Opel Corsa B 1993–2000 Service and Repair Manual: Tailgate - removal and refitting

Removal

1. Open the tailgate and have an assistant support it.

2. Disconnect the rear screen washer tube and any wiring that enters the tailgate - this will vary according to model and equipment.

Remove the tailgate trim panel if necessary to carry out the disconnections.

3. Disconnect the struts from the tailgate.

4. Extract the hinge pin circlips and press or drive out the hinge pins (see illustration). Lift away the tailgate.

Tailgate hinge showing circlip (arrowed)

Refitting

5. Refit in the reverse order to removal. Note that the circlip ends of the hinge pins face outwards. Lubricate the pins before fitting.

Tailgate hinge - removal and refitting

Removal

1. Open the tailgate and have an assistant support it.

2. Disconnect the strut on the side being worked on.

3. Extract the circlip and press or drive out the hinge pin.

4. Unclip the roof trim panels and loosen the headlining to gain access to the hinge screws.

5. Undo the two screws with an offset screwdriver and remove the hinge, seal and screw plate.

Refitting

6. Refit in the reverse order to removal.

Tighten the hinge screws to the specified torque. Lubricate the hinge pin before fitting; fit the pin with its circlip end facing outwards.

Tailgate strut - removal and refitting

Removal

1. Open the tailgate and have an assistant support it.

2. Release the strut from its mounting balljoints by prising the spring clips a little way out and pulling the strut off the balljoints (see illustration). If the strut is to be re-used, do not remove the spring clips completely, nor prise them out further than 6 mm (0.24 in).

Releasing a tailgate strut spring clip

3. Dispose of used struts carefully, since they contain gas under pressure.

Refitting

4. Refit in the reverse order to removal.

Tailgate lock - removal and refitting

Removal

1. Remove the tailgate trim panel by releasing its retaining clips.

2. Remove the retaining screws from the lock (see illustration). There are three retaining screws on the Hatchback, four on the Estate and Van.

Tailgate lock retaining screws (arrowed) - Hatchback

3. Unhook the operating rod from the lock cylinder arm (see illustration). It may be necessary to unbolt the lock cylinder in order to disengage the rod. Remove the lock and rod together.

Lock operating rod connection to arm (arrowed)

4. If a new lock is being fitted, transfer the spring and rod to it.

Refitting

5. Refit in the reverse order to removal. Check for correct operation before refitting the trim panel.

Tailgate lock cylinder - removal and refitting

Removal

1. Remove the tailgate trim panel by releasing its retaining clips.

2. Remove the two retaining nuts, disengage the lock operating rod and remove the lock cylinder, complete with housing.

3. Remove the lock cylinder from the housing by driving out the roll pin, moving aside the catch and extracting the circlip (see illustration). Remove the cylinder with the key inserted.

Tailgate lock cylinder removal - roll pin and circlip arrowed

1. Key number

4. Fit the new cylinder and secure with the circlip and roll pin.

Refitting

5. Refitting is a reversal of the removal procedure. Check for correct operation before refitting the trim panel.