Repairing the Boot Electromagnetic Lock

Assuming that the fault in the boot locking system is due to damage to the actuator motor, first remove the electromagnetic lock from the tailgate to disassemble it. Once the lock is removed, unclip the retaining tabs of the plastic cover and remove it. At this point, you can see the mechanism of the electromagnetic lock, which consists of a motor driving a worm screw that in turn drives a gear wheel, which, through a cam, actuates the opening mechanism (you can also notice the microswitch that indicates the open or closed condition).

Before removing the plastic support housing the opening mechanism, close the lock by activating the lever and turn the gear wheel until the edge of the cam aligns with that of the motor (this will serve as a reference for reassembly).

Now you can unclip the plastic support of the mechanism from the metal one, taking care not to dislodge the actuator spring. Proceed to remove the gear wheel and the motor: the repair will essentially involve transferring the worm screw from the damaged motor to the new one; the new motor can be purchased at any electronics store, but be careful with the position of the power poles and the diameter of the shaft, which should be 2 mm. Note that the overall length of the motor, including the worm screw, is 59 mm and that the part of the shaft protruding from the worm screw itself is 4 mm. Now cut the shaft of the damaged motor from the base of the worm screw and extract it from inside (using the protruding part of the shaft as a puller).

The extracted shaft should be inserted and secured with Loctite into the worm screw, ensuring it protrudes by 4 mm. Finally, secure the other end of the worm screw to the shaft of the new motor with Loctite, verifying that the overall length of the assembly remains 59 mm and ensure everything is securely fixed.

You can reassemble the electromagnetic lock by repositioning the motor in the plastic support first, then the gear wheel, aligning the edge of the cam with that of the motor as during disassembly.

Reattach the plastic support to the metal one, properly repositioning the spring. Turn the gear wheel counter-clockwise to open the lock and move the cam to its limit.

Repeat the closing and opening operation, and once you have confirmed correct operation, reattach the cover of the electromagnetic lock.