discatd support channel fill strip see Section A A Fig 7 11 5 Ensure that support channel inner surfac are clean and free from burrs distortions ei Assembly 1 Apply a thin film of light oil to inner surfac of support channel 2 Position glass on its top edge and place new filler strip evenly over bottom edge glass 3 With open side of lifter cams towards conce side of glass position support channel usi dimensions illustrated in Fig 7 11 4 Using a rubber mallet tap support chann onto glass LOWER SASH PLATE FRONT FIG 7 12 DOOR GLASS ASSEMBLY MODELS COUPE DOORS 7 16 DOOR WINDOW GLASS or SASH PLATE Models Coupe Disassembly 1 Place window assembly face up on a clean protected surtace 2 Using Tool No
144. ndshield centrally in body opening on spacer blocks WARNING Ensure that windshield does not strike 11 12 13 body opening during installation Chip ped edges can cause subsequent break age of windshield Also ensure that windshield is not installed with edges contacting reveal moulding clips Press glass firmly to bed caulking material to dimensions illustrated in View C and F Fig Run a flat bladed screwdriver or spatula around edge of glass ensuring that no gaps in caulking compound exist between rubber seal and edge of glass see View F Fig 9 3 Water test windshield immediately using a moderate water spray If any water leaks are encountered apply additional material to leak area using a flat bladed screwdriver or spatula to work caulking material into leak point to correct leak CAUTION Do not run a heavy stream of water 14 directly on caulking material while the material is still soft Dry off water around edges of windshield then apply VALVOLINE 506 TECTYL rust inhibitor around all flanges of body opening between edge of caulking material and outer edge of moulding clips 15 Install windshield reveal mouldings refer Page 12 1 16 Install windshield wiper rod assemblies refer Page 3 1 17 Install headlining finishing lace refer Page 10 1 18 Install front body pillar garnish panels refer Page 3 1 19 Install internal rear vision mirr
145. ng the stain with a cloth wet with lukewarm water After the spot is dry rub it lightly with a cloth dipped in a volatile cleaner Sweets Sweet stains other than sweets containing chocolate can be removed by rubbing the affected area with a cloth soaked with very hot water If the stain is not completely removed rub the area lightly after drying with a cloth wet with a volatile cleaner Chewing Gum Harden the gum with an ice cube and scrape off with a dull knife If gum cannot be removed completely by this method moisten it with a volatile cleaner and work it from the material with a dull knife while gum is still moist Fruit Stains Liquor Wine Practically all fruit stains can be removed by treat ment with very hot water Wet the stain well by applying hot water to the spot with a clean cloth Scrape all excess pulp if present off the material with a dull knife then rub vigorously with a cloth with very hot water If the stain is very old or deep it may be necessary to pour very hot water directly on the spot following this treatment with scraping and rubbing Direct application of hot water to material is not recommended for general use since discolouration usually results If the above treatments do not remove the stain allow material to dry thoroughly then rub lightly with a clean cloth dipped in a volatile cleaner This is the only further treatment recommended Soap and water are not recommended since th
146. or BACK WINDOW Models Sedan and Coupe Back window removal and electric or air curing methods of installation are similar to those employed for windshield however on Statesman models the application of windshield sealer along lower edge of rear body opening adjacent to front of back panel upper see View F Fig 9 4 is also required WARNING The Solbit Kit available from Bostik Aust and the Silicone Caulking Pack ages available from NASCO which have been referred to in the preceding in structions are the only materials re commended by GMH for windshield and rear window installation REAR QUARTER WINDOW Models Station Sedan Removal 1 Remove rear quarter upper and lower reveal mouldings refer Page 12 1 2 From inside body ease retaining lip of glass retaining channel away from body opening flange using a putty knife or equivalent ADHESIVE 4 CAULKING COMPOUND TR TO BE CLEAN LINE FOR APPEARANCE FIG 9 3 WINDSHIELD INSTALLATION AIR CURING METHOD STATIONARY GLASS 9 8 GLASS PRIMER SOLBIT BEAD METAL PRIMER 814 5 6 ONLY SOLBIT BEAD HORIZONTAL REAR WINDOW OPENING LINE BACK WINDOW 417 WINDSHIELD SEALER FOR WATER LEAK CORRECTION CUT OFF 5 OF ADHESIVE AS SHOWN HORIZONTAL WINDSHIELD SEALER RON REAR WINDOW OPENING LINE 228 MIN 18 maxi
147. or open and window raised remove snib rod knob 2 Remove armrest where fitted disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel water deflector refer Page 7 1 3 On all doors except rear doors disengage lock end of snib rod from lock LOCKING LEVER ANTI RATTLE CLIP FORK BOLT FORK RETURN SPRING BACK PLATE REMOTE LEVER ACTUATING LEVER SPRING INTERMITENT LEVER m FRAME DETENT LEVER ACTUATING LEVER OVERCENTRE SPRING FIG 7 6 FRONT DOOR LOCK 4 On coupe and reat doors remove bolt securing inside locking lever to door inner pane see Figs 7 2 and 7 3 disengage locking lever to door lock connecting rod then remove locking lever Installation Reverse removal operations ensuring that on rear door the bolt securing locking lever to door inner panel is adequately sealed CYLINDER FRONT DOOR LOCK Models Removal 1 With door open and window raised remove snib tod knob 2 Remove armrest where fitted disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel water deflectors refer Page 7 1 3 From inside door disengage spring clip secur ing cylinder to door outer panel see Fig 7 1 or 7 2 TRIP LEVER LOCKING LEVER INTERMITENT LEVER ANTI RATTLE FOR
