Work Procedure
1 Preparatory workCAUTION
Painting components
^ Risk of warping of components
^ Risk of damage to components
--> Observe the guidelines and instructions for painting components in the "Paint" Workshop Manual.
--> Always place parts without tension on the painting devices provided during painting and drying processes.
1.1 Paint all ready primed parts to match the vehicle's color code in accordance with instructions in the Paint Workshop Manual.
1.2 Remove rear logo --> Workshop Manual '665019 Removing and installing rear logo - section on "Removing"'.
CAUTION
Affixing components using adhesive tape
^ Risk of damage to the vehicle or paintwork
^ Risk of damage to components
--> Clean bonding surfaces to remove any dust and grease.
--> Use clean, lint-free disposable cloths for cleaning.
--> Do not touch the bonding surfaces with your fingers.
--> The object (component, vehicle) and ambient temperature must be at least 59° F (15° C).
--> Press component on with a suitable tool (rubber roller) using the prescribed pressure.
1.3 If requested by the customer:
Install new rear logo --> Workshop Manual '665019 Removing and installing rear logo - section on "Installing"'.
Check that dimensions correspond to --> Figure 3.
A - Distance from logo to edge of lid (Aerokit) 130 mm and "S= 125 mm
B - Distance from logo to edge of lid (standard) = 66.1 mm/"S" = 60.1 mm
1.3.1 Remove traces of weathering from the old logo/logos using paint polish if necessary.
Information
Clean bonding surface to remove any dust and grease.
1.3.2 Apply new logos on rear lid.
1.4 Remove both tail lights --> Workshop Manual '943120 Removing and installing tail lights - section on "Removing".
1.5 Remove spoiler drive and both sealing plates (left side --> Figure 4-A-). Workshop Manual '667219 Removing and installing spoiler drive - section on "Removing"'.
1.6 Clean rear apron underneath removed standard spoiler.
1.7 Wrap adhesive tape around connector for spoiler drive (6-pin) and secure it to existing components/lines in the luggage compartment so that it cannot become chafed and will not rattle (--> Figure 5 -arrows-).
1.8 Fit two rubber stoppers in the bores on the luggage compartment floorpan (water drain mechanism for standard spoiler) (left side, --> Figure 5-A-).
1.9 Remove trim panel for rear lid --> Workshop Manual '708719 Removing and installing trim panel for rear lid - section on "Removing"'.
2 Prepare rear lid for installing rear spoiler
2.1 Drill bore holes for rear spoiler on the rear-lid outer panel.
2.1.1 Open the rear lid and cover the luggage compartment with brown paper or a similar protective covering.
2.1.2 Spray water on the surface of the rear lid using a spray bottle.
2.1.3 Place outer panel template on top of the rear lid (--> Figure 6).
2.1.4 Align template with the edge of the lid (--> Figure 6-inset-) and position it symmetrically with respect to the rear lid (--> Figure 6-arrows-)
2.1.5 Copy markings (4 ea.) on the template to the outer panel of the rear lid using a hammer and center punch (--> Figure 7).
CAUTION
Drilling the rear lid
^ Risk of water leaks into the luggage compartment
--> The bore diameter on the outer panel must not be greater than 8.0 mm because otherwise the luggage compartment seal at the screw head/spoiler base cannot be guaranteed.
--> Drill and counter-sink carefully and use stop bit for power drill if necessary.
--> Do not drill through rear lid (outer and inner panel) in one step. Drill bore holes according to the relevant template.
2.1.6 Remove template and drill holes at the four markings on the outer panel as follows:
- Stop bit setting on power drill: 15 mm;
- Drill a small hole first: diameter = 4.0 mm (--> Figure 8-arrows-);
- Drill required bore: diameter = 8.0 mm
2.1.7 Deburr the bores.
2.2 Drill bore holes for rear spoiler on the rear lid inner panel.
2.2.1 Clean inside of rear lid to remove any dust and grease and spray it with water.
2.2.2 Place inner panel template on the inside and align it with the contour of the inner panel of the lid (--> Figure 9-arrows-) and bore (--> Figure 9-A-).
2.2.3 Also fix inner panel template in place on the rear lid using adhesive tape (--> Figure 9).
2.2.4 Copy markings (4 ea.) on the template to the inner panel of the rear lid using a hammer and center punch and remove the template.
Information
The two outer bores (left side: Figure 7 -A-1 right side: Figure 7-8-) must be > 1.0 mm from the radius of the inner panel!
