Installation

Disconnect battery and cover battery terminals.

Place vehicle on hoist and lift to desired working height.

1.0 Mount the side member panel

1.1 Remove the rear wheel housing liners (Boxster Technical Manual, Group 5, Operation 53 69) and side covers (Operation 51 90).

1.2 Remove the plastic plugs from the front wheel housing liners. Clip in a sheet metal clip to each of these respective spots behind the wheel housing liners.





1.3 Remove the film from the bonding points of templates 1, 2 and 3. Position the left and right hand retaining strip on the body rocker panel using the appropriate template set as shown in Figure 2.

Note:
The upper edge of template 1 is located between the body rocker panel and the fender. Place template 2 on the door sill and template 3 in the drip moulding in the rear side panel. To avoid corrosion do not drill pilot holes in the body rocker panel.

1.4 Protect the upper body above the rocker panel with adhesive tape. Use additional adhesive tape (or another technician) to position the retaining strip. Use a hand drill and phillips-head bit to secure the retaining strip with the 3.5 x 16 countersunk sheet metal screws. Check and correct the gap of the retaining strip to the body rocker panel.

1.5 Starting at the rear, fit the side member panel to the retaining strip with the ball of your hand. Clip the U-brackets 4.00 - 4.50 for fastening the rocker panel to the underside of the vehicle to the inside of the vehicle using the tab.





1.6 Make a mark for the mounting hole of the wheel housing liner on the front of the side member panel. Detach the side member panel and use the center bit to drill a 6 mm hole at the mark. Stick matching adhesive film to the outside of the side member panel and cut out or pierce a hole (Figure 3, arrow).

1.7 Grind the inside of the side member panel at three points (Figure 3) on the outside and center. Remove metal chips with compressed air.

1.8 Clean the bonding surfaces with a grease and wax remover such as: Acrysol, or BETACLEAN. Apply adhesive to the bonding points and to the groove of the retaining strip.

1.9 Attach and position the side panel member in the retaining strip. The stone shield attached to the body rocker panel as standard must no longer be visible, and the side panel member must be situated approx. 5 mm beneath the body rocker panel.

1.10 Fasten the side member panels to the wheel housings using the original screw for the rear end and a countersunk screw and conical washer for the front end. On the vehicle floor, screw the side member panel to the U-brackets using 8 x 13 sheet metal screws.

2.0 Fit front spoiler.

2.1 Remove the direction indicator lights but only loosen the front spoiler (Boxster Technical Manual, Group 6, Operation 63 15). Insert a plastic spatula between the wheel housing liner and the front spoiler, and lever out the wheel housing liner via the front spoiler. Dismantle cover of lower part of lock and remove front spoiler from vehicle.





2.2 Fit the bracket to the sheet metal nuts on the radiator holder using phillips-head screws (Figure 4). Clip the sheet metal nuts onto the end which is facing forward.

2.3 Before bonding, fit the grille frame in the front spoiler arid check for correct fit. Grind the bonding surfaces in the grille frame and on the inside of the front spoiler. Clean the bonding surfaces with grease and wax remover such as: Acrysol, or BETACLEAN.

2.4 Apply paint and plastic primer BETAPRIME 5402 (or equivalent) to the ground surfaces and allow primer time to take effect.

Important:
Observe notes on use and bonding times in the "Bonding instructions for K2 adhesives".

2.5 Apply K2 adhesive to the bonding surfaces and fit the grille frame in the front spoiler. Check the gap dimensions. Affix the grille frame to the front spoiler with adhesive tape. Remove escaping adhesive immediately as it dries rapidly.

2.6 Clip sheet metal nuts in the vicinity of the direction indicator lights. Once the bonded joint has set, the front spoiler can be attached, tipper side first, to the front of the vehicle. Ensure that the edges of the front spoiler fit correctly in the area of the direction indicator lights.

2.7 When screwing the front spoiler to the retaining strip, press the upper side towards the front of the vehicle. Fasten the front spoiler in the area of the direction indicator lights. Fasten the horizontal then the vertical screws. Check the gap dimensions.

