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Body Side Inner Panel Sectioning - 5-Door Estate 35 > < Quarter Outer Panel Sectioning - 5-Door Estate 35

Astra J

Body Side Outer Panel Extension Replacement (5-Door Wagon 35)

Removal Procedure

1. Disable the SIR System. Refer to SIR Disabling and Enabling .
2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove all related panels and components.
4. Visually inspect the damage. Repair as much of the damage as possible.
5. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

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6. Locate and mark all the necessary factory welds of the body side outer panel extension (2).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

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8. Remove the body side outer panel extension (1).

Installation Procedure


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1. Drill 3x 5 x 18 mm (4/16 x 11/16 in) to the tail lamp pocket (1) and 4x 5 x 18 mm (4/16 x 11/16 in) to the body rear end panel (2)..
2. Remove the new body side outer panel extension.
3. Clean and prepare all attaching surfaces.

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4. Apply structural adhesive to the attaching flanges (1).

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5. Position the body side outer panel extension (1) on the vehicle.
6. Verify the fit of the body side outer panel extension.
7. Clamp the body side outer panel extension into position.

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8. Spot weld the body side outer panel extension (1) accordingly.

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9. Braze the body side outer panel extension (1) accordingly.
10. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
11. Paint the repaired area.
12. Install all related panels and components.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
14. Enable the SIR system. Refer to SIR Disabling and Enabling .

Body Side Inner Panel Sectioning - 5-Door Estate 35 > < Quarter Outer Panel Sectioning - 5-Door Estate 35