148. orn stains on trim mat erial fail to respond to the above methods a light application of Delco General Upholstery Cleaner or white spirits with a soft cloth will invariably prove satisfactory NOTE Do not use cleaner ot white spirits ex cessively Cleaning Carpets Thoroughly brush or vacuum the carpet In many instances the carpet may require no further cleaning If the carpet is excessively soiled remove carpet from vehicle thoroughly vacuum it to remove loose dirt then with a foaming type carpet cleaner clean approximately one square foot at a time After each area is cleaned remove as much of the cleaner as possible with a vacuum cleaner Atter clean ing the carpet use an air hose to fluff the carpet pile then dry the carpet After the carpet has completely dried use an air hose to again fluff the pile If oil or grease spots are still present on the carpet they may be removed by using a volatile cleaner Removing Specific Stains from Trim For certain specific stains special treatment is necessary It must be expected particularly where water treatment is specified that discol ouration and material disturbance may occur GENERAL INFORMATION 1 14 Battery Acids Apply ordinary household ammonia with a brush or cloth to the affected area saturating it thoroughly Permit the ammonia to remain on the spot for approx imately one minute to neutralize the acid then rinse the spot by rubbing with
149. oth down any hardened adhesive from panel or covering Installation l Spray or brush on an even coat of vinyl trim adhesive to top of filler panel and to inside of covering 2 Apply covering to panel ensuring that edges of covering fit flush with panel and that covering is wrinkle free 3 Install filler panel refer preceding instructions SILL PLATE Models All Removal 1 Remove screws securing park brake cover to brake lever base 2 Remove screws securing sill plate to rocker panel see Fig 2 6 then remove sill plate NOTE The removal of the front sill plate on sedans and station sedans necessitates the removal of the foremost rear sill plate to rocker panel attaching screw see Section Fig 2 6 Installation Reverse removal operations UNDERBODY 2 9 i DOOR OPENING PINCHWELD FINISH LACE TO BE RETAINED UNDER EACH END 4 OF SILL PLATE FORA FLOOR MATS OR CARPETS TO DISTANCE OF 50 FIT UNDER SILL PLATES SECTION COUPE REAR SILL PLATE FRONT AND REAR DOOR OPENING PINCHWELD FINISHING LACE TO BE RETAINED UNDER EACH END OF SILL PLATES FOR A DISTANCE OF 50 FLOOR MATS OR CARPETS TO FIT UNDER SILL PLATES ERONT SILL PLATE SECTION B B FLOOR MATS OR CARPETS TO FIT UNDER SILL PLATES SEDAN amp STATION SEDAN SECTION FIG 2 6 SILL PLATE INSTALLATION UNDERBODY 2 10 NOTES AND BULLETIN REFERENCES DATE SULEETI
150. ound moulding att aching screw holes prior to installing screws and removing masking tape MOULDING REAR END R or LH Models Premier Sedan amp Monaro LS Removal 1 Using a wide From inside rear compartment remove sealing nut securing outer end of moulding to rear quarter panel To protect paint finish apply masking tape below rear end moulding bladed screwdriver located between moulding and panel carefully prise moulding off retaining clip Installation 13 Locate upper edge of moulding over top of retaining clip then using the hand or a rubber mallet lightly tap moulding into position From inside rear compartment install sealing nut securing outer edge of rear end moulding to rear quarter panel EXTERIOR ORNAMENTATION 12 13 TAIL LAMP REVEAL MOULDING Models Statesman Removal Remove tear lamp refer Vol 5 Electrical Instruments and Gauges Remove screw securing top of moulding to rear lamp recess To protect paint finish apply masking tape adjacent to moulding Using a wide bladed screwdriver positioned between moulding and rear quarter panel care fully prise moulding studs out of spring re tainers Installation 1 Apply sealing compound around moulding screw and stud attaching holes in rear quarter panel Install moulding onto end of rear quarter panel using new spring retainers Install screw into top of mould
151. ove bolts securing fender to fender skirt see View A Fig 11 2 and remove fender Installation Reverse removal operations ensuring that the front fender seal attached to the cowl upper flange seals effectively see Section D D View E Fig 11 1 FRONT END PANEL ASSEMBLY Models All Removal 1 Raise engine hood 2 Disconnect front parking lights 3 Remove front bumper bar assembly refer page 14 1 4 Remove bolts securing front of hood lock sup port assembly to front end panel see View C Fig 11 3 5 Remove bolts securing front end panel assembly to front fender and radiator support panel and remove assembly see View D Fig 11 1 Installation Reverse removal operations ENGINE HOOD Models Removal 1 Raise engine hood and place protective covers over front fenders and upper cowl panel 2 Pencil scribe location of hinge brackets on hood inner panel to facilitate installation 3 With an assistant supporting engine hood remove bolts attaching hood to hinge assemblies and remove hood Installation Reverse removal operations SHEET METAL 11 5 Adjustment Engine Hood When adjusting engine hood it is important that uniform spacing and alignment between hood and related parts be maintained Slots in engine hood hinge brackets to hood inner panel and fender assemblies provide ver tical and horizontal adjustment for rear end of engine hood see View C Fig
