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Centre Pillar Reinforcement Replacement > < Front End Upper Tie Bar Support Replacement

Astra J

Front End Upper Tie Bar Support Sectioning


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 (1) on the front end upper tie bar support.

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7. Cut the panel where sectioning is to be performed (1).

Note:  Do not damage any inner panels or reinforcements.

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8. Locate and mark all the necessary factory welds of the front end upper tie bar support (1).
9. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

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10. Remove the damaged front end upper tie bar support (1).

Installation Procedure


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1. Cut the front end sheet metal cross panel reinforcement (1) 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.

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2. Cut the front end upper tie bar support (1) 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.
3. Prepare all mating surfaces as necessary.
4. Align the front end upper tie bar support.
5. Clean and prepare the attaching surfaces for brazing.

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6. Position the front end upper tie bar support (1) on the vehicle.
7. Verify the fit of the front end upper tie bar support.
8. Clamp the front end upper tie bar support into position.

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9. Braze accordingly (1).
10. 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.

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11. Position the front end sheet metal cross panel reinforcement (1) on the vehicle.
12. Clamp the front end sheet metal cross panel reinforcement into position.

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13. Spot weld accordingly (1).

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14. Position the hood front bumper bracket (1) on the vehicle.
15. Clamp the hood front bumper bracket into position.

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16. Spot weld accordingly (1).
17. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
18. Paint the repaired area.
19. Install all related panels and components.
20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection
21. Enable the SIR system. Refer to SIR Disabling and Enabling

Centre Pillar Reinforcement Replacement > < Front End Upper Tie Bar Support Replacement