Work Procedure

1. Preparatory work.

1.1 Paint primed parts of the SportDesign package according to instructions in the Paint Workshop Manual.

1.2 Remove the rear spoiler. --> Workshop Manual '665819' Removing and installing rear spoiler - section on "Removing"

1.3 Remove rear lights. --> Workshop Manual '943179' Removing and installing rear light section on "Removing"

1.4 Remove the rear apron. --> Workshop Manual '635519' Removing and installing rear apron. section on "Removing"

2. Disassemble rear apron.

2.1 Only for vehicles with ParkAssist (I No. 635):

Remove sensors. --> Workshop Manual '917519' Removing and installing sensor for ParkAssist - section on "Removing"

2.2 Remove wire harness for license plate light. --> Workshop Manual '977019' Removing and installing wire harness for number plate light - section on 'Removing'

2.3 Unclip license plate light out of rear apron.

2.4 Unclip license plate out of license plate holder.

Unscrew fastening screws on license plate holder and remove license plate holder.

2.5 Remove rear bumper overrider. --> Workshop Manual '63651' Removing and installing rear bumper overrider - section on "Removing"

3. Complete the new rear apron.

3.1 Only for vehicles with ParkAssist (I No. 635).

3.1.1 Clean bonding surfaces for retainer plates for the sensors and wire harness holders to remove any dust and grease.

Note
Take the installation positions of the wire harness holders and retainer plates from the standard rear apron The installation position for the retainer plate for the outer sensor is marked by the letter A.





3.1.2 Pull protective film --> Figure 3 -C- off the retainer plate for the outer sensor --> Figure 3 -A- and inner sensor --> Figure 3 -B- and insert retainer plates with center piece --> Figure 3 -Arrows- into the rear apron.

3.1.3 Break center pieces out of the retainer plates.

3.1.4 Pull protective film off the wire harness holders and position wire harness holders --> Figure 3 -D- between the retainer plates for the inner and outer sensors.

3.2 Clip license plate lights into the rear apron.

3.3 Install wire harness for number plate light. --> Workshop Manual '977019' Removing and installing wire harness for number plate light - section on "installing"

Note
Ensure that the sealing ring for the sensor is seated properly, re-fit the sealing ring if necessary.

3.4 Only for vehicles with ParkAssist (I No. 635):

Install sensors. --> Workshop Manual '917519' Removing and installing sensor for ParkAssist - Section on 'installing"'





3.5 Position frame --> Figure 4 -A- on rear apron and press it in. Ensure that all locking tabs --> Figure 4 -Arrows- have engaged.

Note
Observe "oben" (top) marking on the retaining strip.





3.6 Push on retaining strip --> Figure 5 -A-and secure with blind rivets --> Figure 5 -B-.





3.7 Insert support --> Figure 6 -A- in rear apron --> Figure 6 -Arrows- and secure with U-clamps --> Figure 6 -B-.





3.8 Lift spring clip --> Figure 7 -Arrows- slightly and place wire harness for license plate light --> Figure 7 -A. into the support.

3.9 Pull securing cord through the eyelet in the rear apron and clip cap into the rear apron. Workshop Manual '635537 Disassembling and assembling rear apron'

3.10 Install rear bumper overrider. --> Workshop Manual '636519 Removing and installing rear bumper overrider - section on "instaling"

3.11 Secure license plate holder with fastening screws. Clip license plate into license plate holder.

4. Fit new rear apron.





Note
To prevent damage while positioning the rear apron, mask the thread of the lifter-rod adjusting screw with insulating tape (Figure 8 -A-).

4.1 Guide rear apron over the retracted lifter rods of the rear spoiler drive from above.

4.2 Pull rear apron back carefully until the bores in the rear apron are touching the lifter rods.





4.3 Press the clamping bows --> Figure 9 -B- down and push the rear apron --> Figure 9 -A- forward at the same time so that the clamping bows slide under the retaining strip --> Figure 9 -C-.

4.4 Secure rear apron --> Workshop Manual '635519 Removing and installing rear apron - section on "installing"

5. Install rear lights --> Workshop Manual '943119 Removing and installing rear light - section on "installing"

6. Install new rear spoiler.

6.1 Check the height of the rear spoiler and adjust it if necessary.

ATTENTION
Danger of injury when manually retracting or extending the rear spoiler on a stationary vehicle.

--> Make sure that no persons or objects are standing in the range of movement of the rear spoiler.





6.1.1 Extend the lifter rods of the rear spoiler drive by pressing the rocker switch in the passenger compartment.

6.1.2 Screw in adjusting screws on the lifter rods by one turn (approx. 1 mm).





6.1.3 Position rear spoiler --> Figure 11 -A- and loosely pre-fit fastening nuts --> Figure 11 -A-.

6.1.4 Retract the rear spoiler by pressing the rocker switch in the passenger compartment. Check gap dimensions between rear lid and rear spoiler.

Gap dimension A 4.5 mm
Gap dimension B 2 mm





6.1.5 Adjust gap dimension B if necessary by screwing the lifter-rod adjusting screw in [by max. three turns (approx. 3 mm)] or out at the right --> figure 13 and left.

