Rear Bumper Reinforcement: Service and Repair

Removing And Installing Rear Bumper

Technical values







Preliminary work

Remove rear apron. Refer to Removing and installing rear apron

General warning notes

Safety instructions for the heat shield

CAUTION: Assembly of deformed heat shields.
- Damage will be caused through heat build up if deformed heat shields are installed.
- Check heat shields for deformation, fixing of the aluminium braided cord, tears and missing or damaged fixing tabs.
- Damaged or distorted heat shields must be straightened or replaced.

Removing rear bumper

Removing support with heat shield at the sides







1. Unscrew fastening nuts -1, 2- and remove support with heat shield at the sides -3-.







Removing rear bumper







1. Unscrew fastening screws -1-, remove rear bumper -2 - or (USA/Canada version) -2A- with mounted lower centre heat shield -3-.







2. Unscrew fastening screw -4- with washer -5-.
3. Unscrew fastening screws -7-, remove lower centre heat shield -3- and rear supports -8-. If necessary disassemble rear supports by unscrewing the fastening screws -7-. Remove connecting angle -9- and fastening nuts -10-.

Checking anti-chafing film







INFORMATION: Replacing anti-chafing film:
- The bonding surface must be free from dirt, oil, and water residues.
- Ensuring there are no bubbles, bond in the anti-chafing film to the dimension X= 0 - 2 mm at the hole opening and side panel surface.

1. Check anti-chafing film -1-, and replace if necessary.







2. Check fastening nuts -2- and replace if necessary.

Installing rear bumper







1. Position lower centre heat shield -3- together with rear support -8- and screw in with fastening screws -6-.







2. Screw in fastening screw -4- with washer -5-.
3. Position connecting angle -9- and screw in with fastening screws -7- to the fastening nuts -10-.
4. Position rear bumper -2- or (USA/Canada version) -2A- with mounted centre heat shield at the bottom -3-.
5. Tighten fastening screws -1-. Tightening torque: 85 Nm (63 ftlb.)
6. Check the functional dimensions of the rear bumper and the correct assembly of the heat shield and correct if necessary. Refer to Removing and installing rear bumper

Installing support with heat shield at the sides







INFORMATION: Make sure that the plastic tabs are in contact with the side panel at the top.

1. Install support with heat shield at the sides -3-.







2. Tighten fastening nuts -1-. Tightening torque: 2 Nm (1.5 ftlb.)
3. Tighten fastening nuts -2-. Tightening torque: 9.7 Nm (7.0 ftlb.)
4. Check correct fitting of heat shield,and correct if necessary. Refer to Removing and installing rear bumper

Additional assembly instructions for installation of the bumper

Functional dimensions of the bumper

INFORMATION:
- In order to reduce adjustment work to a minimum when assembling the rear apron, the rear bumper or bracket (impact pipes, impact absorbers) must be positioned with respect to the lower edge of the rear lid according to the dimensions shown.
- However, the precondition for precise positioning of the components is that the rear lid is optimally adjusted and correctly locked in the lock in accordance with the functional dimensions, before the rear bumper or rear retaining strip are assembled.

1. Check the functional dimensions for the rear retaining strip, and correct if necessary. Refer to Removing and installing rear retaining strip
2. The adjustment dimensions at the measuring points -V = 345 mm- are to be adjusted.
3. Set adjustment dimension for the upper edge of retaining strip -2- to rear lid, -3- lower edge -X = 72.5 mm-.







4. Set adjustment dimension for the upper edge of bumper -1- to retaining strip, -2- upper edge -Y = 165 mm-.
5. Set adjustment dimension for the lower edge of rear lid -3- to bumper, -1- upper edge -Z = 234 mm-.
6. The measurements can be changed by undoing and moving the brackets (impact pipes, impact absorbers) or retaining strip.

Correct assembly of the heat shields

CAUTION: Damage will result if heat shields are fitted incorrectly.
- Observe the following points during assembly.
- Make sure the heat shields overlap correctly (arrows).
- There should not be any continuous gaps along the entire length of the heat shields.
- A gap of up to 2 mm wide and 30 mm long is permissible locally.
- At least more than 80 % of the total sealing area should be sealed off without gaps.







Subsequent work

Install rear apron. Refer to Removing and installing rear apron