152. ove screws securing moulding to front fender or rear quarter panel see Sections W W X X or Z Z Fig 12 2 then remove moulding Installation Reverse removal operations NAMEPLATE FRONT FENDER Models All Removal 1 From within front end of engine compartment remove sealing nuts securing nameplate to front fender outer panel see Fig 12 2 Installation Reverse removal operation NAMEPLATE REAR COMPARTMENT LID AND END GATE Models All except Statesman De Ville Removal 1 To protect paint finish apply masking tape below nameplate to be removed 2 Using a wide bladed screwdriver located be tween nameplate and panel carefully prise nameplate from tubular lock type clips see Pig Installation 1 Apply sealing compound around nameplate attaching studs prior to inserting studs into clips and lightly tapping nameplate into pos ition using the hand or a rubber mallet 2 Remove masking tape NAMEPLATE AND OR EMBLEM REAR COMPARTMENT LID Models Statesman De Ville Removal 1 With rear compartment lid raised and from be tween inner and outer panels of lid remove sealing nut securing one side of emblem or nameplate to lid see Fig 12 2 2 To protect paint finish apply masking tape adjacent to emblem or nameplate to be removed 3 Using a wide bladed screwdriver located be tween emblem or nameplate and panel care fully prise emblem or nameplate from tubular loc
153. p LH side of instrument panel compress top and bottom of upper level air out let and withdraw outlet assembly rearwards from instrument panel see Section C C Fig 2 De 3 From behind instrument panel and under pad on RH side remove screws and nuts securing top and bottom of pad to instrument panel and surround see Fig 3 4 then remove pad assembly INSTRUMENT PANEL PAD END 3 7 WINDSHIELD GARNISH MOULDING MW s INSTRUMENT PANEL Installation Reverse removal operations attaching centre of pad first Adjustment Elongated holes in instrument panel provide hor izontal adjustment for pad assembly FACIA PANEL INSTRUMENT Models All Removal 1 Remove light switch knob control tod refer Volume 5 HQ Electrical Instruments and Gauges 2 Remove cigar lighter from all models except Belmont 3 Remove sctews securing tear edge of facia closing panel to instrument carrier see Fig 3 5 FIG 3 4 INSTRUMENT PANEL PAD amp WINDSHIELD GARNISH MOULDING INSTALLATION 4 Ease out rear edge of instrument facia closing panel then remove screws securing lower edge of facia panel to instrument carrier 5 Pull out ventilator and choke controls and ease base of facia panel down and rearwards dis engaging top edge of facia panel from carrier surround see Section A A Fig 3 5 CONTROL CABLE BODY VENTILATION Models AI
154. panner between hood lock plunger bracket assembly and engine hood see Fig 11 3 loosen lock nut and using a screwdriver turn plunger bolt clockwise to increase tension and anti clockwise to achieve opposite effect 6 When correct adjustment is achieved tighten plunger lock nut BRACKET ASSEMBLY Hood Lock Plunger Models All Removal 1 Raise engine hood 2 Remove screw attached hood lock bracket from engine hood assembly see Fig 11 3 Installation Reverse removal operations observing caution ary paragraph following Engine Hood Adjust ment on page 11 5 CABLE ENGINE HOOD RELEASE Models All Removal 1 Raise engine hood 2 Disconnect front end of engine hood release cable from cable anchor and retaining clips securing cable to lock plate radiator support panel and front fender see Views B C and D Fig 11 3 3 From within vehicle to right of steering column and from below instrument panel withdraw control knob and cable assembly see View Fig 11 3 4 Remove nut securing cable casing to hood release control bracket and withdraw casing Installation Reverse removal operations HINGE ASSEMBLY ENGINE HOOD Models All Removal 1 Raise engine hood and place protective cover over fender on side from which hinge assembly is to be removed 2 Pencil scribe location of hinge brackets on hood inner panel and fender assembly to facilitate installation
155. position glass in body opening on spacer blocks then apply a piece of masking tape over each side edge of glass and adjacent front body pillar Slit tape vertically at edge of glass During installation tape on glass and pillar can be aligned ensuring correct location of glass 5 Place glass on a clean protected surface then water clean and dry inner surface of glass to which the caulking compound is to be applied 6 Remove backing material protecting contact adhesive from foam rubber seal 7 Evenly apply seal 187 inboard of edge of glass see View D Fig 9 3 CAUTION Avoid touching cleaned area of glass to which adhesive caulking material is to be applied If this does occur reclean STATIONARY GLASS 9 6 8 Remove cap and protective end cover from tube of adhesive caulking compound and install nozzle Insert tube into hand operated household type G E N caulking gun available from Dow Coming Aust or their Agencies Apply a 38 high smooth continuous bead of adhesive caulking material to inside surface of glass between seal and edge of glass see View E Fig 9 3 using cut out in end of plastic nozzle against edge of glass to guide application of material IMPORTANT Due to the fast curing characteristics 10 of adhesive caulking material glass install ation should be completed within 15 minutes from start of application of material to glass With the aid of an assistant locate wi
