Body Kit
Body kit
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.
Body kit
Note! Paint in accordance with the "Touch up spraying" service instructions. Note that the body kit must be cleaned, ground and then cleaned again before painting in accordance with the instructions. The structured door trim strips are treated in accordance with the instructions in step 1.
Caution! The body kit is manufactured of a PUR plastic which is very malleable. If the plastic parts are not adequately supported when storing or mounting during painting then there is significant risk that the plastic will change shape. Guide pins or other protruding parts must not bear the weight of a plastic part. Lay the plastic parts with support across a wide area. The malleability will be even greater when heated. Drying in an oven must not be used in temperatures above 50°C (however the structured door trim strips can tolerate heat treatment at 60° in accordance with step 1). The best method is to allow the plastic parts to dry in the air.
Hint: Work is easier if the car is raised to a suitable height. In addition, the risk of scratching parts by mistake during installation/removal is reduced as they do not make contact with the ground as easily.
Preparations, door trim strips
Illustrations A and B
- Dampen a Scotch-Brite gray 3M, P/N 07522, and wash/grind the plastic.
- Wipe dry.
- Place the parts in 60°C for one hour.
- Wash and wipe dry.
- Apply plastic primer and plastic filler in accordance with the paint supplier's instructions.
- Wipe and grind smooth.
- Paint in accordance with the paint supplier's instructions.
Installing the panels for the door sills
- Remove the three screws at the front edge of the rear wing liner. On some cars it may be necessary to remove the rear wheel first in order to remove the screws.
- Position a shim between the front edge of the wing liner and the bodywork, so that the rear panel of the door sill is exposed.
- Remove the three screws at the rear edge of the front wing liner.
- Secure the rear edge of the front wing liner.
- Unscrew the center screws on the seven clips on the underside of the panels for the door sills. Remove the screws.
- Open the doors on one side
- Using a plastic weatherstrip tool, pry off the front and rear panels from the bodywork. Start at one end and continue along the entire panel until all the clips release. The front panel is secured with nine clips in the middle and a locating pin at the front edge. The rear panel is secured with a clip and a locating pin. The front panel sits in the rear panel and is secured to it by two mounting hooks. Do not damage the paintwork on the doors and door sills.
- Remove the rubber strip from the old panels. The rubber strip will be reused
- Place the panels to one side. The panels will not be used again
- Clean the surfaces where the new panels are to be installed
- Clean the rubber strip and install it on the new panel from the kit
- Install new clips and spring nuts (from the kit) on the new panels. Check on the old panels how the various clips and spring nuts are to be located.
- Slide the rear panel section (from the kit) onto the long panel.
Note! It is recommenced that two people press the panels into place.
- Press the new panels into place on the door sill using new clips from the kit. Ensure that all the clips have engaged
- Install the existing screws in the front edge/rear edge of the wheel arches, but do not tighten yet.
The panels are tightened at the front edge and rear edge after adjustment to the wing and door edge in step 13.
- Repeat all the above steps on the other side of the car.
Installing door trim strips
- Open the rear door on one side
- Carefully pry off the door trim strip using a plastic weatherstrip tool. The door trim strip is secured with four clips (it is secured with six clips on the front door).
- Wipe clean the surfaces where the door trim strips were located
- Take a new door trim strip from the kit.
- Press the door trim strip into place.
- Repeat steps 11 and 12 on all doors.
Illustrations A and B
Adjusting the rear wing
- Adjust the rear section of the door sill panel so that approximately the same horizontal play is obtained between the top edge of the door sill panel and the lower/front edge of the rear wing, as between the top edge of the door trim strip and door edge as in image A. At the same time, the top edge of the door sill panel must also be positioned correctly in relation to the lower edge/front edge of the rear wing, as in illustrationB.
- Secure the door sill panel in the correct position and tighten the screws.
- Reinstall the rear wheel if this was removed. Tighten the wheel nuts. Tighten to 90 Nm (66 lbf. ft.).
- Repeat the above procedure for the front section and for the other side.
Illustration C and D
Adjusting the front wing
Installing the spoiler on the rear bumper cover
- Remove the two screws (1) at the rear at the bottom of the bumper cover.
- Remove the three screws (1) securing the bottom section of the rear bumper cover to the rear edge of the wheel arch, on the right and left-hand sides.
- Remove the bumper cover's lower section. Pry up the mounting hooks on the inside and pull it loose. Place the lower section to one side, it must not be used again.
Applies to cars with towbar
On cars with a towbar, a cut-out for this must be made in the new spoiler for the bumper cover. See illustrations A, B C and D.
Illustration A applies to cars with a fixed towbar
- Apply tape to the outside of the spoiler, opposite the markings on the inside. This is done to protect the paint from the saw when cutting out the cut-out for the tow hitch wiring connector. (Applies to painted spoilers.)
- Cut out the cut-out following the existing markings.
Note! Do not damage the painted surface of the spoiler. Cut so that the raised edge on the inside remains. The raised edge marks the cut-out.
- Smooth off the sawn edges using a fine toothed file. Remove the tape.
Illustration B applies to cars with a detachable towbar, AUS, and EU older models
Illustration C applies to cars with a detachable towbar, USA
Illustration D applies to cars with a detachable towbar, EU, new model P/N 30633681 and 30744274. (See type plate on towbar)
Note! This marking is not on older spoilers, so draw the marking as follows:Height 100 mm, start from the marking furthest to the left in the illustration (1).Width 250 mm, start from the marking at the top of the illustration (2). The radius of the two corners is 30 mm.
Applies to all models
- Clean the surfaces of the rear bumper cover where the new spoiler is to be secured
- Press the spoiler into place on the bumper cover. Ensure that all the catches engage. Do not damage the paintwork
- Tighten the spoiler to the inner wings and brackets in the bodywork with new screws from the kit.
Installing the spoiler on the front bumper cover
- Remove the two screws securing the bumper cover and air baffle at the front edge of the wheel arch, on the left and right-hand sides.
- Remove the four screws securing the air baffle to the lower section of the bumper cover.
- Remove the two screws along the sides of the engine splashguard.
- Remove the air baffle by first carefully pulling the lower section of the bumper cover and air baffle forward until the air baffle can be unhooked from its rear mounting in the bracket under the radiator. Then carefully pull it loose from the lower section of the bumper cover and the sides of the engine splashguard.
Note! Do not damage the outer ends of the air baffle. These can easily break off.
- Release the mounting hooks on the inside of the bumper cover, which holds the lower section. Carefully pull the lower section loose and place it to one side, it will not be used again.
- Clean the surfaces of the bumper cover where the spoiler is to be secured
- Press the spoiler into place on the bumper cover. Ensure that all the mounting hooks have secured
Illustration A
- Reinstall the air baffle for the bumper and mounting in the bracket on the radiator. Ensure that the front and rear edges of the air baffle come into the right position on the bumper cover and the bracket on the bottom edge of the radiator.
- Tighten the brackets for the spoiler to the air baffle. Use new screws from the kit.
Illustration B
- Tighten the bumper cover with the spoiler to the front edge of the wheel arch on both sides, and to the engine splash guard. Use the screws from the kit.