Trunk / Liftgate Lock Cylinder: Service and Repair

Luggage Compartment Lid Lock Cylinder (76.19.19)

Removal

1. Remove trunk floor carpet.
2. Remove battery cover.
3. Remove trunk rear finisher.
4. Remove adhesive tape from trunk access aperture
5. Slacken and remove lock barrel housing securing nuts and release housing from operating cable abutment bracket.







6. Disconnect cable from lock barrel operating arm and remove barrel and housing from trunk.







7. Remove circlip securing operating arm to lock barrel and remove operating arm and bias spring from barrel.







8. Remove barrel from housing.
- Release detent plunger and spring from housing and withdraw barrel assembly.
- Remove spring clip from housing groove.







9. Using a flat-bladed screwdriver, ease barrel cover free and discard cover and plastic tension ring.







10. Remove:
1. Closing plate.
2. Shutter flap, tension spring and pivot pin.
3. Retaining key.
4. Shutter housing.







11. NOTE: If original discs and spacers are to be fitted, record sequence during removal.

Remove discs and spacer washers from barrel.







Installation

1. Fit and fully seat plastic sealing ring on barrel flange.







2. If original discs are to be fitted, proceed to step 3 noting positions recorded during removal.
3. Identify key cut code.
- Hold key so that cut outs can be identified and commencing at key grip, note and record cut out sequence.







4. Fit lock discs to barrel.
1. Apply grease supplied to bore of lock barrel.
2. Ensure lock discs match recorded key code.
3. Grease the first seven discs and install them in the barrel in sequence with embossed spacers in between and orientated to align roller locations.
4. Fit wavy spring spacer.
5. Grease and fit final disc.
6. Through barrel slot, check discs for correct sequence and orientation.







5. Align discs and spacers to accept the steel rollers grease rollers and fit into disc recesses via barrel slot.







6. Grease and fit shutter pivot and spring ensuring that spring is correctly tensioned.







7. Grease and fit detent plunger and spring to lock barrel recess.







8. Grease and fit spring clip into groove in bore of barrel housing.







9. Aligning detent plunger with groove in housing, push barrel assembly home until plunger engages in rear recess.







10. Turn key to locate plunger in housing detent, check for satisfactory lock operation and remove key.
11. Fit operating arm and bias spring to barrel.
- Fit bias spring to barrel, locating lower tang on lock housing pillar.
- Position operating arm at housing, locate bias spring upper tang on arm pillar and seat arm with spring tensioned.







12. Fit and fully seat arm securing circlip.







13. Position lock barrel and housing at cable abutment bracket and connect operating cable.







14. Position barrel and housing assembly on cable abutment bracket studs and fit and tighten securing nuts.







15. Fit new adhesive tape to panel aperture.
16. Fit trunk rear finisher.
17. Fit trunk floor carpet.
18. Fit battery cover.