156. r Retainer Assembly Front Door Rear DES TA Rocker Panel Moulding in un e PT Rod Assembly Windshield Wiper esae spears in A wn Sindee 3 15 Read Rect ee 12 8 Roof Interior Lamp mete NA R dm co napaq ioo A 10 3 Ret CO eN E SA 12 9 Reef Side Reveal Moulding Ca Se PME 12 9 ROADS 1 PA CZY s Ed 4 tite 1 NO O O O sess Safety Glass TID 1 16 Safety Switch D Operaren End Gare Window w Regulator SE 6 9 1 Seal Lock Pillar Corner pas ee 4 9 ALPHABETICAL INDEX 16 4 SUBJECT Seat Separator Section Index C sal Sheet Metal po ipla CR C REN ME UNE aa S oc divo asp dit anco to Snib Lock Rod Speciali Stationary Glass Desert yh ROE SEDA BE orm Striker Bolt Assembly Door Lock Striker Rear Compartment Lid 8 8 Switch Assembly Windshield Wiper amp Washer er Control Switch Door Jamb Reveal Meulding eet ete MERE LEER TREE loon x eet wa wawie tiem c pota ce eat MEE Torque Rod End Gate Porque Rods Reat
157. r then remove hinge Installation l Apply plastic sealer on hinge to pillar and hinge to door attaching faces 2 With an assistant supporting door align hinge within pencil scribe marks on pillar and door then install bolts torquing them to 14 17 ft Ibs LOCK ASSEMBLY DOORS Models All Removal l With door open and widow raised remove snib rod knob 2 Remove armrest where fitted disconnect el ectrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel water deflectors refer Page 7 1 3 Remove screws securing lock to rear face of door 4 inside door disengage remote control snib lock knob outside handle and on front doors lock cylinder pawl connecting rods from lock see Fig 7 1 7 2 or 7 3 and remove lock through door inner panel aperture DOORS 7 10 Installation 1 Ensure frictional surfaces of lock are adequate ly lubricated with zinc oxide grease or light oil 2 Apply caulking compound around edge of outer face of lock and around screw attaching holes to effect a water tight seal 3 After installation of lock check operation of all lock connecting rods prior to reversing removal operations NOTE Figs 7 6 and 7 7 identify the various parts which make up the front and rear door locks SNIB LOCK ROD ASSEMBLY Models All Removal 1 With do
158. r quarter window fully lowered remove screws securing weatherstrip assembly to rear quarter outer panel see Fig 4 7 Installation Reverse removal operations FINISHING LACE REAR QUARTER WINDOW Models Coupe Removal On GTS and luxury sports coupes remove rear quarter armrest and on all coupes rear quarter window regulator handle see Fig 4 4 2 Remove rear seat cushion and seat back refer Fig 8 1 3 Remove rear quarter inner trim panel refer Page 4 5 4 Ease rear finishing lace off quarter inner panel see Fig 4 5 9 Installation Reverse removal operations UPPER WEATHERSTRIP AND RETAINER Models Coupe Removal 1 With door open lower rear quarter window on side from which weatherstrip and or retainer is to be removed 2 Ease weatherstrip the front end of which is attached to retainer with neoprene cement out of retainer 3 Remove screws securing weatherstrip retainer to roof side rail then remove retainer 4 Remove or smooth off any hardened sealer from weatherstrip retainer and or roof side rail Installation Apply a continuous bead of plastic sealer between retainer and roof side rail priorto reversing removal operations SEAL LOCK PILLAR UPPER CORNER Models Coupe Removal 1 Remove screw securing leading end of quarter belt moulding to rear quarter outer panel 2 Ease off seal which is attached to lock pillar upper corner with Neopr
159. r test windshield by applying moderate spray of water around edges of windshield gradually working water spray up from bottom of windshield to top NOTE Avoid using a strong jet of water directly onto the edges of windshield 15 If any water leaks are evident they can be corrected by thoroughly drying out and applying windshield sealer to the leak area STATIONARY GLASS 9 5 16 Dry off water around edges of windshield then apply VALVOLINE 506 TECTYL rust inhibitor around all flanges of body opening between edge of Solbit bead and outer edge of moulding clips 17 Install front headlining finishing lace refer Page 10 D 18 Install windshield gamish mouldings refer Page 3 1 19 Install internal rear vision mirror assembly 20 Install windshield reveal mouldings refer Page 12 1 21 Install windshield wiper rod and blade ass emblies refer Page 3 1 Installation AIR CURING METHOD THE CURING OF SILICONE SEALANT IS SLOW AT TEMP ERATURES OF 50 F AND BELOW THEREFORE IT SHOULD NOT BE USED IN COLD CLIMATES WITHOUT PROVISION FOR THIS CONDITION IMMEDIATELY AFTER INSTALLATION l Visually check body opening flange and correct any existing irregularities 2 Prme shaded area of all body opening flanges with the paint finish primer supplied in the Kit see Views A and B Fig 9 3 3 Position two spacer blocks at locations ill ustrated in View C Fig 9 3 4 Centrally
