Side panel (2004, 2005)

• Wash and degrease the car.

Примечание: It is important that the surfaces on which the side panels will be mounted are completely free of tar and other road dirt.

Illustration A

• Drill out the six rivets (1) holding the front wheel arch extension to the edge of the wheel arch. Use a 6 mm (1/4”) diameter drill bit.
• Remove the remains of the rivets.

Illustration B

• Carefully pry off the front lower edge of the wheel arch extension. Use a plastic weatherstrip tool.

Примечание: Do not damage the paint work.
- Fold out the front lower edge of the wheel arch extension to expose the first mounting clip
- Insert the weatherstrip tool at the side of the clip, between the panel and the wheel arch extension. Twist the weatherstrip tool to pull the clip away from the edge of the wheel arch or so that it breaks
- Then continue in the same way until all five clips have released
- Remove the wing extension. Place the wing extension to one side. This will not be reused.

Remove the front wheel arch extension (secured by three hooks at the bottom, tape at the top, five clips and six rivets):

Removing the lower trim strip on the front door:

• Use the weatherstrip tool to pry the rear edge of the trim strip until the tape comes away at the bottom and top edges.

Примечание: Do not damage the paint work.
- Push the trim strip to one side to expose the first clip
- Remove the clip in the same way as for the clips on the wheel arch extension
- Pry the trim strip off working forwards. Remove the last clip in the same way as previously
- Place the trim strip to one side. This will not be reused.

Illustration A

• Remove the parking lamp. Carefully pry off the bottom edge. The parking lamp has a cut out on its lower edge to make prying it off easier
• Disconnect the connector from the parking lamp.

Примечание: Ensure that the connector does not fall into the door.

Illustration B

• Use the weatherstrip tool to pry the rear edge of the trim strip until the tape comes away at the bottom and top edges.

Примечание: Do not damage the paint work.
- Continue to pry off the trim strip working forwards until it has detached completely
- Place the trim strip to one side. This will not be reused.

Remove the upper trim strip on the front door:

Remove the lower trim strip on the rear door:

• Carry out the same procedure as for the front door (step 3), but start at the front of the trim strip and work backwards
• Place the trim strip to one side. This will not be reused.

Removing the upper trim strip on the rear door:

• Carry out the same procedure as for the front door (step 4), but start at the front of the trim strip and work backwards
• Place the trim strip to one side. This will not be reused.

Illustration A

• Drill out the four rivets (1) holding the wheel arch extension to the edge of the wheel arch. Use a 6 mm (1/4” ) diameter drill bit.
• Remove the remains of the rivets.

Illustration B

• Carefully pry off the front lower edge of the wheel arch extension. Use a plastic weatherstrip tool.

Примечание: Do not damage the paint work.
- Fold out the front lower edge of the wheel arch extension to expose the first mounting clip
- Insert the weatherstrip tool at the side of the clip, between the panel and the wheel arch extension. Twist the weatherstrip tool to pull the clip away from the edge of the wheel arch or so that it breaks
- Then continue in the same way until all six clips have released
- Pull the two mounting hooks at the rear edge of the wheel arch extension off from their mountings
- Remove the wing extension. Place the wing extension to one side. This will not be reused.

Removing the rear wheel arch extension (secured by two hooks at the rear bottom edge, tape at the top, six clips and four rivets):

• Remove the stone-chip protection at the rear edge of the rear door.

• Grip the bumper shell at point (1) and pull it out slightly so that the weatherstrip tool can be inserted in the opening formed.
• Position and turn the weatherstrip tool in the lower edge of each mounting hook (approx. in front of the three arrows) so that they release from the catch in the body.
• Carefully pull the bumper shell end with the small painted panel in the top edge from the body starting from the front. It is held in place by four clips.

• Bend the small painted panel loose from the bumper shell end and then pull it off at an angle upwards. It is held in place by ten mounting hooks along its periphery. Lay it aside. It will not be used again.

• Press the bumper shell end into the catches in the body. Make sure that all seven mounting hooks engage.

• Remove the screw and washer from the rear edge of the bumper shell end.
• Take the clamp from the kit and tighten it with the screw and washer as illustrated. The clamp should fix the bumper shell end against the body.

• Wash the entire surface of where the new decor panels and wing extensions shall sit. Use cleaner H (part no. 1161436).
• Wipe dry

• Remove the side panel components from the packaging
• Check how the mounting tape is positioned on the components. This determines where the primer must be applied and where the markings must be made
• Clean the backing tape using a moist cloth. Use a mixture of 30% windscreen washer fluid and 70% water.

Примечание: There must not be any dirt or grease on the backing tape on the panel. This could contaminate the bodywork when making markings in the next step.
- Wipe dry

Illustration A

• Check that the embossings (1) in the rear edge of the front door and the corresponding rear door are in the centre of the cut out (2) in the relevant side panel (both door panels should end up at the same height horizontally).

Примечание: Leave the backing tape for the mounting tape in place. Ensure that the panels are aligned horizontally.

Illustration B

• Mark the outer contours of the panels using a Whiteboard pen. Refer to the information under point A.

