Station Wagon Rear Door

Station Wagon Rear Door Lock Drive
1 – lock cylinder;
2 – rear door handle drive;
3 – connecting rods;
4 – lock.

To adjust the rear door from inside the vehicle, insert a 3 mm spacer plate between the lock and the striker plate (highlighted in red in the illustration).

Removal
PROCEDURE

Remove the rear door trim panel.

Disconnect or remove the electrical connectors, the central locking hose and the hose to the rear washer nozzle.

Open the rear door and support it.

Disengage the gas springs from the upper ball studs (on the door).

Remove the hex bolts at the top of the door hinge. Two assistants must hold the door on the left and right.

When installing, replace the sealing washers between the hinge and the rear door.

Adjust the rear lid stop buffer so that, with the door closed, the clearance between the buffer and the body is 2–4 mm.

Removing the Lock Cylinder
Removal of the lock cylinder is identical to the procedure described in the section "Removing the Trunk Lock" for the sedan.

Removing the Rear Door Handle Drive
Station Wagon
PROCEDURE

Remove the rear door trim panel.

Disconnect all connecting rods from the handle drive.

To do this, move the retaining clips of the lock connecting rods aside.

Unscrew the two hex bolts with nuts.

Remove the handle drive.

Installation: insert the handle drive from the luggage compartment centrally and in parallel through the rectangular opening in the lower outer part of the door.

The stopper and the sealing gasket with the groove must rest against the lower outer part of the door.

Turn the handle drive until the through holes and mounting holes in the lower part of the door align.

Tighten the handle drive with a washer and hex bolt (10 N·m).

Reconnect all connecting rods and adjust their length.

Cylinder connecting rod: set the release lever to the "open" position.

Move the sliding sleeve in the middle of the connecting rod back so that the halves are freely inserted into each other.

In this position, secure the threaded parts of the rod halves into each other and lock them with the sliding sleeve.

Adjust the connecting rods to the rear door locks – see the next section.

Removing the Rear Door Locks

Station Wagon
PROCEDURE

Remove the rear door interior trim panel.

Disconnect the lock connecting rods by moving the retaining clips aside.

In each lock, unscrew two hex nuts inside the door frame.

Remove the lock inward.

Installation: lightly tighten the lock nuts and position the mounting points centrally.

Slightly loosen the striker bracket (the part of the lock at the bottom on the body).

Close the rear door.

From inside the luggage compartment, insert a 3 mm spacer plate between the lock and the striker bracket.

Engage the lock in the second latch notch and align the rear door.

Adjust and secure the gaps. The gap between the upper edge of the bumper and the lower edge of the rear door must be 6.5–7.5 mm.

Tighten the hex nuts.

Remove the spacer plate. Rear door lock adjustment is complete.

Now set the length of the (built-in) drive rod: move the sliding sleeve in the middle of both connecting rods back so that the halves are freely inserted into each other.

With the rear door open, set the lock latch to the "closed" position (second latch notch).

In this position, secure the threaded parts of the rod halves into each other and lock them with the sliding sleeve.