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Spoiler Assembly > < Add-ons to 'Side panel, Replace' (Side panel removed) (Model L 35)

Astra H

Rear Frame Side Member, Right Side, Replace (Model L 08, L 48)

  Remove

1.   Detach attaching parts
Object Number: 8036402 Size: DEFAULT

2.   Drill away luggage compartment floor

Object Number: 8036400 Size: DEFAULT

3.   Detach luggage compartment floor
Note:   Note parting cuts!

Object Number: 8036401 Size: DEFAULT

4.   Detach luggage compartment floor
Note:   Observe cutting line!

Object Number: 8036403 Size: DEFAULT

5.   Drill open and lift up flange, rear panel crossmember

Object Number: 8036404 Size: DEFAULT

6.   Detach and drill away rear frame side members
Note:   Note size of new part and cutting line!

  Install

Object Number: 8036411 Size: DEFAULT

7.   Prepare rear panel crossmember
•   Incorporate 2x ( 6x18 mm ) slot

Object Number: 8036405 Size: DEFAULT

8.   Prepare and adjust rear frame side member to fit
Note:   Incorporate 11x ( 8x24 mm ) slot

Object Number: 8036406 Size: DEFAULT

Important:   Ensure the slots and the flanges to be attached are correctly aligned!
9.   Prepare rear panel anchor plate
•   Incorporate 11x ( 6x18 mm ) slot
•   Drill 1x hole (1) ( 8 mm )
Note:   Incorporate slots and hole via anchor plate and rear panel!
Note:   Comply with drilling template!

10.   Adjust rear frame side member to fit


11.   MIG-braze rear frame side member
Note:   Note specification for welded and riveted joints.



12.   MIG-braze rear frame side member
Note:   Note specification for welded and riveted joints.



13.   Set aside flange, rear panel crossmember and MIG-braze
Note:   Note specification for welded and riveted joints.



14.   Weld in rear frame side member
Note:   Note specification for welded and riveted joints.

15.   Grind down brazed seams in the area with which the luggage compartment floor is in contact
Object Number: 8036412 Size: DEFAULT

16.   Prepare luggage compartment floor
•   Cut new part to size from luggage compartment floor component supplied
•   Bend down front tab
  1. = 20 mm



17.   Adjust luggage compartment floor to fit
•   Push bent down front tab under old luggage compartment floor component
•   Drill 14x fastening holes for waterproof rivets
Note:   Do not damage existing brazed slots!



18.   Apply adhesive from corrosion protection adhesive system 93 160 535/15 05 000 to new component, luggage compartment floor
1. = Upper side
2. = Lower side




19.   Adjust luggage compartment floor to fit and rivet on
•   Rivet on 14x waterproof rivet (93 184 033/15 05 000)
•   Apply excess adhesive as a seam seal and corrosion protection using a spatula or flat paintbrush
Note:   Note specification for welded and riveted joints.



20.   MIG-braze anchor plate, rear panel
Note:   Note specification for welded and riveted joints.

21.   Grind down brazed seams in the area with which the impact limiter is in contact
Note:   Do not damage stud bolts on anchor plate!
22.   Seal body, weld and brazing seams
Note:   Observe corrosion protection measures for seam seals.
23.   Apply underseal.
Note:   Observe corrosion protection measures for PVC protection.
24.   Seal cavity
Note:   Observe protective wax corrosion protection measures.
25.   Fit attaching parts

Spoiler Assembly > < Add-ons to 'Side panel, Replace' (Side panel removed) (Model L 35)