2.8 Use a plastic spatula to position the wheel housing liners behind the edges of the front spoiler. Fasten the complete spoiler to the vehicle. Affix the wheel housing liners to the front spoiler with the plastic plugs. Attach the temperature sensor to the grille frame, or bond with adhesive if necessary.

2.9 Mount cover of lower part of lock. Fasten the cover for the towing lug to the bumper with the safety thread. To do so, drill two 2.5 mm holes in the front spoiler at the marks. Route the safety thread through the holes and seal. Insert cover in the front spoiler.

2.10 Align the rubber seals of the radiator with the front spoiler so that they run past the outside of the ventilation grilles.

3.0 Fit rear lid with spoiler.

3.1 Remove the spoiler, standard rear lid and 3rd brake light.

3.1.1 Extend the spoiler completely and push the pins inside the plastic expanding rivets (qty. 3) through into the rear luggage compartment. Take off the top section and remove the bottom section (2 combination screws) See Boxster Technical Manual, Group 6, Operation 66 58.

3.1.2 Retract the spoiler adjusting elements and mount the spoiler cover using phillips-head screws (qty 3, left over after the side member panel was fitted to the rear wheel housing liner). Ensure that the cover is correctly fit in relation to the rear luggage compartment seal. Remove the luggage compartment lining in the area of the rear panel (4 plastic pegs) and disconnect the plug connection to the spoiler drive motor. Bond pins and fix plug halves to the body.

3.1.3 Remove upper part of lock from the standard rear lid (2 combination screws M6 x 12) and install on the new rear lid. Remove the hinge screws and detach the rear lid from the hinge (Boxster Technical Manual, Group 5, Operation 55 90).





3.1.4 Uncover the control modules in the rear luggage compartment. Remove the foam section and press the plug connection beneath it out of the fixture on the body (Figure 5, black arrow). Pull the plug connection down and out of the recess, and disconnect.

3.1.5 Open the convertible top compartment lid approx. 45 degrees while ensuring that it is not damaged by the hinges of the detached rear lid. Remove the phillips-head screws of the 3rd brake light, and take the brake light with connecting cable upwards and out. Seal the hole for the connecting cable in the body with the 20.0 x 30.0 mm plug. Fit the cover for the 3rd brake light with two countersunk screws.





3.2.1 Enlarge holes in rear lid (Figure 6, arrows) for the cable connection to grommet size. Insulate pins at end of third brake light cable and route through spoiler. Thread rubber grommets (qty 2) onto the cable and route cable to the rear lid hinge holder. Insert rubber grommets in the holes.

3.2.2 Securely screw spoiler onto rear lid with the washer and the M8 hexagon nut. (tightening torque: 23 Nm (17 ft/lb.).





3.2.3 Insert the third brake light into the spoiler with the left side first. Position and lock in place (Figure 7). Pull cable tight and seal off the hole in the rear lid reinforcement with the rubber grommet. Thread rubber sealing grommet for the rear luggage compartment onto the cable.

3.2.4 Guide the cable pins through the plug housing and push into the two-pole insert. Engage insert in plug housing.

3.3 Fit rear lid to the vehicle and finish the installation of the rear lid with spoiler.

3.3.1 Position rear lid with spoiler on the hinges and attach loosely to the hinges with the new screws - (4 x M6 x 22) and washers.

3.3.2 Connect the spoiler brake light cable connection (see step 3.1.4). Attach the plug connection to the body and tie the cable in place. Insert the rubber grommet in the hole to seal the body. The upper portion of the grommet should not be visible when the rear lid is closed. Also ensure that the cable runs past the rear luggage compartment seal without chafing (when the lid is closed).

3.3.4 Perform function test of the brake light. Fit luggage compartment lining.

4.0 Disconnect the retractable spoiler warning light.

4.1 Remove instrument cluster according to the Boxster Technical Manual, Group 7, Operation 7018.

4.2 Remove spoiler warning light bulb by turning 180 degrees.

4.3 Reinstall instrument cluster.