Background: New bores must not be visible when the rear lid trim panel is fitted.
2.2.5 Draw a circle with diameter = 15.0 mm at the four markings using a drawing compass.
CAUTION
Drilling the rear lid
^ Risk of water leaks into the luggage compartment
-->The bore diameter on the outer panel must not be greater than 8.0 mm because otherwise the luggage compartment seal at the screw head/spoiler base cannot be guaranteed.
--> Drill and counter-sink carefully and use stop bit for power drill if necessary.
-->Do not drill through rear lid (outer and inner panel) in one step. Drill bore holes according to the relevant template.
2.2.6 Remove template and drill holes at the markings on the inner panel as follows:
- Stop bit setting on electric drill: 15 mm;
- Drill a small hole first: diameter = 4.0 mm;
- Drill required bore: diameter = 15.0 mm
2.2.7 De-burr the bores.
2.3 Remove beading joint seal on rear lid.
2.3.1 Mask the outer edges of the rear lid (left side --> Figure 11-A-, right side --> Figure 11-B-) and along the beading joint seal, if necessary (--> Figure 12-arrows-) with adhesive tape.
2.3.2 Cut into the beading joint seal up to the edge of the rear lid (--> Figure 12-arrows-). To do this, carefully go along the edge of the rear lid vertically as far as the beading joint seal with a spatula.
2.3.3 Remove the beading joint seal for the inner/outer panel of the rear lid on the inside across its entire width (--> Figure 12 -arrows-) as far as the adhesive tape using a spatula.
2.4 Treat all bores with corrosion protection and then paint the bores to match the vehicle's color code using a touch-up stick (--> Figure 13).
Paint the visible part of the beading joint seal with a touchup stick.
2.5 Clean the surface of the rear lid and remove the protective covering (paper or film) from the luggage compartment.
Use a vacuum cleaner to remove metal chips.
3 Fit the rear spoiler to the rear lid.
3.1 Preparatory work
Information
Clean bonding surface to remove any dust and grease.
3.1.1 Insert sealing cord into the groove on the underside of the spoiler base and stick it on with Loctite 406 (--> Figure 14 -insets-).
Remove adhesive residue on visible and contact surfaces of the sealing cord.
3.1.2 Insert hexagon socket head bolt (M6 x 25, 4 ea.) into the spoiler base from underneath (--> Figure 15).
3.1.3 Carefully position the spoiler base on the underside of the spoiler.
3.1.4 Tighten the four hexagon socket head bolts (M6 x 25) crosswise on alternate sides
Tightening torque 7 Nm (5.0 ft.lb.)
Information
Clean bonding surface to remove any dust and grease.
3.1.5 Stick support tape (transparent adhesive film) to the bar on the underside of the spoiler base (--> Figure 16, shaded area).
3.1.6 Insert M6 threaded plate (4 ea. --> Figure 17-A-) into the slot (4 ea.) on the spoiler base and slide into the required position (--> Figure 17 -arrow-).
Cover the threaded plates with adhesive tape, if necessary, to prevent them from slipping out of the slot (--> Figure 17-B-).
3.2 Fit the rear spoiler on the rear lid.
Information
Clean bonding surface to remove any dust and grease.
3.2.1 Slide the groove on the rear spoiler base onto the edge of the rear lid from behind (--> Figure 18-A, arrow-).
Press the rear spoiler onto the edge of the rear lid until gap dimension X (--> Figure 18 -X-) is at zero all the way around.
Make sure that the pull tabs on the adhesive tape are still accessible after positioning the components.
3.2.2 Align the rear spoiler with the axis of symmetry of the rear lid so that dimension Y (--> Figure 18-Y-) is the same on both sides.
Information
Check the position of the threaded plate with respect to the bore and correct it using a small screwdriver if necessary.
3.2.3 Fit hexagonhead bolt (M6 x 8, 4 ea.) into the corresponding bores (underside of rear lid, left side --> Figure 18-B1-) on the M6 threaded plate (4 ea.).
3.2.4 Carefully pull out the pull tabs on the adhesive tape between the spoiler base and rear lid (--> Figure 19). Press sealing cord into position using a plastic spatula if necessary.
Press the spoiler base onto the rear lid with a rubber roller.
Pressure 100 N
3.2.5 Secure the rear spoiler, starting from the inside out.
Tightening torque 9.7 Nm (7.5 ft.lb.)
