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Rear Wheelhouse Panel Replacement - 5-Door Estate 35 > < Roof Outer Panel Replacement - 5-Door Estate 35

Astra J

Roof Rear Header Panel Replacement (5-Door Wagon 35)

Removal Procedure

Warning:  Refer to Approved Equipment for Collision Repair Warning .

1. Disable the SIR System. Refer to SIR Disabling and Enabling .
2. Disconnect the battery negative 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 roof rear header panel (1).
7. Drill all factory welds. Note the number and location of welds for installation of the service assembly.

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8. Remove the damaged roof rear header (1).

Installation Procedure


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1. Create 8x 6 x 20 mm (4/16 x 12/16 in) slots for MIG-brazing to body side inner upper panel (1).

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2. Create 10x 6 x 20 mm (4/16 x 12/16 in) slots (1) for MIG-brazing to roof rear header panel.

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

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6. Spot weld the roof rear header panel (1) accordingly.

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7. MIG-braze the roof rear header panel (1) accordingly.
8. Apply the sealers and anti-corrosion materials to the repair area as necessary.
9. Paint the repaired area.
10. Install all related panels and components.
11. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
12. Enable the SIR System. Refer to SIR Disabling and Enabling .

Rear Wheelhouse Panel Replacement - 5-Door Estate 35 > < Roof Outer Panel Replacement - 5-Door Estate 35