Points 1 and 2 apply to unpainted roof spoilers
- Clean the surfaces on the spoiler that mate to the tailgate. Use a mixture of 30% windscreen washer fluid and 70% water
- Wipe dry
- Position the tape on the mating surfaces. Press the tape into place. Leave the thick outer protective film in place.
Примечание: The tape must cure for 24 hours at a minimum of 20º C (68º F) before painting.
- Spray paint according to the Service Manual “Touch up spraying”, section 8 (80). The underneath of the spoiler must not be sprayed
- Mask the underneath of the spoiler. Use the groove as a guide
- Carefully grind the dividing edge.
- Open the tailgate
- Remove the four screws (1) from the lower section of the panel on the tailgate
- Grasp the edges of the panel. Carefully pull off the panel. The panel is secured by eight clips.
- Pull down the sides of the panel around the tailgate window to release it from the two clips
- Grasp the upper section of the panel. Carefully pull the upper section of the panel to release the clips
- Place the panel to one side.
- Remove the connector (1) from the brake lamp
- Press the centre of the clip (2) until a click is heard
- Remove the clip
- Slide the brake lamp to the left to release it from the guide holes.
Pre-drilling
- Open the tailgate
- Punch and drill the hole (1) following the existing marking. Use a 3 mm (1/8” ) diameter drill bit.
Примечание: Drill only through the first layer of plastic. Drill at right angles to the surface. Use a drill stop.
- Repeat the operation on the other side of the tailgate
- Mark the hole (2) so that it can be drilled for the cable for the spoiler mounted brake lamp. See illustration B
- Punch and drill the hole (2) on the right-hand side following the existing marking. Use a 3 mm (1/8”) drill bit. Drill at right-angles to the surface. Drill through both plastic layers. The hole is for the cable lead-in.
Hole enlarging
- Drill out the hole (1) using a 10 mm diameter (25/64”) drill bit on the left and right-hand sides.
Примечание: Drill only through the first layer of plastic. Drill at right angles to the surface. Use a drill stop.
- Drill out the hole (2) on the right-hand side. Use a 5.5 mm (7/32”) diameter bit. Drill at right angles to the surface. Drill through both plastic layers.
- Take the left and right drilling templates from the kit. Use scissors to cut the templates apart. See the illustration.
Pre-drilling
- Close the boot lid
- Position the left template on the upper left corner of the tailgate. See the illustration
- Mark both holes through the template and inside the tailgate using an awl
- Drill the markings at right angles to the surface. Use a 3 mm (1/8”) diameter drill bit.
Примечание: Only drill through the first plastic layer at the hole (1). Use a drill stop. Drill through both layers at the hole (3).
- Take the right-hand template and do the same on the other side of the tailgate.
Hole enlarging
- Drill the hole (1) at right angles to the surface. Use a 16 mm (5/8”) diameter hole saw. Only drill through the first plastic layer. Use a drill stop
- Drill the hole (3). Use a 10 mm (25/64”) diameter hole saw at right angles to the surface. Drill through both plastic layers
- Take the right-hand template and do the same on the other side of the tailgate.
- Check that the roof spoiler aligns with the drilled holes. Ensure that the screws (from the kit) align with the nuts for the roof spoiler
- If necessary: adjust the holes using a round file.
- Route the cable (1) through the spoiler. Drill at the brake lamp. Thread a piece of wire or a thin plastic rod into the hole for the cable lead-in. Then tape the terminal and the cable to the wire and pull it out through the hole.
Примечание: Do not damage the pins.
- Remove the covers (2)
- Install the brake lamp. Use the two screws (3). Tighten to a maximum of 2.5 Nm (2 lbf.ft.). Greater torque may damage the threaded joint
- Reinstall the covers.
- Clean the surfaces where the roof spoiler will be positioned. Use a mixture of 30% windscreen washer fluid and 70% water
- Wipe dry.
Illustration A
- Remove the protective film from the tape.
Illustration B
- Insert and pull the brake lamp cable through the hole in the tailgate
- Press the spoiler into place on the tailgate.
Illustration C
- Install the four screws (from the kit). Tighten the spoiler
- Tighten the screws. Tighten to a maximum of 5 ± 1 Nm (3.7 ± 0.7 lbf.ft.). A greater torque may damage the threaded joint.
Примечание: To ensure the best results, it is recommended that two people press the roof spoiler onto the tailgate.
- Cut the rubber nipple (1) off the rubber grommet for the brake lamp. Do not damage the existing washer hose
- Thread the brake cable from the roof spoiler between the hinges and tailgate behind the existing washer hose. Thread the brake cable through the hole in the rubber grommet and out of the hole in the corner of the tailgate.
Подсказка: Use soap to facilitate the lead-in.
- Clean the rear windscreen by the brake lamp socket
- Wet the window. Soak the tape which will cover the socket. Use a mixture of 30% windscreen washer fluid and 70% water
- Apply the tape over the socket. Press out the water and air bubbles. Use a plastic card or similar
- Reinstall the brake lamp.
Applies to vehicles manufactured before year 3, week 10
- Drill holes in the tailgate for the attachment of the connector
- Drill out the holes. Use a 6.5 mm (17/64”) diameter drill bit
- Press in the holder together with the clip.
Applies to vehicles manufactured after year 3, week 10
- Press in the holder together with the clip.
- Take the connector (2) from the kit. Open the catch
- Connect the cable harness for the spoiler to the connector. Connect the red (R) cable to position 1. Connect the black (SB) cable to position 5
- Press the catch together
- Connect the existing brake lamp cable (1) to the new connector as illustrated.
- Press the connector for the spoiler cable into place in the holder.
Applies to cars built before week 310
- Drill a hole in the tailgate to secure the cable for the spoiler mounted brake lamp. See the illustration. Use a 6.5 mm (17/64”) diameter drill bit
- Remove any swarf.
Примечание: Only drill through the first plastic layer. Use a drill stop.
- Take the two tie straps and clips from the kit and press them into place in the drilled holes
- Secure the cables using the tie straps.
- Check the function of the brake lamp
- Reinstall the panels on the tailgate
- Post-tighten the screws for the spoiler to the correct torque. See point 12C.