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post #2 of (permalink) Old 6th December 2011
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Re: rear door removal

ok... WHY ????

they are fitted by machines to tight tollerances, once removed they are a utter SOB to re-align correctly.

ok, first off, there are x2 plastic plugs in the roof lining, unscrew them. you then expose x2 nuts and at least 1 allenkey headed bolt.
you must use an allen key to hold the bolt in place of you will find it is going to be a nightmare to refit it back in later!

the struts have a reccessed slot in them to shove a screwdriver in to pull the spring clip back to you can pull it off the ball joints. (dont get them mixed up !!!)

if your trying to do the eastate version the rear glass is going to be a pain to re-align and reset back up without loading it up with extra stresses when mounted and then closed (this is why they tend to go BANG! on odd occasions, even factory fitted ones)
and at a easy 700+ for a new peice of glass you are going to be very carefull about messing about with this peice of glass (not all insurance companies will cover this window, check your T&C's before touching it)

glass wiring on the estate version is via connector just inside the roof lining, which needs to be pulled out though the rubber gromet hole.
lift the hatch glass
undo the 2 screws holding the inside black plastic cover on, you should then see 2 screws on the glass. undo those. the brake light (RED plastic) on the outside can then be pushed up and should simply unclick. undo the brown connector. mark around the large grometed/washered mounts holding the glass to the hinge frame.(its really not a good idea to mess around with these unless really needed)
lower the glass, undo the x2 screws under where the light was. you may have the x2 square bump stops fall off , dont loose them. then undo the x2 end screws that hold the spoiler on.
close the hatch glass, lock it. raise the entire boot, once raised you can then see the lower x2 screws holding the spoiler on, undo them a little (dont take off) dont allow the spoiler to move.
lower the boot, then push the spoiler back and it should unclip, you will need to undo the waterjet pipe to finally release the entire spoiler.

if you then want to remove the boot, you will need to unhook the cable loom on the left of the boot, removing the rubber from the frame and pulling the cable out of the chassis till you can undo the connector.
then undo the nuts holding the boot to the chassis, did you mark the edges before you released it? cos you need to know exactly how it refits square on the chassis later. and dont loose the rubber seals and washer that sit under the mounts.

dont mess with the hindges unless really neccesary as the glass is a nightmare to reset backonto the hindge/frame without it constantly slipping down.

new screw/washer fitting kits are over 45 from dealerships.

it takes x2 people to lift the boot off. even though it is fiberglass.

the hatchback is similar to the estate, but not as much grief as the hinges are not as complex.

have fun. and double check everything before you start undoing things and make sure you have clean hands before you start, or you will wind up with mucky finger prints all over the roof lining!
the last thing you want to do is touch the roof lining as once you unclip the boot frame edging it will completly fall apart on you !!!!!
(and you cannot easily reglue it back together either!) new ones are 350+fitting+vat!!!
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