4 Fit spoiler trim.
4.1 Fit the two adapters for the spoiler trim mounting.
4.1.1 Pull off film on adhesive tape on the underside of both adapters (left: --> Figure 20 -L-/right: --> Figure 20
Information
Clean bonding surface to remove any dust and grease.
4.1.2 Position adapter using the corresponding bore in the rear apron (pass-through mechanism on standard spoiler).
Observe marking "L = left" and "R = right" on the adapter --> Figure 20.
Information
The position of the adapter cannot be changed once it is pressed in. There should be no need to remove the adapter!
4.1.3 Align the adapters as follows:
- Slot in adapter in direction of travel (right side --> Figure 21-A-)
- Mounting in rear apron
4.1.4 Push adapter into the mounting and press it on (left side --> Figure 21 -B-).
4.2 Fit spoiler trim.
4.2.1 Insert the two mounting pins into the spoiler trim (--> Figure 22-A-) and fit spacer onto each mounting pin (--> Figure 22-B, arrow-).
Information
Clean bonding surface to remove any dust and grease.
4.2.2 Guide spoiler trim with both mounting pins and spacers into the slots on the adapters (--> Figure 23 -A and B-).
4.2.3 Guide pull tab on adhesive tape (--> Figure 24-A-) between the spoiler trim and rear apron out towards the rear.
Information
The opening in the tail light mounting can be useful as a visual contact when fitting the hexagon nuts or attaching tools.
4.2.4 Fit M6 hexagon nuts on both sides and tighten slightly (--> Figure 23 -C-) so that the spoiler trim can still be moved.
4.2.5 Set the gap dimension between the spoiler trim and rear apron using a gap dimension gauge (--> Figure 24 -arrows-).
Gap dimension 1.5 mm +0.3 mm -0.2 mm
Check symmetry with respect to the rear apron and correct it if necessary.
4.2.6 Tighten the spoiler trim.
Tightening torque 9.7 Nm (7.5 ft.lb.)
4.2.7 Carefully pull out the pull tab on the adhesive tape (--> Figure 24-A-).
4.2.8 Press the spoiler trim onto the rear apron with a rubber roller.
Pressure 100 N
5 Concluding work on rear spoiler
5.1 Adjust rubber buffer on rear lid --> Workshop Manual '559015 Adjusting rear lid'.
5.2 Fit sealing plate assembly (2 ea.) for luggage compartment seal.
5.2.1 Guide mounting plate (--> Figure 25-A1-) into the cavity in the rear wall/end plate and position it correctly.
5.2.2 Slide sealing plate (--> Figure 25 -B1-) onto both pins with foam rubber facing the rear wall of the luggage compartment and fit M6 hexagon nut (--> Figure 25 -B2-).
5.2.3 Tighten M6 hexagon nut.
Tightening torque 4.5 Nm (3.0 ft.lb.)
5.3 Install trim panel for rear lid --> Workshop Manual '708719 Removing and installing trim panel for rear lid - section on "Installing"'.
5.4 Install both tail lights --> Workshop Manual '943120 Removing and installing tail lights - section on "Installing"'.
5.5 Install cover for rear lock support --> Workshop Manual '703919 Removing and installing cover for rear lock support - section on 'Installing"
5.6 In stall trim panel for rear luggage compartment --> Workshop Manual '700619 Removing and installing trim panel for rear luggage compartment (carpet lining) - section on "Installing"'.
6 Fit front spoiler lip.
6.1 Drive the vehicle onto a lifting platform and raise it to working height --> Workshop Manual '400000 Lifting the vehicle'.
6.2 Remove the two standard spoiler lips (--> Figure 26-1-) --> Workshop Manual '660319 Removing and installing front spoiler - section on "Removing"'.
6.3 Clean around the spoiler lips (--> Figure 26 -1-, shaded area) on the front apron.
6.4 Install the two new spoiler lips (--> Figure 26 -2-) --> Workshop Manual '660319 Removing and installing front spoiler - section on 'Installing"'
7 Concluding work
7.1 Code "Fixed spoiler" using the PIWIS Tester 9718.
7.1.1 Select "Rear" control unit group and press [>>].
7.1.2 Select "Coding" menu item and press [>>].
7.1.3 Select "Fixed spoiler - not installed" in the menu and change the coding by pressing [>>].
7.1.4 Switch from "not installed" to "installed" under "Change coding".
7.1.5 Write coding with [F8].
7.2 Read out the fault memory of all control units, correct any existing faults, and then erase the fault memory.