Spoiler Boot Lid
Spoiler boot lid
INTRODUCTION
- NOTE! Read through the whole installation instruction before starting the work.
- The front page gives the date of this edition and the edition it replaces
- The second page shows the tools needed for the installation and the contents of the installation kit
- The illustrations display the procedure in order of operation. The order of operation is repeated in the text section
- Cut out the text page in order to follow the illustrations and text at the same time.
Spoiler boot lid
Preparations
Illustration A shows templates for the top of the boot lid
Illustration B shows templates for the underside of the boot lid
- Take the sheets containing the drilling templates from the kit. Cut out the templates.
- Open the boot lid. Remove the clips from the boot lid panel
- Remove the warning triangle holders. First pry up and remove the centres of the clips. Then pull off the holders
- First slide up the inner handle for the boot lid. Then pry off the bottom edge of the handle. Remove the handle.
- Take the left drilling template from the top of the boot lid. Close the boot lid. Position the template against the left-hand rear corner of the boot lid. See the illustration
- Secure two rulers or similar using butyl tape. The rulers are used to guide the template up against the sides and rear edge of the boot lid. The rulers must be positioned in the middle of the front and rear edge of the template, with the rear ruler 50 mm (2") down from the top edge of the boot lid
- Position the template against the rulers so that it is edge to edge with the corner of the boot lid
- Tape the template in position
- Take out the right-hand drilling template for the top of the boot lid. Follow the same procedure on the right-hand side.
- Check the distance between the holes in the drilling templates. The distance must be 1054 mm (41 1/2") between the outer holes and 841.5 mm (33 7/64") between the inner holes. Adjust symmetrically if necessary.
Drill from the outside of the boot lid
- Mark through the templates and onto the boot lid using an awl
- Remove the templates, the rulers and the butyl tape.
Note! Do not damage other paintwork when drilling.
- Pre-drill the hole through the boot lid. Use a 3 mm (1/8") diameter drill bit. Ensure that the drill is held at right-angles to the boot lid. When drilling the outer holes, drill through the inner panel at the same time. Check that the measurement is 1054 mm
- Drill out the holes. Use a 7 mm (9/32") diameter drill bit.
Note! Only drill through the outer panel.
- Drill out the holes further. Use an 11 mm (7/16") diameter drill bit.
Note! Only drill through the outer panel.
Drilling from the inside of the boot lid, inner holes (check measurement 841.5mm)
Illustration A
- Open the boot lid in order to drill the inner holes (check measurement 841.5 mm). Take out the left drilling template for the underside of the boot lid. Position the drilling template along the edges of the boot lid as illustrated. The edges of the drilling template must be at the start of each radius
- Mark through the template and onto the inner panel in the boot lid using an awl
- Pre-drill the hole through the inner panel. Use a 3 mm (1/8") diameter drill bit. Ensure that the drill is held at right-angles to the inner panel
- Take out the right template for the underside of the boot lid. Follow the same procedure on the right-hand side.
Illustration B
- Drill out the same hole. Use a 29 mm (1 1/8") diameter hole saw:
-
Note! Ensure that the hole is inside the marked area, so that it can be concealed by the boot lid panel.
Note! Only drill through the inner panel in the boot lid.
Angle the hole saw after cutting through the paint layer and part of the panel thickness. This avoids the risk of the cut section falling between the panels. Drill carefully in this way until the hole saw passes through the panel.
Illustration C
- Bend up the cut section and work it away from the panel. Use round-nosed pliers.
Note! There may be sealing compound residue between the outer and the inner panels in the boot lid, where the screws are to be tightened. Remove the sealing compound residue.
- Repeat the operation on the other side.
Drilling from the inside of the boot lid, outer holes (check measurement 1054mm)
- Drill the outer holes (check measurement 1054 mm). Use a 20 mm (25/32") diameter hole saw:
-
Note! Only drill through the inner panel in the boot lid.
Angle the hole saw after cutting through the paint layer and part of the panel thickness. This avoids the risk of the cut section falling between the panels. Drill carefully in this way until the hole saw passes through the panel
- Bend up the cut section using round-nosed pliers and "work" it away from the panel (see previous point, illustration C). There may be a piece of intermediate panel left inside. Drill out any intermediate panel.
Note! There may be sealing compound residue between the outer and the inner panels in the boot lid, where the screws are to be tightened. Remove the sealing compound residue.
- Repeat the operation on the other side.
Installing the spoiler
- File down the edges of the holes. Remove any swarf from all the drilled holes
- Check that the spoiler aligns in the four drilled holes. Screw the two locating pins (as far as they will go) into the nuts in the spoiler. Then insert the locating pins into the holes in the boot lid
- If necessary: adjust the holes using a small round file.
- Clean the surfaces where the spoiler will be positioned. Use a mixture of 30% windscreen washer fluid and 70% water
- Wipe dry
- Treat the edges of the holes using a rust-proofing agent. Avoid getting rust-proofing agent on the areas around the holes. Rust-proofing agent can make the blind cover plugs/tape difficult to secure.
Note! To ensure the best results, it is recommended that two people press the spoiler onto the boot lid. Remember that the spoiler must be installed symmetrically on the boot lid. Tips: Look on the inside of the boot lid. Check that the locating pins are in the centre of the drilled holes.
Illustration A
- Remove the protective film from the mounting tape for the spoiler.
Illustration B
- Grip both ends of the spoiler. Carefully insert the locating pins in the holes in the boot lid
- Press the spoiler firmly against the boot lid. (Otherwise there is a risk of the tape coming away when installing the screws and nuts)
- Open the boot lid. Remove the two locating pins
- Take the screws, nuts, washers and blind cover plugs from the kit
- Tighten the screws, nuts and the washers for the spoiler. Tighten to 5 Nm (3.7 lbf.ft.).
Note! Do not exceed this torque.
- Post-tighten the screws and nuts after 5 minutes
- Press the blind cover plugs into the holes (check measurement 1054 mm) in the inner panel in the boot lid
- Reinstall the panel on the underside of the boot lid.
Note! Leave the car indoors for 2 hours after carrying out the work. Do not wash the car for 48 hours.