Eliminating Symptoms on Body Exterior - Reworking Rear Lid

Eliminating Symptoms On Body Exterior - Reworking Rear Lid

Technical values







General information

Symptoms

Strong closing force on rear lid.

Causes and remedial action

Incorrect adjustments at the rear lid may result in a strong closing force when closing the rear lid.

In the event of a complaint, the following remedial actions must be carried out to remedy the situation on vehicles manufactured before the date of introduction October 2006:

Remedial action 1: Replace rubber stop for the rear lid on the left and right.

Remedial action 2: Replace buffer in upper part of rear lid lock.

Remedial action 3: Adjust guide wedge stop at the left and right on the rear lid.







Tools and materials

955.512.681.01 Rubber stop
000.043.206.91 Buffer
Sliding compound (e.g. tire mounting paste)
White washable marker

Reworking rear lid

1. Open the rear lid.
2. Remedial action 1: Replace rubber stop for the rear lid on the left and right.







2.1. Pull the old rubber stop -1- first to the right and then backwards -arrows- out of the slot in the rear apron -2-.
2.2. On the new rubber stop -1- coat the assembly pin -2- with sliding compound (e.g. tire mounting paste).







2.3. Press the new rubber stop -1- forward into the slot in the rear apron -arrow A-.







2.4. Insert a T20 Torx wrench into the opening on the rubber stop -1- and align the assembly pin on the rubber stop -2- so that it is the same height as the bore in the slot -3-.

INFORMATION: Do not exert any great pressure on the assembly pins with the Torx wrench because this can damage the pins.

2.5. Use a Torx wrench to guide the assembly pin and press the rubber stop -1- onto the rear apron with your thumb -arrow B- until the assembly pin engages in the bore in the slot.

INFORMATION: If the rubber lip -1- on the rubber stop is still protruding from the rear apron as shown in the figure -top-, press the rubber stop into the cutout in the rear apron at this position using a small screwdriver as shown in the figure -bottom- (-arrow A and arrow B-).







2.6. Press the rubber stop -1- firmly onto the rear apron again with your thumb -arrow C- so that the rubber lip fits snugly against the rear apron all the way around as shown in the illustration.







3. Remedial action 2: Replace buffer in upper part of rear lid lock.







3.1. Use a screwdriver to lever the lock cover -1- out of the rear lid lining -2- as shown in the illustration.
3.2. Remove housing on upper part of lid lock -1-.

INFORMATION: The illustrations below show the upper part of the rear lid lock as viewed "while standing under the open rear lid, looking away from the direction of travel".







3.2.1. Lever the housing out of the locking lugs -2, 3- on the upper part of the lid lock. To do this, lift up the housing at the locking lugs -2, 3- using a small screwdriver -arrow A-. At the same time, pull the housing out slightly at the rear right locking lugs -arrow B- and press it forward away from the locking lugs -arrow C-.
3.2.2. Hold the housing in both hands. Pull the housing out slightly at the rear locking lugs -arrow B- and pull it down off the upper part of the lid lock at the same time -arrow C-.

3.3. Replace buffer in upper part of lid lock.







3.3.1. Use a small screwdriver to pry the old buffer -1- up out of the guide -2- and out of the locking lugs -3- on the upper part of the lid lock -arrow A-.
3.3.2. Pull buffer forward out of the upper part of the lid lock -arrow B-.
3.3.3. Insert new buffer with the assembly pin -1- into the opening -2- on the upper part of the lid lock -arrow A-.







3.3.4. Then press the buffer down into the guide -3- and into the lugs -4- as far as it will go -arrow B-.

3.4. Fit housing on upper part of lid lock.







3.4.1. Slide the housing -1- onto the upper part of the lid lock -arrow A-.
3.4.2. Engage the housing -1- securely in the locking lugs -2- on the upper part of the lid lock. The locking lug on the new buffer must be inserted in the cut-out on the housing -3-.







3.5. Clip lock cover -1- into the rear lid lining -2- (-arrow-).







4. Remedial action 3: Adjust guide wedge stop at the left and right on the rear lid.







4.1. Clean the area at the left and right of the stop -1- and guide wedge -2- on the rear lid -arrow A and arrow B- with a grease- and lint-free cloth.
4.2. Mark the current position of the stop -1- in the guide wedge -2-. To do this, use a white, washable marker to mark the guide wedge and the stop approx. 10 mm from the lower edge of the guide wedge. Mark the guide wedge on the left and right -arrow A and arrow B-.







4.3. Loosen the fastening screws -3- for the guide wedge -2- until the adjustable stop -1- can be moved in the guide wedge.







4.4. Press the adjustable stop -1- in the guide wedge -2- up two notches -arrow A-.
The marking on the stop is then approx. 2 mm above the marking on the guide wedge.







4.5. Check that the stop in the guide wedge was pressed up parallel and that the marking on the stop is approx. 2 mm above the marking on the guide wedge on both sides. Adjust the position of the stop if necessary.
4.6. Position and secure the guide wedge -1-. To do this, press the guide wedge -1- up with your finger -arrow A-. Hold the guide wedge at this position and tighten the fastening screws -2-.
Tightening torque: 6 Nm (4.5 ftlb.)







4.7. Remove the white markings on the guide wedge and on the stop.

5. Grease the guide wedge at the left and right.







5.1. Clean contact surface on guide wedges -1- in the marked area -A-.
5.2. Lubricate contact surface on guide wedges -1- in the marked area -A- with Krytox.

6. Close the rear lid.