Work Procedure
1. Preparatory work.1.1 Disconnect and cover the battery.
1.2 Remove the rear lid.
Figure 2:
1.3 Place a tape measure 50 mm from the edge (position A), determine the center of the lid (position B) according to the instructions on the template and mark the center using a pen with water-soluble ink.
Work Procedure:
1.4 Place template on the lid, align it and secure it on the lid using adhesive tape.
1.5 Using a center punch lightly mark the rear lid at the template markings.
WARNING
Damage to the rear lid by the chuck or drill bit.
> Mask the drilling area with tape.
> Drill carefully without applying too much pressure.
1.6 Carefully drill pilot holes with a 3.0 mm drill bit.
1.7. Enlarge the holes in Figure 3 to the following final diameters:
Position A. 6.0 mm
Position B: 6.5 mm
Position B: 10.5 mm
Observe the instructions on the template.
Figure 3:
1.8 Check whether the distances and diameters of the bores in Figure 3, position C, are adequate.
Note:
Observe the markings on the parts, e.g. L for left and R for right, and the direction (arrow indicates the direction of travel).
Figure 4:
Insert both molded plates into the opening on the underside of the lid in order to check the distances and diameters. Both flat shoulders of the molded plate (Item A) must fit into both bores without difficulty. Rework the bores if necessary.
1.9 Deburr the bores on both sides and treat them with rust inhibitor.
2. Partially install and connect electrical wiring harness.
2.1 Remove the plug to the rear luggage compartment (position: refer to arrow A.
2.2 Detach the trim in the rear luggage compartment at the front wall and in the area of relay carrier 2 and pull relay carrier 2 out of its holder.
2.3 Remove foam part at the front wall of the luggage compartment and unclip the 2-pole plug connection (X24 raised brake light) from the holder.
2.4 Disconnect 2-pin plug connection X24. Route the branch (wiring harness) with the two-pole jack to the plug of the standard raised brake light. Join the plug connection, fix it on the front wall and fit the molded part.
2.5 Route the branch (wiring harness) with the two-pole plug to the standard two-pole jack and join the plug connection.
2.6 Plug the relay socket into slot 5 of relay carrier 2. Plug relay into the relay socket. Note: Relay can be inserted in two positions; make sure it is inserted in the correct position.
2.7 Starting from the luggage compartment, route the branch with the two jacks and the wire sleeve through the bore to the left pneumatic spring of the rear lid.
Figure 5:
2.8 Fit the wire sleeve (Item A) in the bore.
2.9 Fix the colored area of the branch to the pneumatic spring using adhesive tape (Item B) or two tie-wraps.
3. Fit the rear-lid rack.
3.1 Fit both rails (Item A) on the rear lid as shown.
3.1.1 Guide the contact pin of the rail through the bore of the associated seal (Item B) and through the bore in the rear lid (Item C).
3.1.2 Place the rail and its seal on top of the rear lid.
3.1.3 Insert both flat steps of the molded plate (Item D) into the bores (10.5 mm) from below. Fasten the molded plate and rail with two M6 x 25 pan-head screws and two 6.4 washers; tighten only handtight.
3.1.4 Fit the second rail accordingly.
3.2 Fit the locking bar.
Figure 6:
3.2.1 Place the locking bar( Item E) with its two seals (Item F) on top of the rear lid and align.
3.2.2 Fasten the molded plate (Item G) to the locking bar using two M6 pan-hand screws and two 6.4 washers from the bottom side of the rear lid; tighten only handtight.
Work Procedure:
WARNING
Damage to the rear lid (distortion, dents) if the tightening torques are not observed.
> Observe the tightening torques listed below.
> Fasten the rear-lid rack on the rear lid only using micro-encapsulated pan-head screws.
3.3 Tighten all pan-head screws.
Tightening torques:
Rails (Figure Item A): 4.0 Nm (3.0 ftlb.).
Locking bar (Item E): 5.0 Nm (3.5 ftlb.).
4. Complete the vehicle.
4.1 Install the rear lid and adjust the gaps.
4.2 Push the single-pole connector housings (4 X) onto the two pins and jacks and lock.
4.3 Make plug connections to the wiring harness and insert into the hollow space of the rear lid. Tape the opening on rear lid frame.
4.4 Fit trim panels in the luggage compartment.
4.5 Connect battery and set the time on the clock.
4.6 Enter radio code.
5. Function test.
5.1 Switch on the ignition, press the brake pedal and have a second person check the function of the raised brake light.
5.2 Fit the case.
Figure 7:
5.2.1 Turn key in the lock barrel of the case counter-clockwise (enlarged view). The case is locked when the key is in this position and can be fitted on the vehicle or removed.
5.2.2 Unfold the handle of the case to position A.
5.2.3 Lift the case at the side handholds in the lower case shell and hold the case horizontally above the rear lid. Align the feet on the case with the two rails on the rear lid.
Figure 8:
5.2.4 Carefully place the lower part of the case onto both rails of the rear lid.
5.2.5 Carefully push the case in the direction of travel until resistance is felt.
Figure 9:
5.2.6 Insert the clamping claw (Item B) into the locking bar by moving the handle( Item A).
5.2.7 The case is fixed on the locking bar when the handle is folded in. Lift the case at the lateral handholds to check whether the case is fastened securely.
Figure 10:
5.2.8 Turn the key in the lock barrel of the case clockwise by one quarter turn until the key is vertical. With the key in this position, the case can be opened and closed using the small handle (Item A). It is not possible to remove or fit the case on the vehicle.
5.2.9 Turn key in the lock barrel of the case clockwise by one quarter of a turn. The case is locked in this position and cannot be removed from or fitted on the vehicle.
6. Function test.
6.1 Switch on the ignition, press the brake pedal and have a second person check the function of the raised brake light in the case.