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Vauxhall Workshop Service and Repair Manuals

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Quarter Outer Panel Sectioning - 5-Door Hatchback 68 > < Tail Lamp Pocket Replacement - 5-Door Hatchback 68

Astra J

Rear End Lower Panel Replacement (5-Door Hatchback 68)


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

Removal Procedure

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. Locate and mark all the necessary factory welds of the rear end lower panel (1).

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

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8. Remove the rear end lower panel (1).

Installation Procedure

1. Clean and prepare the attaching surfaces for welding.

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2. Apply structural adhesive (1) to the attaching surfaces.

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3. Position the rear end lower panel (1) on the vehicle.
4. Verify the fit of the rear end lower panel.
5. Clamp the rear end lower panel into position.

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6. Spot weld the rear end lower panel (1) accordingly with 64 spot welds.
7. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
8. Paint the repaired area.
9. Install all related panels and components.
10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
11. Enable the SIR system. Refer to SIR Disabling and Enabling .

Quarter Outer Panel Sectioning - 5-Door Hatchback 68 > < Tail Lamp Pocket Replacement - 5-Door Hatchback 68