Rear Bumper Fascia Center Support Replacement Sportwagon

Caution: Refer to Approved Equipment for Collision Repair Caution in the Preface section.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Foam Sound Deadeners Caution in the Preface section.

1. Disable the SIR system. Refer to SIR Disabling and Enabling.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement
4. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement
5. Remove the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
7. Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
8. Remove the rear bumper impact bar. Refer to Rear Bumper Impact Bar Replacement.
9. Remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.



10. Locate, mark and drill out the spot welds in the rear bumper fascia centre support to the rear end panel assembly (1).

Important: Spot welding is the preferred method for attaching panels and should be used whenever possible. A plug weld should only be performed where spot welding is not possible.

Important: If the location of the original spot weld holes cannot be determined, or if structural weld-thru adhesive is present, space the puddle weld holes every 32 mm (1¼ in).

Important: Follow the adhesive manufacturer's instructions during the assembly process. Heat must be applied as per the manufacturer's specifications to cure the adhesives and to expand the sealing baffles.

1. Drill 8 mm (5/16 in) plug weld holes as necessary in the locations noted when disassembling.
2. Clean and prepare the mating surfaces of both parts of the panel.



3. Utilising the two holes in the rear end panel assembly (2) as a reference point, mark the centre line of the vehicle (C) onto the rear end panel assembly (1).
4. Utilising the two holes in the rear end panel assembly (2) as a reference point, measure 57.5 mm (B) above each hole onto the rear end panel assembly (1) to establish the rear bumper fascia centre support location alignment mark (A).



5. Measure and mark the centre point on the bumper facia centre support assembly (D).
6. Align the centre point mark on the rear bumper facia centre support assembly (1) with the centre line mark on the rear end panel assembly (C).
7. Align the lower edge of the rear bumper facia centre support assembly (2) with the alignment marks (A) on the rear end panel assembly (3).

Important: Secondary sealer must be applied to the perimeter of all flanges. Secondary sealer must be applied to all welds/joints that were originally covered by secondary sealer.

8. Weld the centre support assembly (2) to the rear end panel assembly (3).
9. Apply the sealers and anti-corrosion materials to the repair area, as necessary. Refer to Anti-Corrosion Treatment and Repair.
10. Paint the repaired area. Refer to Basecoat/Clearcoat Paint Systems.
11. Install the rear bumper impact bar. Refer to Rear Bumper Impact Bar Replacement.
12. Install the rear bumper fascia. Refer to Rear Bumper Fascia Replacement.
13. Lower the vehicle.
14. Install the liftgate weatherstrip. Refer to Liftgate Weatherstrip Replacement.
15. Install the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement
16. Install the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
18. Enable the SIR system. Refer to SIR Disabling and Enabling.