160. r to reversing removal operations EXTERIOR ORNAMENTATION 12 9 QUARTER BELT MOULDING Models Coupe Removal 1 With door open remove screw securing lower end of moulding to body lock pillar see Sec M M Fig 12 1 2 To protect paint finish apply masking below moulding to be removed 3 Using a wide bladed screwdriver carefully ptise moulding off retaining clips Installation 1 Engage upper edge of quarter belt moulding over top of retaining clips 2 Using the hand or a rubber mallet lightly tap moulding into position 3 Apply sealing compound around moulding att aching screw hole prior to installing screw and removing masking tape BELT MOULDINGS FRONT amp REAR DOORS Models All except Belmont Removal 1 To protect paint finish apply masking tape below moulding to be removed 2 With door open remove screws securing rear end of front door belt moulding to door see Section L L or Fig 12 1 3 On rear door remove screws securing front and rear ends of belt moulding to door see Sections L L and N N Fig 12 1 4 Using a wide bladed screwdriver carefully prise moulding off retaining clips See Section J J or K K Fig 12 1 Installation l Locate upper edge of moulding over top of retaining clips then using the hand or a rubber mallet lightly tap moulding into position EXTERIOR ORNAMENTATION 12 10 2 Apply sealing co
161. rol cable knob situated below the RH side of the instrument panel controls the concealed hood lock release catch see view A Fig 11 3 The engine hood when released from the locked position engages on a secondary safety catch To open the hood following its release from the locked position insert the fingers beneath leading edge of engine hood then press upwards on the catch SHEET METAL 11 2 ENGINE HOOD HINGE ASSEMBLY HOOD SPRING HINGE ROCKER INNER PANEL section FRONT FENDER section BOLT FRONT END SHEET METAL TO FRAME M n de PANEL ASSEMBLY RADIATOR SUPPORT BUMPER ENGINE HOOD BOLT HOOD ADJUSTING SS LOCK NUT 4 FRAME ASSEMBLY FLAT WASHER section B B NUT FRONT END SHEET METAL TO FRAME _ ATTACH WITH NEOPRENE GEMENT FRONT END section D D Fig 11 1 SHEET METAL INSTALLATION SHEET METAL 11 3 With the engine hood and front bumper bar removed and the engine hood release cable and head and parking lights disconnected the front fender and skirt panel radiator support and front end panel assemblies can be removed from the vehicle as one assembly see views A B amp D Fig 11 1 During assembly a 020 shim is installed between upper flange of front end partial frame and body mount upper see Section B B View B Fig 11 1 Horizontal adjustment of the front end sheet metal
162. rs see Figs 8 3 and 8 4 An additional one inch rearward adjustment can be obtained by repositioning the seat adjuster to floor attaching bolts in the forward set of attaching holes in the seat adjusters see View A Fig 8 3 The rear seat cushion on all models is screwed to the rear floor crossbar through brackets attached to the lower section of the rear seat cushion frame see View D Fig 8 6 On sedans and coupes the upper section of the rear seat back frame is hooked over hanger brackets attached to the rear compartment front panel see View A Fig 8 6 The outer lower section of the sedan and coupe seat back frame is secured to the rear wheelhouses with clinch over tabs On coupes these tabs are screwed to the rear wheelhouses see View C Fig 8 6 View B Fig 8 6 illustrates the method of attaching the inner lower ends of the seat back on sedans and coupes On sedans the bend over tabs are screwed to the rear compartment front panel see Section Fig The rear seat back on station sedans is hinged at the tear wheelhouse and is retained in the upright position by remote control plungers engaging in rear seat back stop brackets see Section Fig 8 7 SEATS 8 2 PAD END COVER A SEAT BACK PAD ASSEMBLY SEAT BACK COVER ASSEMBLY ASHTRAY ASHTRAY hg CUSHION COVER ASSEMBLY VIEW ADJUSTER LEVER CUSHION PAD ASSEMBLY UPPER CUSHION PA
163. s Removal 1 With end gate lowered remove screw securing tear end of moulding to end gate body pillar 2 To protect paint finish apply masking tape below moulding to be removed 3 Using a wide bladed screwdriver carefully ptise moulding off retaining clips installation 1 Locate upper edge of moulding over top of retaining clips then using the hand or a rubber mallet lightly tap moulding into position 2 Apply sealing compound around moulding att aching screw hole prior to installing screw and removing masking tape END GATE GLASS OPENING MOULDING Models Station Sedan Removal 1 From inside body remove screws securing moulding to end gate body pillar and remove moulding see Section D D Fig 12 1 Installation Apply sealing compound around moulding attaching screw holes prior to reversing removal operations END GATE OUTER amp CENTRE BELT MOULDING Models Station Sedan Removal 1 With end gate open remove screws securing outer end gate mouldings to end gate then remove outer mouldings 2 To protect paint finish apply masking tape below centre moulding 3 Using a wide bladed screwdriver carefully ptise centre moulding off retaining clips see Section T T Fig 12 2 Installation l Locate upper edge of centre moulding over top of retaining clips then using the hand or a rubber mallet lightly tap moulding into position 2 Locate outer mouldings under ends of centre
