Tailgate Replacement

Tailgate

Replacing the tailgate
- After spraying, rust-proof the new tailgate
- Transfer all shock absorbers and covers.

Note! All components must be removed from the tailgate while in position.

- Ensure that the components and wiring are installed in such a way that they do not rattle
- Install the cable harness using a piece of string.

Removing entire tailgate




- Partially remove the headlining at the rear
- Pull the cable harness out of the tailgate. (Leave it secured in the roof)
- Disconnect the washer hose. See the Service Manual, Group 3.

Note! Two people are required to lift out the tailgate.

- Remove the screws on both tailgate hinges
- Remove the spacers from the tailgate
- Remove the screws. Remove the tailgate.

Installing the tailgate
- Install in reverse order
- Lubricate the ball joints
- Install the sheath for the cable harness.

Adjusting the tailgate




The tailgate must be adjusted at the top so that there is 0.5-2.0 mm below the edge of the roof. This distance must be the same along the width of the tailgate.
The gap between the panels must be 6.0±0.5 mm parallel to the edge of the roof (1).
The bottom of the tailgate must be parallel to the car body (2).

Note! Twist in the rubber stops (3) on the underneath before making adjustments.





Adjusting the upper section of the tailgate
The upper section of the tailgate can be adjusted in two ways.
(A): Adjustment to the sides, centered with the opening of the tailgate. Adjustment of the depth against the edge of the roof.
The gap between the panels must be 6.0±0.5 mm along the entire width of the tailgate.
Slacken off the screws securing the hinges at the tailgate on both sides. Adjust the tailgate. Tighten the screws. Tighten to 24 Nm.
(B): Height adjustment, 0.5-2.0 mm below the edge of the roof and the gap.
Adjust the height as follows. Install spacers between the hinges and the tailgate. The distance between the left and right-hand sides must not exceed 0.5 mm. Remove the 2 x screws securing the hinges at the tailgate. Install the spacers.
Install the screws. Adjust the tailgate and hinges. Tighten the screws. Tighten to 24 Nm.

Caution! The hinge on the body must not be adjusted because of the seal.





Adjusting the lower section of the tailgate
The lower section of the tailgate can be adjusted in two ways.
(1): Adjusting the lock downwards.
Close the tailgate. Adjust the lock and striker plate so that the tailgate can close without any gaps.
Unscrew the screws. Adjust the striker plate/lock.
Tighten the screws for the lock. Tighten to 24 Nm.
Tighten the screws for the striker plate. Tighten to 10 Nm.
If the lock or striker plate cannot be adjusted due to excessive height, adjust the hinge at the top.

Note! If the tailgate is too low, the rubber stops can be used. See below.




(2): Adjusting the bottom edge using the rubber stops.

Note! First adjust the lock.

Turn the rubber stops outwards to correct the position of the tailgate against the car body (A) when the tailgate is closed. Use a sheet of paper as a guide. Turn the rubber stops ¾ turn outwards (1).
If the tailgate is too low in relation to the car body, turn the rubber stops as far out as possible.