Procedures

Tailgate Components, Changing

Removing/fitting the tailgate insulation







- Remove the cover panel from the tailgate.
- Remove the self-tapping screws (2x) from the handle.
- Pull the panel free of the clips.
- Check the clip attachments.

Changing the high-mounted brake light







- Turn the locking pins on both sides 90 degree.
- Remove the cover.
- Unplug the connector.
- Remove the two self-tapping screws.
- Refit in reverse order.

Changing the tailgate lock mechanism







- Remove the panel from the tailgate, see (BCA 1)
- Remove the rear light unit, see (BCA6).
- Uncouple the lock's link rod by the lock.
- Undo the three lock retaining screws and remove the lock.
- Remove the connectors.
- Refit in reverse order.
- Move the link rod over and adjust it. Pull the rod back and press on the retaining clip.
- Tighten the bolts. Tightening torque 10 Nm.

Removing/fitting the tailgate lock cylinder







- Remove the tailgate cover panel, see (BCA1).
- Remove the rear light unit, see (BCA6)
- Remove the central locking control rod.
- Remove the pull rod from the lock.
- Press out the lock cylinder and holder, and remove by twisting.
- Refit in reverse order.
- Check the rubber seal.

NOTE: When adjusting the pull rod, press the lock cylinder as far as it will go to the right.

Changing the gas spring







- Open the tailgate and support it.
- Raise the catch slightly and pull the gas spring from the hall joint (2x).
- Refit in reverse order.
- Grease the ball joints.

NOTE: When changing the gas spring, the gas should be released from the old spring.

- Drill a 4 mm hole as illustrated.

WARNING: Use protective goggles when drilling.

Model year 1996 - 1999, see (BCA 6-65).
Model year 2000-, see (BCA66-68).

Model year 1996-1999

Changing the rear light unit







- Remove the cover panel, see (BCA1)
- Unplug the white connector.
- Remove the 10 nuts.
- Carefully press the unit out of the tailgate.

Fitting the rear light unit

- Check the rubber seal.
- Clean the rear light unit and the tailgate.
- Fit the rear light unit and tighten the bolts (10) finger tight.

Hint: Check and fit the rubber seal when fitting the rear light unit.

- Tighten the bolts to 7.5 Nm. Start in the center.
- Plug in the white connector.
- Check the function of the rear lights.
- Fit the rear panel.

Model year 2000

Changing the rear light unit







- Remove the cover panel, see (BCA1).
- Unplug the white connector.
- Remove the 8 nuts.
- Press the clip (A) together.
- Carefully press the unit out of the tailgate.

Fitting the rear light unit

- Check the rubber seal.
- Clean the rear light unit and the tailgate.
- Fit the rear light unit and tighten the bolts (8) finger tight.
- Check that the clip (A) has engaged.

Hint: Check and fit the rubber seal when fitting the rear light unit.

- Tighten the bolts to 7.5 Nm. Start in the center.
- Plug in the white connector.
- Check the function of the rear lights
- Fit the rear panel.

Changing the fuel filler flap







- Remove the two bolts.
- Loosely tighten the two bolts, position the fuel filler flap and tighten. Tightening torque: 8 Nm.