164. s between outer edge of lamp lens and base pulling lens away from base b Remove lamp and on dome lamp base straighten roof support tangs securing base to roof support see View A Fig 10 1 On rear quarter interior lamps remove screws securing lamp base to rear quarter inner panel upper see Views B and F Fig 10 1 d Disengage lamp holders from lamp base see Views C D amp E Fig 10 1 then remove base 2 Remove sun visors and interior rear vision mirror coat hooks and body pilar gamish panels 3 Remove front and rear headlining retainer finishing lace see Views A and F Figs 10 2 to 10 4 inclusive 4 Remove teat seat cushion back and teat parcel shelf refer pages 8 1 and 4 1 S Remove finishing lace protecting side edges of headlining see Section Figs 10 2 to 10 4 inclusive 6 Carefully ease off outer edges of headlining cemented to roof side rails and front and rear headlining retainers 7 Disconnect ends of Nos 1 2 5 and 4 listing wires from roof side rails 8 Ease back tabs securing No 3 listing wite to roof support see View D Figs 10 2 to 10 4 inclusive disengage ends of listing wire then temove headlining assembly 9 Clean or smooth off any hardened cement from roof side rails and front and rear headlining retainers Installation 1 If the listing wires have been removed or if a new headlining is to be installed install l
165. s of unit DISASSEMBLY AND ASSEMBLY means to 8 SEATS completely dismantle and put together a unit or parts of a unit after it has been removed from the vehicle 9 STATIONARY GLASS REPLACE means the substitution of a new part for a defective part 10 ROOF All information illustrations and specifications con tained in this manual are based on the latest product information available at the time of publication ap 11 SHEET METAL proval The right is reserved to make changes at any time without notice 12 EXTERIOR ORNAMENTATION Companion Volumes SUSPENSION BRAKES STEERING WHEELS Part No M 37016 TRANSMISSIONS AND 14 BUMPERS REAR AXLES Part No M 37017 ENGINE AND GENERAL INFORMATION Part No M 37018 3 SPECIA TOOLS ELECTRICAL AND ATR CONDITIONING Part No M 37019 16 ALPHABETICAL INDEX 5 REAR COMPARTMENT 13 RADIATOR GRILLE UR GENERAL MOTORS HOLDEN S SALES PTY LTD SERVICE DEPARTMENT PART No M 37015 COPYRIGHT GENERAL MOTORS HOLDEN S SALES PTY LTD REPRODUCTION IN WHOLE OR IN PART PROHIBITED WITHOUT WRITTEN APPROVAL GENERAL INFORMATION 1 2 SECTION 1 INDEX Subject nfroduction 2 lt TT ORR Section Index 2 2 Manual Description eM Model Identification sse Body Identification sent Basic Body Construction Body Shell Parts Repla
166. screw securing rear end of sill plate to rocker panel then remove finishing lace from leading edge of rear quarter panel see Fig 4 5 4 Remove plastic sleeve covering seat belt att aching bolt then remove bolt and associated parts 5 Carefully ease off leading edge of trim panel whichis attached tp leading edge of rear quarter panel with adhesive cement 6 Remove screws securing tear lower and upper end of trim panel to rear quarter inner panel 7 Using a wide bladed screwdriver positioned between leading edge of trim and rear quarter inner panels carefully prise trim panel clips from inner panel see Fig 4 5 NOTE On models fitted with the electric window regulator disconnect switch from back of rear quarter trim panel 8 Partly raising lower end of trim panel inboard push trim panel up off quarter inner panel retaining brackets removing trim panel Installation Reverse removal operations ARMREST REAR QUARTER Models All Coupes except 803 437 Removal l Remove screws installed through lower section of armrest which secure armrest to rear quarter inner panel removing armrest nstallation Apply caulking compound around armrest to tear quarter inner panel attaching screw holes prior to reversing removal operations TRIM REAR SEAT PARCEL SHELF Models Sedan and Coupe Removal 1 Remove rear seat cushion and seat back refer Page 8 1 2 With rear compartment H
167. ssibility of a bulls eye remove the scratch or abrasion as illustrated in Fig 1 6 7 Clean off compound and remove protective covering FEATHERING OUT MOTION GUIDELINES HOLD PAD FLAT AGAINST GLASS FIG 1 6 MIRROR GLASS SCRATCH REMOVAL NOTES AND BULLETIN REFERENCES ION 1 18 ENERAL INFORMAT 2 ig a a4 2 m u lt O sS UNDERBODY 2 1 SECTION 2 INDEX Subject Page Underbody Alignment 2 1 Covering Front Floor 2 5 Covering Rear Floor 2 6 Seat TNR 2 6 Console Transmission Control 2 6 Tonneau Floor Front sass 2 6 Covering Tonneau Floor Front or Rear 2 7 Covering Tonneau Floor Side Sill 2 8 we 1e 2 8 Covering Filler Panel 2 8 22202112 2 8 UNDERBODY ALIGNMENT Correct underbody alignment is essential as any misalignment of the underbody can affect suspension fitment of doors engine hood rear compartment lid or end gate The underbody should therefore be aligned to within 1 16 in of dimensions specified in Figs 2 1 2 2 and 2 3 These dimensions should be accurately checked with a tram gauge consisting of a parallel bar or rod fitted with two adjustable trammels capable of gauging all underbody dimensions specified In preparing a
168. t back attaching bolts see View B Fig 8 7 2 Coupes remove quarter armrest where Remove seat back from body and place on a fitted clean protected surface 3 Lift rear seat cushion from body and place on a clean protected surface Remove screws securing seat cushion frame 4 Unclinch retainers and remove screws securing brackets to rear floor crossbar see View C seat back to rear wheelhouse and rear com Fig 8 7 prem front panels see ViewsB and C ig 8 6 Lift rear seat cushion from body and place on 5 Lift seat back off hanger brackets attached to a clean protected surface teat compartment front panel see View A Fig 8 6 remove from body and place on a clean protected surface Installation Reverse removal operations ensuring that sealing instructions illustrated in Section and Fig 8 6 are observed Installation 1 Apply caulking compound around seat back hinge attaching holes in wheelhouse see Section Fig 8 7 prior to reversing removal operations cnc SEATS 8 4 FRONT SEAT ADJUSTER Models Description The front seat adjuster see Figs 8 3 and 8 4 comprises a right and left hand channel assembly each incorporating ball rollers and rack engaging spring loaded lock bars The seat adjuster control lever located adjacent to the outer seat adjuster at front of seat RH side only on bench seat govern a temote control Auxili