6.2 Secure rear spoiler.

6.2.1 Loosen fastening nuts on the rear spoiler.

6.2.2 Coat the fastening nuts with Loctite 262 and tighten rear spoiler hand-tight with the fastening nuts.





6.2.3 Check gap dimension A --> Figure 12 -A- and adjust it if necessary.

6.2.4 Extend the rear spoiler and tighten the fastening nuts counter at the lifter-rod adjusting screw if necessary.





6.2.5 Clip spoiler covers (987.504.983.01) into the rear spoiler on the right --> Figure 14 -A- and left.

6.2.6 Retract rear spoiler.

7. Fit the spoiler lips on the front apron.
(Only the right-hand side is described here.)

7.1 Preparatory work.

7.1.1 Remove cover for lock support. --> Workshop Manual '703919 Removing and installing cover for front lock support - section on "Removing"

7.1.2 Remove front section of front wheel housing liner on the left and right. --> Workshop Manual '505619 Removing and installing front wheel housing liner section on "Removing"

7.1.3 Remove the front apron. --> Workshop Manual '631519 Removing and installing front apron section on "Removing"





7.1.4 Remove frame at the right --> Figure 15 -A- and left. --> Workshop Manual '631537 Disassembling and assembling front apron'





7.1.5 Take hose for headlight washer system out of the clips for the front apron at the left --> Figure 16 -B- and right.





7.1.6 Make two templates out of cardboard packaging.

For dimensions, see --> Figure 17.

Note
The processing and component temperature must be at least 60°F. (15°C.).

7.1.7 Cut two adhesive strips (approx. 3 cm long) from the double-sided adhesive tape (adhesive kit).

Remove protective film and affix to the templates --> Figure 17 -A-.





7.2 Position templates --> Figure 18 -A- on the guide pins --> Figure 18 -B- of the spoiler lip.

7.3 Make holes for the spoiler lip guide pins.





7.3.1 Position the spoiler lip --> Figure 19 -A- on the front apron --> Figure 19 -B- and fix in place with clamping pliers. There should only be a small gap --> Figure 19 -Arrow- between the spoiler lip --> Figure 19 -A- and front apron --> Figure 19 -B-.





7.3.2 Align the tip of the spoiler lip centered at the highest point --> Figure 20 -Arrow- (dashed line) of the radius.

Get another person to press the templates --> Figure 20 -Arrows A- firmly onto the front apron. Carefully remove the spoiler lip without loosening the templates.





7.3.3 Make markings --> Figure 21 -Arrows- for the guide pin holes in the templates.

7.3.4 Remove templates and drill a hole (diameter = 5.5 mm) at each marking.

7.4 Make a hole for the spoiler lip fastening screw.

7.4.1 Fix spoiler lip in place on the front apron using clamping pliers (see Step 7.3.1). Carefully press guide pins into the front apron and position the tip of the spoiler lip centered at the highest point (see Step 7.3.2) of the radius.

7.4.2 Mark the contour of the spoiler lip on the front apron using a water-resistant pen.





7.4.3 Place marking for hole from the tip of the spoiler lip contour --> Figure 22 -Arrow-. Dimension X 20 mm

Note
Measure the marking again before drilling.

7.4.4 Drill a hole (diameter = 4 mm) at the marking.

7.5 De-burr all drill holes.

Note
The processing and component temperature must be at least 60°F. (15°C.).

7.6 Stick adhesive strips and double-sided adhesive tape from the adhesive kit on the spoiler lip.

7.6.1 Clean bonding surfaces on the spoiler lip and front apron to remove any dust and grease.





7.6.2 Stick triangular adhesive strip --> Figure 23 -A- and L-shaped adhesive strip --> Figure 23 -F- from the adhesive strip set at the correct position at the tip of the spoiler lip and in the wheel arch area.

Note
Allow approx. 20 mm extra on top of the specified lengths Figure 23 as a pulling aid (protective film without adhesive tape). The pulling aid makes it easier to pull off the protective film when the spoiler lip is fitted.





7.6.3 Cut adhesive strips with the lengths shown (B - E) from the double-sided adhesive tape.

7.6.4 Measure the additional 20 mm of adhesive strip.





Cut as much of the adhesive tape --> Figure 24 -A- as you need to pull it off the protective film.





7.6.5 Stick adhesive tape on the spoiler lip according to the designations (B - E). Lay the pulling aids over the edge of the spoiler lip --> Figure 25 -Inset X-.

Start by sticking adhesive strips --> Figure 25 -E- in the recess --> Figure 25 -Inset Z-.

7.7 Fit spoiler lip on front apron.

7.7.1 Pull protective film off the L-shaped adhesive strip --> Figure 23 -F- and triangular adhesive strip --> Figure 23, -A- and position spoiler lip on the front apron as described in Step 7.3.1.

7.7.2 Carefully press guide pins into the holes on the front apron and position the tip of the spoiler lip centered at the highest point (see Step 7.3.2) of the radius.





7.7.3 Pull off protective film --> Figure 26 -A- and press spoiler lip onto the front apron.

7.7.4 Press spoiler lip on with a rubber roller.

Contact pressure: 30





7.7.5 Press spoiler lip firmly onto the front apron and tighten with a self-tapping Torx screw (999.073.426.01) --> Figure 27 -A-.

Tightening torque 3 (2 ft-lb.) Nm

7.7.6 Secure the spoiler lip guide pins on the front apron with clamping washers.

7.7.7 Pull protective film off the adhesive tape on the spoiler lip/underside of front apron.





7.7.8 Press spoiler lip onto the front apron and drill a hole --> Figure 28 -A- through the pre-drilled holes on the spoiler lip into the front apron (diameter= 6.5 mm).

7.7.9 Insert expansion rivets (999.597.712.40) into the holes.

7.7.10 The left spoiler lip is fitted in the same way.

8 Concluding work.





8.1 Insert hose for headlight washer system into the clips --> Figure 29 -A- for the front apron.

8.2 Install the front apron. --> Workshop Manual '631519 Removing and installing front apron - section on "Installing"

8.3 Install front section of front wheel housing liner on the left and right. --> Workshop Manual '505619 Removing and installing front wheel housing liner - section on "Installing"

8.4 Install cover for lock support. --> Workshop Manual '703919 Removing and installing cover for lock support - section on Installing"