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Rear End Lower Panel Reinforcement Replacement - Standard > < Rear End Lower Panel Replacement - 5-Door Hatchback 68

Astra J

Quarter Outer Panel Sectioning (5-Door Hatchback 68)

Special Tools

•  BO-6392   Flanging Tool Kit
•  BO-6396   Bonding Pliers

For equivalent regional tools, refer to Special Tools .


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 quarter outer panel (1).

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

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9. Locate and mark all the necessary factory welds of the quarter outer panel (1).
10. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

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11. Remove the damaged quarter outer panel (1).

Installation Procedure


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1. Cut the quarter outer panel (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 quarter outer panel.
4. Clean and prepare the attaching surfaces for spot welding and brazing.

           2658486


5. Create 18 x 5 x 18 mm slots (1) for MIG-brazing.

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Note:  In MIG-brazing areas 50 mm (2 in) must be kept clear of structural adhesive.
6. Apply structural adhesive (1) to all attaching surfaces.
7. Clip in a new sound barrier to body side outer panel rear reinforcement

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8. Apply one-part urethane adhesive (1) to the sound barrier (2).

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9. Position the quarter outer panel (1) on the vehicle.
10. Verify the fit of the quarter outer panel.
11. Clamp the quarter outer panel into position.

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12. Spot weld the quarter outer (1) accordingly.
  •  Rear flange rocker panel (2) - 3 spot welds
  •  Rocker panel (3) - 8 spot welds
  •  Flange rear side door opening (4) - 23 spot welds
  •  Flange quarter window (5) - 6 spot welds

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13. Braze the quarter outer panel (1) accordingly with 18 x 5 x 18 mm slot brazes.

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14. Braze the quarter outer panel (1) accordingly.
  •  Quarter outer panel / body side outer upper panel (2) - 130 mm
  •  Quarter outer panel / body side outer upper panel (3) - 210 mm
  •  Quarter outer panel / rocker panel (4) - 350 mm
15. 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.
16. Pre-flanging the flange with BO-6396   pliers and BO-6392   tool kit .

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17. Finish closing the wheelhouse flanging.
18. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
19. Paint the repaired area.
20. Install all related panels and components.
21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
22. Enable the SIR system. Refer to SIR Disabling and Enabling .

Rear End Lower Panel Reinforcement Replacement - Standard > < Rear End Lower Panel Replacement - 5-Door Hatchback 68