169. ter panel see Section 0 0 Fig 12 2 4 To protect paint finish apply masking tape below moulding 5 Using a wide bladed screwdriver located be tween moulding and panel carefully prise mould ing off retaining clips see Section P P Fig 12 2 Installation l Locate upper edge of moulding over top of retaining clips and using the hand or a rubber mallet lightly tap moulding into position 2 On Statesman models apply caulking compound around screw attaching hole at rear end of moulding prior to installing screw and lower reveal moulding EXTERIOR ORNAMENTATION 12 14 3 On other models and from inside rear compart ment install sealing nut securing rear end of moulding onto reat quarter panel REAR QUARTER SIDE UPPER amp LOWER REVEAL MOULDINGS Models Station Sedan Removal 1 Insert moulding removal tool No 1A6 between moulding and rubber weatherstrip until point of tool engages with one of the retaining clips then using the tool in a rocking motion see Fig 12 9 progressively disengage moulding from clips see Section U U Fig 12 2 Installation 1 Locate moulding over retaining clips and lightly tap moulding into position using the hand or a rubber mallet FIG 12 9 REAR QUARTER SIDE REVEAL MOULDING REMOVAL EXTERIOR ORNAMENTATION 12 12 MOULDING QUARTER Models Premier Station Sedan amp Optional on other Station Sedan
170. the stain 2 The effect of the stain removal agent upon the colour structure and general appearance of the trim material It is essential that stains be removed from trim material as soon as possible after they have been made If they are allowed to remain on the material indefinitely they can become oxidised and removal is difficult if not impossible Description and Cleaning Methods In general vinyl material is used for seating head lining and auxiliary trimming The grades of vinyl used vary with the particular wear required of them The seat insert on some production options are man ufactured with synthetic nylon rayon fibres CAUTION When cleaning such fabrics do not use a whisk brush since damage to the fine threads may result Care of P V C material is a relatively simple but important matter The surface should be wiped over occasionally with a dry cloth and if dirt should accumulate the following cleaning instructions should be used 1 Using lukewarm water and neutral soap work up a soap lather on a piece of cheese cloth and apply to the material A soft bristled brush may be used to advantage to remove stubborn stains or dirt embedded in the grain of the material 2 The operation should be repeated using only a damp cloth and no soap 3 The trim should then be wiped dry with a soft cloth The above cleaning instructions also apply to the rubber floor covering IMPORTANT Where stubb
171. then reverse removal oper Reverse disassembly operations ations HOUSING J RETAINING CLIP PAWL FIG 7 8 SCALP SPRING CYLINDER FRONT DOOR LOCK DOORS 7 12 STRIKER BOLT ASSEMBLY DOOR LOCK Models All Removal 1 Pencil scribe position of lock striker bolt assembly on body lock pillar to facilitate in stallation 2 Using a 5 16 Allen key in tool recess in head of striker boit remove striker bolt assembly and spacer see Fig 7 9 Installation Reverse removal operations IMPORTANT Whenever a door has been replaced or realigned do not completely close door until a visual check is made to determine if lock fork bolt will correctly engage striker Adjustment To adjust striker horizontally or vertically loosen striker bolt and position striker assembly in the desired location Forward or rearward adjustment of striker is achieved by addition or deletion of spacers between strker bolt assembly and lock pillar as required SPACER LOCK STRIKER BOLT ASSY FIG 7 9 DOOR LOCK STRIKER BOLT INSTALLATION REGULATOR DOOR WINDOW Models Removal 1 With door open and window supported in the raised position remove snib rod knob 2 Remove armrest where fitted and disconnect electrically operated window regulator switch where fitted remove door interior handles inner trim panel and door inner panel water deflector refer Page
172. this operation on LH side of roof Using a strip of plastic 8 x 2 x 1 8 with rounded edges and comers rub along stitched seams of cover This operation increases adhesion of cover to roof and also tightens up cover Use this plastic tool when inserting cover into drip gutter see Section C C Figs 10 9 and 10 10 Lift roof cover off RH rear quarter panel upper then apply an even coat of Nitrile adhesive cement to this area Carefully smooth out cover over rear quarter panel upper ensuring that any air pockets or wrinkles in the cover are smoothed out Notch cover at upper corners of back window to dimensions illustrated in View D Figs 10 9 and 10 10 Cut and remove fold at end of stitched seams above windshield and back window see View A Figs 10 9 and 10 10 ROOF 10 13 14 Carefully trim cover along top of windshield back window and around rear quarter panel upper see Sections A A B B D D and Figs 10 9 and 10 10 15 Ensure that all edges of cover are com pletely adhered to roof panel 5 16 Prior to installation of roof panel cover retainers see Section C C Figs 10 9 and 10 10 spread walls of retainers to ensure a tight fit 1 NOTE Two pairs of adjustable vice grip clamps and a metal bar x 3 8 x 3 16 are required to insert the retainers 17 Locate retainer in rear of roof drip gutter 20 place metal bar inside retain
