Rear Bumper Mounting

Rear Bumper Mounting

Removal
1.
NOTE:
The removal and installation steps shown within this procedure may differ depending on whether the panel in question is being replaced in isolation, or, is being replaced in combination with panels other than those listed.

The rear bumper mounting is a category A repair.





2.
NOTE:
The rear bumper mounting is manufactured from gravity die-cast aluminium (GDC).

The rear bumper mounting is serviced as a separate riveted and bonded panel, it is also on the rear side member service panel.

3. In this procedure, to make sure that the vehicle is correctly aligned, it must be placed on an approved alignment jig.

4. The rear bumper mounting is replaced in conjunction with:
- Rear bumper cover
- Rear bumper
- Back panel

NOTE:
A new rear side member closing panel service panel will be required

A section of the rear side member closing panel is required for access
- The adjoining flanges of the spare wheel well and the rear floor side extension will need to be opened up to enable welding access

5. For additional information relating to this repair procedure please see the following: For additional information, refer to Health and Safety Precautions
For additional information, refer to Body Repairs
For additional information, refer to Corrosion Protection
For additional information, refer to Body and Frame

6. Disconnect the battery. For additional information, refer to Battery Disconnect and Connect

7. Disconnect the generator electrical connectors.

8. Remove the back panel. For additional information, refer to Back Panel

9. If the right-hand rear bumper mounting is to be replaced, remove the battery and battery tray. For additional information, refer to Battery

10. If the right-hand rear bumper mounting is to be replaced, remove the insulating material from the luggage compartment floor.

11. Remove any electrical components in the local area of repair to prevent damage.

12. Release and position the back panel and loadspace wiring harness to one side.





13.
CAUTION: Consideration should be given to the location of holes, weld-studs and rivet-nuts.

Mark out the position where the rear side member closing panel section MIG butt joint is to be made as indicated.

14. Remove sealer from the area of repair as required, to reveal the panel joints.





15. Using a 6.5mm Cryobit drill bit, remove the self piercing rivets from the spare wheel well and from the rear floor side extension.





16. Remove the Hemloks from the rear side member closing panel.





17. Remove the Hemloks from the rear side member panel.

18. Carefully separate the flanges of the spare wheel well and the rear floor side extension to allow access to where the rear side member closing panel is to be sectioned.





19.
CAUTION: Care should be taken not to cut through into the inner reinforcement.

Cut through the rear side member closing panel as indicated.

20. Separate the joints and remove the rear side member closing panel section.





21. Using a 6.5mm Cryobit drill bit, remove the Hemloks from the rear bumper mounting.

22. Separate the joints and remove the rear bumper mounting.

Installation
1. Remove rivet remnants.

2. Using a Roloc fine bristle disc, clean and prepare the panel surfaces removing any sealer and adhesive residue.

3. Dress flanges where necessary.

4. Offer up the new rear bumper mounting and clamp into position. Check alignment, if correct proceed to next step, if not, rectify and recheck before proceeding.





5. Using a 6.5mm Cryobit drill bit, drill a hole through the rear side member panel into the rear bumper mounting.





6. Mark out the position on the rear side member closing panel service panel, where the section MIG butt joint is to be made and cut the panel at this point as indicated.

7. Offer up the new rear side member closing panel section and clamp into position. Check alignment, if correct proceed to next step, if not, rectify and recheck before proceeding.





8. Using a 6.5mm Cryobit drill bit, drill holes at the points where Hemloks are to be installed.

9. Remove the new panel.

10. Deburr the drilled holes.

11. Using a Roloc fine bristle disc, clean and prepare the panel surfaces, including the inner panel surfaces where backing plates are to be welded.

12.
NOTE:
The backing plate may need to be trimmed to fit around holes and rivet-studs.

Measure and cut a backing plate, approximately 50mm wide (25mm each side of the MIG butt joint), from the unused part of the new rear side member closing panel or from similar material.

13. Cut a run on/run off tab from the unused part of the new rear side member closing panel, or from similar material.

14. Using a Roloc fine bristle disc, clean and prepare the backing plates and the run on/run off tab.





15. MIG weld the backing plate onto the new rear side member closing panel section.





16. Drill 2 10mm holes through the rear side member closing panel, where the backing plate is to be MIG plug welded.

17. Deburr drilled holes.

18. Using a Roloc fine bristle disc, clean and prepare the panel joints.

19. Pyrosil the joints at the points where 3M 8115 adhesive is to be applied.

20. Apply the coupling agent where 3M 8115 adhesive is to be applied and allow to dry.





21.
NOTE:
Make sure a continuous bead of adhesive surrounds fixing holes.

Apply a 5mm zig zag bead of 3M 8115 adhesive to the rear bumper mounting.

22. Offer up the new rear bumper mounting, align and clamp into position.





23. Using the Genesis G4, install the Hemloks.





24. Using the Genesis G4, install the Hemloks.

25.
NOTE:
Make sure a continuous bead of adhesive surrounds fixing holes. Do not apply adhesive in the vicinity of the MIG weld.

Apply a 5mm zig zag bead of 3M 8115 adhesive to the rear side member and the rear bumper mounting.

26. Offer up the new rear side member closing panel section, align and clamp into position.





27. Using the Genesis G4, install the Hemloks.





28. Tack weld the run-on/run-off tab to the rear side member closing panel section.





29. Install 2 MIG plug welds.





30. MIG weld the rear side member section butt joint.

31. Cut off the run on/run off tab.

32. Dress the welded joints.

33. Pyrosil the flanges of the spare wheel well and rear floor side extension, at the points where 3M 8115 adhesive is to be applied.

34. Apply the coupling agent to the flanges of the spare wheel well and rear floor side extension where 3M 8115 adhesive is to be applied and allow to dry.

35.
NOTE:
Make sure a continuous bead of adhesive surrounds fixing holes.

Apply a 5mm zig zag bead of 3M 8115 adhesive to the flanges of the spare wheel well and rear floor side extension.

36. Re-align the flanges of the spare wheel well and rear floor side extension and clamp into position.





37. Using the Genesis G4, install the Hemloks.

38. Remove any excess adhesive.

39. Using the old panel for reference, install the rivet-studs into the new rear side member closing panel section.

40. Make sure that any open or exposed panel joints are suitably sealed following this procedure.

41. The installation of associated panels and components is the reversal of removal procedure.