My front facia mating to the fenders under the headlights was not right from day 1. There is a gap there and on both sides it was protruding outward and when washing the car I was always catching the mit or chamois on the edges. Last summer I took it in and the dealer put different clips in and although the problem was not totally corrected it was improved.
Well just a month ago I took it back in after the problem resurfaced. I could pull it out from under the headlights. I believe the heat has something to do with it. Told them I want it right, and either you get it right or get me a new front end. Well, now it's right. Although there is still a slight gap (wide enough to get a playing card between) the protrusion has been corrected. Apparently the clips that hold the front end in place there could use some improvement. As I stated before, I have seen some where there is no gap and it looks like a weld, and I have seen some with gaps.
My rear facia behind the rear wheels was also popping out at times, and I could pop it back in place. Again, new clips were installed and it is now tight. I do think the heat is affecting this. I don't live in a constant high heat area, but that's the only explanation I can come up with.
I took a look at the pics in a previous thread, and the gap behind the rear wheels from the rear facia to the fenders (quarter panel) appears to be normal. Where the rear facia meets at the wheel is tight but as you follow the seam around to the rear there is maybe a 1/16" space until the facia begins its wrap around to the rear. I think this is just the nature of it, at least for the SAP facia. I see no way to eliminate the slight gap. The gap is barely noticible, and the facia to quarter panel is tight the whole way around except for a small area on both sides.
I do wish that when you order a package, or options it would be done at factory in the assembly environment like it used to be instead of it being a dealer installed option. The Q.C. process is monitored more...well, it's supposed to be anyway.