Rear LId - Gas Filled Struts

GROUP: 55
NUMBER: 91-04
DATE: June 30, 1991

SUBJECT:
Rear Lid Gas-filled Struts - Retrofit Installation

MODEL(S):
100/200/Quattro 1989-1991 M.Y.

V8 Quattro 1990 M.Y.

CONDITION:




Rear lid tension springs have become weak, and will not hold trunk open even when set into last adjustment hole (arrow)

PRODUCTION:

100/200/Quattro - no change

V8 - tension springs replaced with gas filled struts,

As of: July 1990 VIN 4C-MN000318

SERVICE:

Replace original rear lid tension springs with gas filled struts.

Note
Zone/DSM approval is required before performing this repair.

CAUTION
Part numbers are for reference only. Always check with your Parts Department for latest information.




Parts required

^ raise and support rear lid in fully open position
^ remove both tension springs




^ remove molded carpet trunk liner from each side




^ remove plastic bushing from hinge plate (arrow)




^ install ball pin 3, flat washer 1, and self locking nut 2 to hinge plate




^ snap gas filled struts (wide side) onto ball pin

^ with trunk lid open, place strut on edge of wheel housing, as shown




^ mark location of strut mounting hole on edge of wheel housing (arrow A)

CAUTION
Use care when drilling into wheel housing edge. A wire harness is mounted onto the opposite side.

CAUTION
Deburr and touch-up edge of hole drilled in wheel housing with anti-corrosion primer as required.

^ drill 8 mm (5/16 in.) hole in wheel housing edge
^ install ball pin, with self locking nut and washer (inset B)
^ repeat procedure on opposite side




^ install strut (arrow)
^ check operation of lid and struts

Note
Allow enough slack in left rear wiring harness to prevent interference with struts.

^ loosely reinstall molded trunk liner




^ mark and cut out small opening in trunk liner for strut mounting (arrow)

^ just sufficient to clear strut mounting
^ pull off strut at hinge plate
^ slide liner over strut and reinstall
^ reconnect strut to hinge plate
^ repeat procedure on opposite side
^ check for free movement of strut at trunk liner


Gas-filled Diag. Quality
struts, installing Check Repair Check

Labor Op.
5564310 - 110 T.U. -