Removal, installation and adjustment of the tailgate (Opel Astra H)

Removal and installation

1. Disconnect the cable from the negative terminal of the battery (see Chapter 5).

2. Open the tailgate and remove the luggage compartment shelf (with appropriate equipment).

3. Remove the trim of the rear door at the window frame (see Section 15) and seal the edges of the tailgate with tape.

4. Disconnect the tailgate electrical wiring connector and disconnect the rear window washer hose (see accompanying illustration).



5. Pull out the wiring harness (see illustration 14.4) from the back door.

Note: To facilitate subsequent installation, attach a cord to the end of the wire, which will remain in the tailgate after the wires are pulled out.

6. Use a small screwdriver to slightly lift the locking bracket (see accompanying illustration) and disconnect the gas-filled struts one by one from the upper spherical supports of the tailgate.



7. Remove the clamps (see illustration 14.6) knock out the hinge pins and, with the help of an assistant, remove the tailgate.



8. Installation is performed in the reverse order of removal. After installing the door hinge pins, close the tailgate and make adjustments (see below)

Adjustment

9. Remove the rear door sill trim (see section 43, 44, 45).

10. Unscrew the 2 bolts securing the lock bracket on the lower edge of the rear door frame and remove the bracket.

11. If necessary, remove the trim at the top of the car's rear pillars (C or D, depending on the model), and on Estate and Zafira models, the rear roof trim (see Section 44).

12. Carefully pull down the headliner panel and loosen the door hinge mounting screws.

Note: At the rear, the headliner is attached to the roof using Velcro.

13. Close the tailgate and check the uniformity of the gap between the adjacent body elements (see Specifications). The tailgate is adjusted correctly if, when closed, there is an even gap around the entire perimeter and the door is flush with the surrounding body surfaces.

14. If necessary, the gaps are adjusted by moving the tailgate in the appropriate direction.

15. To adjust the depth of the rear door in the door opening, it is necessary to release the rubber dampers (see accompanying illustration), turning their locks at an angle of 60 to 80° counterclockwise. Then install the dampers on both sides so that the tailgate fits freely against them in the closed position.

Note: To make adjustment easier, apply a paste-like mass to the dampers - use the imprint on the mass to determine whether the door is properly seated.

16. After completing the adjustment, return the lock to its original position - installation marks (see illustration 14.15) must match. Tighten the door hinge bolts to the required torque (see Specifications).

17. Replace the tailgate lock bracket and tighten the bolts by hand. Carefully close the tailgate: the lock bracket will take the desired position. Open the door and tighten the bracket mounting bolts to the required force.

18. Close and open the tailgate several times and make sure that it is adjusted correctly and that the lock is functioning properly; repeat the adjustment if necessary.

19. Install the tailgate trim.