vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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B-Pillar, Complete, Replace (Models L 35, L 48, L 69) > < Replace one door hinge on the A-pillar or B-pillar

Astra H

B-Pillar, Exterior, Replace (Models L 35, L 48, L 69)

Important:   Note specification for welded, brazed and riveted joints LUREF_1.gif and body repair with structural adhesive !

Important:   Observe SPP, PSO welding parameters for resistance spot welding! See TIS Newsletter for equipment recommendations! LUREF_1.gif

  Remove

1.   Detach attaching parts
Object Number: 7361639 Size: DEFAULT

Important:   When making the parting cut on the exterior of the B-pillar, do not damage the B-pillar reinforcement underneath it! Maximum submersion depth of tool = thickness of material 0.8 mm plus gap 1.5 mm
2.   Cut away exterior of B-pillar at the top
•   Mark parting cuts
– I = approx. 30 mm
Note:   Parting cut at the top is located centrally in the upper fixing bore of the additional seal for the B-pillar!
3.   Drill away exterior of the B-pillar at the top



Important:   Do not damage the interior of the B-pillar underneath when making the parting cut in the reinforcement of the B-pillar! Parting cut must be above the mounting for the seat belt height adjustment on the interior of the B-pillar!
4.   Cut interior reinforcement of the B-pillar
•   Mark parting line



Important:   Note size of new part! When making the parting cuts for the exterior sill panelling, do not damage the reinforcement for the B-pillar underneath it!
5.   Cut away front sill panelling
•   Mark parting cuts
6.   Drill away front sill panelling in area between the cutting lines

Object Number: 7361641 Size: DEFAULT

Important:   Note size of new part! Do not damage the reinforcement on the interior of the sill panelling with the parting cut!
7.   Cut B-pillar away from the rear sill panelling
•   Mark parting line
– I (model L 48) = approx. 430 mm
– I (model L 35) = approx. 510 mm



8.   Drill away reinforcement of B-pillar at the front
•   Drill away 7x spot weld



Important:   Do not drill into reinforcement for sill panelling on the inside!
9.   Drill away lower B-pillar with interior reinforcement



10.   Drill B-pillar with reinforcement away from interior of B-pillar
Note:   Remove drilling and cutting swarf from cavities!

  Install

Object Number: 7361645 Size: DEFAULT

Important:   Note length of connection area on the vehicle at the top of the B-pillar! Assembly window (1) must be re-used! When making the parting cut on the exterior of the B-pillar do not damage the reinforcement for the B-pillar underneath it! Maximum submersion depth of tool = Thickness of material 0.8 mm plus gap 1.5 mm !
11.   Cut away exterior of B-pillar new part at the top
•   Mark parting cuts
12.   Drill away exterior of the B-pillar at the top



Important:   Do not damage the interior of the B-pillar underneath when making the parting cut! Parting cut must be above the mounting for the seat belt height adjustment on the interior of the B-pillar!
13.   Cut away reinforcement on inside of B-pillar new part
•   Mark parting line



Important:   Do not damage original spot welds in the drilling area! If there are overlaps, move hole accordingly! Slots must be made for subsequent MIG-brazing!
14.   Prepare new part for lower B-pillar
•   Scribe 4 slots ( 6x20 mm )
Note:   Arrow shows new part in the installed position and direction of travel!



15.   Prepare new part for lower B-pillar
•   Scribe 3 slots ( 8x24 mm )
Note:   Arrow shows new part in the installed position and direction of travel!