173. used and for your guidance we list locarions and recommended lubricants WARNING Careless or excessive application of body lubricants can result in staining of paint finish or damage to clothing Use lubricants sparingly and remove accidental application from paint finish immediately Parts Readily Accessible Where practicable use Zinc Oxide Grease other wise use light oil Engine Hood Catch Engine Hood Lock Engine Hood Hinge Door Hinge and Hold open Clips Instrument Compartment Lid Hinge Rear Compartment Lid Hinge Rear Compartment Lid Lock Mechanism Rear Seat Hinges Station Sedan Floor Filler Panel Hinge Station Sedan End Gate Hinge Assembly End Gate Locking Mechanism Lower End Gate Limit Arm Plenum Chamber Control USE NASCO SOLIDOIL Door Lock Striker Bolt Door Lock Fork Bolt Instrument Compartment Lid Lock Tongue Parts Readily Accessible Apply Powdered Graphite through Key Aperture do not oil Ignition Lock Cylinder Rear Compartment Lid Lock Cylinder Door Lock Cylinder Instrument Panel Compartment Lock Cylinder End Gate Lock Cylinder End Gate Lock and Switch Assembly Parts Concealed Necessitating Disassembly Where practicable use Zinc Oxide Grease other wise use light oil Door Window Regulator Door Window Glass and Cams Door Lock Mechanism Door Lock Remote Control Rear Quarter Window Guides and Cams Front Seat Adjuster End Gate Regulator E
174. usting bracket to lower section of quarter window guide assembly see Section A A Fig 4 1 8 Loosen lock nuts locking quarter window guide assembly upper adjusting studs to quarter inner panel 9 Turn these studs in an anti clockwise direction to allow window to be positioned for removal through window aperture 10 Raise and remove window assembly out through window aperture and place on clean protected surface REAR QUARTER 4 4 Installation Reverse removal operations Adjustment Forwatd rearward or in and out adjustment of the reat quarter window is provided by a slotted bracket attached to the lower section of the guide assembly and a slotted hole in the quarter inner panel see Section Fig 4 1 Similar adjustment of the upper section of the guide assembly is provided by adjusting studs mounted in the guide assembly and secured through slotted holes in the quarter inner panel with lock nuts see Fig 4 1 FlG 4 2 REAR QUARTER WINDOW ASSEMBLY CHANNEL QUARTER WINDOW FRONT SASH GLASS QUARTER WINDOW WEATHERSTRIP QUARTER WINDOW FRONT FILLER QUARTER WINDOW LOWER SASH PLATE PLATE QUARTER WINDOW LOWER SASH NUT QUARTER WINDOW GUIDE ROLLER TEE BUSHING QUARTER WINDOW GUIDE ROLLER PIN QUARTER WINDOW GUIDE UPPER FRT ROLLER SPRING QUARTER WINDOW GUIDE ROLLER TENSION WASHER QUARTER WINDOW GUIDE LOWER R
175. val Tool No 21812X between base of handle and bearing plate and in line with arm of handle disengaging horse shoe shaped retaining spring as illustrated in Fig 7 14 Installation 1 Locate retaining spring in handle with open ends of spring facing arm of handle pressing spring into the engaged position 2 Place handle bearing plate onto remote control splines with raised face towards door 3 Press handle onto remote control splines until horse shoe retaining spring engages in groove at base of remote control splines ensuring that handle is located symetrically with handle on opposite door i e end of handle pointing forward in a horizontal plane RETAINING SPRING DISENGAGED TOOL No 21812X 7 1 1 i 1 4 PUSH TOOL IN DIRECTION OF ARROW INSIDE HANDLE FIG 7 14 DOOR INTERIOR HANDLE REMOVAL DOORS 7 HANDLE DOOR INTERIOR WEATHERSTRIP ASSEMBLY DOOR Front Door Models All except Belmont Models All except Coupe Rear Door Models Premier and Statesman Removal Sedan Removal 1 Remove armrest and screw securing door inter ior handle to remote control assembly see Figs 7 1 7 2 or 7 3 Installation Reverse removal operations ensuring that handle is positioned in a horizontal plane in line with top of armrest HANDLE DOOR EXTERIOR Models All Removal 1 With door open and window raised
176. w Install rear quarter upper and lower reveal mouldings refer Page 12 1 TON S REAR QUARTER WINDOW INSTALLATION MODEL STATION SEDAN STATIONARY GLASS 9 10 NOTES AND BULLETIN REFERENCES SUBJECT BULLET NO SECTION 10 INDEX Subject Page Headlining Description 10 1 Headlining Assembly Sedan amp Coupe 10 2 Roof Interior Lamp Installation 10 3 Headlining Assembly Station Sedan 10 8 Vinyl Roof Cover o eee 10 10 HEADLINING Description The roof headlining which follows the contour of the roof is supported in its curved shape with transverse listing wires These wires are located in holes spaced atregular intervals along the roof side rails see Figs 10 2 10 3 10 4 and 10 8 These listing wires are inserted through a series of stitched listing pockets the stitch lines of which are visible across the headlining The edges of the headlining are cemented to the front and on all except Station Sedans the rear headlining retainers and roof 514 rails The finishing lace attached to the front and rear headlining retainers and door openings assist in retaining and protecting the headlining NOTE Clean hands are essential when handling body interior trim ROOF 10 2 HEADLINING ASSEMBLY Models Sedans and Coupes Removal 1 Disconnect battery ground cable and remove interior lamp s see Fig 10 1 by a Placing finger

document in original format

Contents

Download Pdf Manuals

Related Search

Related Contents