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Centre Pillar Inner Panel Replacement > < Underbody Rear Side Rail Sectioning

Astra J

Center Pillar Sectioning - Outer


Note:  According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Removal Procedure

Warning:  Refer to Collision Sectioning Warning .
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. Create cut lines on the center pillar outer panel (1).

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Note:  Do not damage any inner panels or reinforcements.
7. Cut the panel (1) where sectioning is to be performed.

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8. Locate and mark all the necessary factory welds of the center pillar outer panel (1).
9. Drill all factory welds.

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10. Remove the damaged center pillar outer panel (1).

Installation Procedure

1. Cut the center pillar outer panel in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.
2. Prepare all mating surfaces as necessary.
3. Align the center pillar outer panel.
4. Clean and prepare the attaching surfaces for spot welding and brazing.

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5. Apply structural adhesive (1) to all attaching surfaces

Note:  In MIG-brazing areas 50 mm (2 in) must be kept clear of structural adhesive.

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6. Position the center pillar outer panel (1) on the vehicle.
7. Verify the fit of the center pillar outer panel.
8. Clamp the center pillar outer panel into position.

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9. Spot weld the center pillar outer panel (1) accordingly.
  •  Flange front side door opening (2) - 25 spot welds.
  •  Flange rear side door opening (3) - 24 spot welds.
  •  Flange rocker panel (4) - 14 spot welds

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10. Braze the center pillar outer panel (1) accordingly.
  •  Center pillar / body side outer upper panel (2) - 890 mm
  •  Center pillar / rocker outer panel rear (3) - 350 mm
  •  Center pillar / rocker outer panel front (4) - 350 mm
11. To create a solid braze with minimum heat distortion, make 25 mm (1 in) stitch brazes along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch braze.
12. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
13. Paint the repaired area.
14. Install all related panels and components.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
16. Enable the SIR system. Refer to SIR Disabling and Enabling .

Centre Pillar Inner Panel Replacement > < Underbody Rear Side Rail Sectioning