Removing
Note: This work will require the assistance of another person.
1. Open the tailgate, and remove the shelf from the rear window.
2. Remove interior trim panel (Chapter 22) and a polyethylene membrane.
3. Where equipped, disconnect the washer system tube from the top edge of the tailgate (photo), and seal it to prevent water loss.
4. On early Hatchback models, the wiring to the electric heater in the tailgate is connected via one or two spring-loaded contact plates. For such models, the next paragraph can be skipped.
5. On Station Wagon and later Hatchback models, disconnect the wiring from the heated rear window, wiper motor, and tailgate lights, where equipped (photo). Tie strong cords to the ends of the individual wire harnesses. Remove the o-rings and remove the wire harnesses until the cords appear. Untie the harnesses, leaving the cords inside the door.
6. On all models, trace the tailgate hinges with a pencil, and place a thick cloth under the corners of the top of the tailgate to protect the paint.
7. While supporting the tailgate, remove the pillars (Chapter 14).
8. Remove the two bolts securing the hinge to the tailgate (photo), then remove the door.
Installation
9. Install in the reverse order of removal paying attention to the following.
- A) If the previous tailgate is installed, align the one made before removing the label; if installing a new door, center the hinges on the bolt holes. Lightly tighten the bolts first, then close the door and make sure it fits properly.
- b) When the door is correctly placed (see below), tighten the bolts with a torque specified specifications.
Adjustment
10. Close the tailgate and check that it is evenly pressed against the seal along the entire perimeter and is centered relative to the opening in the body.
11. If the door is not installed correctly, open it and loosen the hinge bolts.
12. Adjust the position of the door so that there is an even gap between it and the opening in the body, then tighten the hinge bolts with the tightening force regulated specifications.
13. If you need to adjust the tailgate impact plate, refer to Chapter 15.