Vauxhall Workshop Service and Repair Manuals > Astra J > Body Repair | Collision Repair | Repair Instructions

Front Wheelhouse Panel Brace Sectioning

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

Warning: Refer to Approved Equipment for Collision Repair Warning .

Warning: Refer to Collision Sectioning Warning .

Warning: Refer to Glass and Sheet Metal Handling 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.

6.	Create cut lines on the front wheelhouse panel brace (1).

Note: Do not damage any inner panels or reinforcements.

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

8.	Locate and mark all the necessary factory welds of the front wheelhouse panel brace (1).

9.	Drill all factory welds. Note the number and location of welds for installation of the service assembly.

10.	Remove the damaged front wheelhouse panel brace (1).

1.	Cut the front wheelhouse panel brace (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.

2.	Prepare all mating surfaces as necessary.

3.	Align the front wheelhouse panel brace.

4.	Clean and prepare the attaching surfaces for spot welding and brazing.

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

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

6.	Position the front wheelhouse panel brace (1) on the vehicle.

7.	Verify the fit of the front wheelhouse panel brace.

8.	Clamp the front wheelhouse panel brace into position.

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 braze.

11.	Spot weld accordingly (1).

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 .