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Headlamp Mount Panel Replacement > < Rocker Outer Panel Sectioning - Front

Astra J

Rocker Outer Panel Sectioning (Rear)

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 rocker outer panel - rear (1).

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Note:  Do not damage any inner panels or reinforcements.
7. Cut the rocker outer panel - rear (1) where sectioning is to be performed.

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8. Locate and mark all the necessary factory welds of the rocker outer panel - rear (1).
9. Drill all factory welds.

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10. Remove the damaged rocker outer panel - rear (1).

Installation Procedure


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1. Cut the rocker outer panel - rear (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 rocker outer panel - rear.
4. Clean and prepare the attaching surfaces for spot welding.

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Note:  In MIG-brazing areas 50 mm (2 in) must be kept clear of structural adhesive.
5. Apply structural adhesive (1) to the attaching surfaces.

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6. Position the rocker outer panel - rear (1) on the vehicle.
7. Verify the fit of the rocker outer panel - rear.
8. Clamp the rocker outer panel - rear into position.

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9. Spot weld the rocker outer panel - rear (1) accordingly.
  •  Flange rear side door opening (2) - 12 spot welds
  •  Rocker panel rear (3) - 3 spot welds
  •  Lower flange (4) - 10 spot welds

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10. Braze the rocker outer panel - rear (1) accordingly.
  •  Rocker outer panel / center pillar (2) - 350 mm
  •  Rocker outer panel / quarter outer panel (3) - 320 mm
11. 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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12. Pre-flanging the flange with BO-6396   pliers and BO-6392   tool kit .
13. Finish closing the wheelhouse flanging.
14. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
15. Paint the repaired area.
16. Install all related panels and components.
17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
18. Enable the SIR system. Refer to SIR Disabling and Enabling .

Headlamp Mount Panel Replacement > < Rocker Outer Panel Sectioning - Front