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Vauxhall Workshop Service and Repair Manuals

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Rear Floor Rear Panel Replacement - 5-Door Estate 35 Standard > < Rear Wheelhouse Panel Replacement - 5-Door Estate 35

Astra J

Rear Bumper Fascia Energy Absorber Bracket Anchor Plate Replacement (5-Door Wagon 35)

Removal Procedure

Warning:  Refer to Approved Equipment for Collision Repair 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. Remove the rear end lower panel. Refer to Rear End Lower Panel Replacement .
5. Visually inspect the damage. Repair as much of the damage as possible.
6. Remove the sealers and anti-corrosion materials from the repair area, as necessary.

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7. Locate and mark all the necessary factory welds of the rear bumper fascia energy absorber bracket anchor plate (1).
8. Drill all factory welds.

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9. Remove the rear bumper fascia energy absorber bracket anchor plate (1).

Installation Procedure

1. Clean and prepare the attaching surfaces for brazing.

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2. Create 2x 6 x 20 mm (4/16 in x 12/16 in) slots for MIG-Brazing to the rear bumper fascia energy absorber bracket anchor plate (1).

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3. Create 7x 6 x 20 mm (4/16 in x 12/16 in) slots for MIG-Brazing to the rear end lower panel reinforcement (1).

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4. Position the rear bumper fascia energy absorber bracket anchor plate (1) on the vehicle.
5. Verify the fit of the rear bumper fascia energy absorber bracket anchor plate.
6. Clamp the rear bumper fascia energy absorber bracket anchor plate into position.

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7. MIG-Braze the rear bumper fascia energy absorber bracket anchor plate (1) accordingly.

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8. Spotweld the rear bumper fascia energy absorber bracket anchor plate (1) accordingly.
  Spotweld the rear bumper fascia energy absorber bracket anchor plate / rear end panel reinforcement - 4 spotwelds.
9. Install the rear end lower panel. Refer to Rear End Lower Panel Replacement .
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 .

Rear Floor Rear Panel Replacement - 5-Door Estate 35 Standard > < Rear Wheelhouse Panel Replacement - 5-Door Estate 35