Test mount the panels according to points 19-22.

Marking the centre panel tape

• Measure from the upper marking (1) and mark out a line (2) for the centre panel tape. On the front door, the distance between the lower limits of the markings must be 180 mm (7 1/16”). On the rear door, the corresponding distance must be 190 mm (7 1/2”).

Applying primer to the bodywork

Осторожно: The side panels must be installed at the earliest 15 minutes, and at the latest 3 hours, after applying the primer.

• Take the primer (part no. 1161727) and cotton buds from the kit.

Примечание: The primer must be applied to the whole car in one operation. Any spillage must be wiped up immediately.

• Apply the primer inside the outer contours of the panels. It is important that nothing goes outside the markings, particularly on the upper sides of the panels, where there should be a space of approximately 1 mm between the primer and the marking.
• Apply the primer immediately below the markings for the central mounting tape for the panel
• Allow the primer to harden for 15 minutes.

Applies to all components

• Remove the backing tape at each corner of the panel.

Applies to the door panels

• Remove the backing tape from the middle of the panel.

Securing the front wing side panel

Illustration A

Carried out by two people, one at the front and one at the rear of the side panel:

• Carefully insert the panel locating pins in the holes in the edges of the wing
• Move the panel as close as possible to the wing without the tape on the corners securing. Adjust the panel. There must be parallel vertical play between the panel and the rear edge of the front wing
• Press the panel into place at the upper corners (A). Carefully remove the upper backing tape (B) by pulling it off from both sides at the same time.

Примечание: Ensure that the backing tape does not come off the reverse of the panel as the panel may lie firmly against the front wing.
- Press the upper section of the side panel (C) into place on the front wing so that it is firmly secure.

Illustration B

• Remove the backing tape on the sides (A) of the panel.

Примечание: Ensure that the backing tape does not come off on the reverse of the panel.
- Press the panel into place on the front wing at every point that there is tape (C)
- Apply a pressure of 1-2 kg/cm² (14-28 lbf/in²) around the entire panel so that the tape sticks firmly.

Securing the rear wing side panel

Carried out by two people, one at the front and one at the rear of the side panel:

• Insert the four mounting hooks in the rear edge of the side panel in the corresponding recess in the bumper shell end.
• Bend the panel in toward the rear wing while making sure that each side panel locating pin fits in the corresponding hole in the edge of the wheel arch.
• Follow the same procedure for the front wing. The front edge of this panel, however, will not need adjustment as the position is fixed against the door sill.

Securing the side panel for the rear door

Illustration A

Carried out by two people, one at the front and one at the rear of the side panel:

• Carefully insert the panel locating pins in the holes in the door
• Move the panel as close as possible to the door without the tape on the corners securing. Ensure that the rear upper corner of the panel follows the same line as the side panel for the rear wing (there is little clearance between the locating pins and the holes in the side of the door)
• Press the panel into place at the upper corners (A). Carefully remove the upper backing tape (B) by pulling it off from both sides at the same time.

Примечание: Ensure that the backing tape does not come off on the reverse of the panel as the panel may be firmly attached to the door.
- Press the upper section of the panel (C) into place on the door. Press the panel so that it is firmly secured.

Illustration B

• Remove the backing tape on the sides (A) and lower edge (B) of the panel.

Примечание: Ensure that the backing tape does not come off on the reverse of the panel.
- Press the panel into place on the door at every point where there is tape (C)
- Apply a pressure of 1-2 kg/cm² (14-28 lbf/in²) around the entire panel so that the tape sticks firmly.

Securing the front door side panel

Illustration A

Illustration B

• Carry out the same procedure as for the rear door. Ensure that the rear edge of the panel is parallel with the rear edge of the door. In addition, adjust the height of the panel so that the top is in line with the panels for the rear door and the front wing.

• Remove the Whiteboard ink from the car. Use a rag.

• Reconnect the connector to the lamp
• Press the parking lamp into the hole in the side panel. Ensure that the parking lamp clips into place correctly.

• Fold in the mounting lugs on the front wing side panel so that the holes in the mounting lugs align with the holes in the wing liner.

Applies to cars missing a hole in the inner wing for the mounting lug for the panel

• Certain cars do not have holes for the mounting lug (1) on the left and right-hand sides. In these cases the holes must be carefully cut. Use a knife or a hacksaw blade
• Fold the mounting lug in (the second mounting lug in the front edge of the panel counted from underneath ) and saw off at the crack which forms
• Smooth off the edges using a file
• Repeat the operation on the other panel.

Illustration A shows the rear wheel

Illustration B shows the front wheel

• Rivet the edges of the wheel arch extensions to the wing liner along the edges of the wheel arches. Do this on both the front and rear wheels. Use the rivets from the kit.

Illustration A shows the front edge of the rear door

Illustration B shows the rear edge of the front door

• If there is a visible gap between the black painted lower section of the side panel and the front edge of the rear door or the rear edge of the front door: cut the supplied tape to the same length as the lower gap. Apply the tape.

• The car must be kept dry and at a temperature of at least 15°C (59°F) for 2 hours
• Do not wash the car for 72 hours after installing the side panel.