Object Number: 7361651 Size: DEFAULT

16.   Unscrew bolt (1), steering cross-member
Note:   Bore serves as measuring point!

Object Number: 7361652 Size: DEFAULT

17.   Adjust exterior of B-pillar to fit
Note:   In addition, observe body dimension chart!
•   1 = Diagonals A-/B-pillar ( 1136 mm )
– III = 100 mm

Object Number: 7361653 Size: DEFAULT

18.   Adjust exterior of B-pillar to fit
Note:   In addition, observe body dimension chart!
•   2 = Diagonals A-/B-pillar ( 1017 mm )
– III = 100 mm

Object Number: 7361654 Size: DEFAULT

19.   Adjust exterior of B-pillar to fit
Note:   In addition, observe body dimension chart!
•   3 = Opening of rear door frame - B-pillar to C-pillar ( 995 mm )
– III = 30 mm

20.   Cut B-pillar to size at the top and at the rear sill panelling
Note:   Joint on front sill panelling is not cut to size until after the assembly window has been adjusted to fit!
Object Number: 7361655 Size: DEFAULT

Important:   Assembly window (1) must be re-used!
21.   Remove B-pillar
22.   Cut B-pillar new part
•   Mark parting line
– I = approx. 120 mm

23.   Adjust exterior of B-pillar to fit
•   See steps 17 to 19
Note:   In addition, observe body dimension chart!
24.   Remove B-pillar


25.   Make slots (1) at lower B-pillar reinforcement
•   Incorporate 3x ( 8x24 mm ) slot



Important:   Pre-spot operation: The number of spots is specified in the documentation from the welding equipment manufacturer!
26.   Prepare sill panelling



Important:   Pre-spot operation: The number of spots is specified in the documentation from the welding equipment manufacturer!
27.   Prepare new part, B-pillar



28.   Apply corrosion protection adhesive system 93 160 535 / 15 05 000 to interior of B-pillar
•   Leave at least 50 mm in the connection area of the MIG-brazed seams free of adhesive!
•   Paint on surplus adhesive in the area of the lower sill panelling as seam sealant and corrosion protection with a spatula or flat brush

29.   Adjust exterior of B-pillar to fit
•   See steps 17 to 19
Note:   In addition, observe body dimension chart!


Important:   Observe special parameter program!
30.   Weld B-pillar
Note:   Do not weld B-pillar top area (1) yet!



31.   MIG-braze top of B-pillar
Note:   Grind down MIG-brazed seam in the joint area on the outside of the B-pillar!



32.   MIG-braze the bottom of the B-pillar



33.   MIG-braze the bottom of the B-pillar
Note:   MIG-brazing the slot (1) is undertaken subsequently with the front sill panelling!



34.   MIG-braze the bottom of the B-pillar

35.   Fit the upper exterior B-pillar and cut to size


36.   Apply corrosion protection adhesive system 93 160 535 / 15 05 000 to interior reinforcement of B-pillar
•   Leave at least 20 mm in the connection area of the MIG-brazed seams free of adhesive
•   Paint on surplus adhesive with a spatula or flat brush to fill in the spot weld bores



Important:   Observe special parameter program!
37.   Weld upper outer B-pillar



38.   MIG-braze upper outer B-pillar

Object Number: 7361666 Size: DEFAULT

39.   Fit the front sill panelling and cut to size

Object Number: 7361667 Size: DEFAULT

40.   Prepare front sill panelling
•   Scribe slot ( 8x24 mm
Note:   mark slot (1) corresponding to the position of the slot for the interior reinforcement of the B-pillar (see step 35)!
41.   Make slot in front sill panelling



42.   Apply corrosion protection adhesive system 93 160 535 / 15 05 000 to interior reinforcement of B-pillar
•   Leave at least 20 mm in the connection area of the MIG-brazed seams free of adhesive



Important:   Observe special parameter program!
43.   Weld front sill panelling



44.   MIG-braze front sill panelling



45.   MIG-braze front sill panelling at the bottom

46.   Grind MIG brazed seams
47.   Tighten bolt, steering crossmember 20 Nm
Important:   The door hinges on the delivered B-pillar are only tack welded!
48.   Adjust door hinges to fit and weld LUREF_1.gif
49.   Seal body, weld and brazing seams
Note:   Observe corrosion protection measures for seam seals.
50.   Apply underseal.
Note:   Observe corrosion protection measures for PVC protection.
51.   Seal cavity
Note:   Observe protective wax corrosion protection measures.
52.   Fit attaching parts

B-Pillar, Complete, Replace (Models L 35, L 48, L 69) > < Replace one door hinge on the A-pillar or B-pillar