Front Compartment Side Rail Sectioning (Collision Repair)

Make

Vauxhall

Model

Astra J

Section

Collision Repair › Repair Instructions › Front Compartment Side Rail Sectioning

Body RepairFront Compartment Side Rail Sectioning

Front Compartment Side Rail Sectioning 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. 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.            6. Create cut lines on the center reinforcement - left side (1) or right side (2).            7. Cut the center reinforcement left side (1) and grind the factory butt weld (2). 8. Cut the center reinforcement right side (3) and grind the factory butt welds (4).            9. Locate and mark all the necessary factory welds of the center reinforcement. 10. Drill all factory welds of the center reinforcement - left side (1) or right side (2).            11. Remove the center reinforcement (1)            12. Locate and mark all the necessary factory welds of the front compartment front side rail. 13. Drill all factory welds of the front compartment front side rail (1)            14. Remove the front compartment front side rail (1). Installation Procedure            1. Remove the front compartment intermediate side rail (1) from service part.            2. Use the drill holes to create 20x 8 x 24 mm (5/16 x 14/16 in) slots (1) on the front compartment intermediate side rail - left side (2)            3. Use the drill holes to create 27x 8 x 24 mm (5/16 x 14/16 in) slots (1) on the front compartment intermediate side rail - right side (2)            4. Install the front compartment side rail (1) using a 3 dimensional measuring system refer to Computerized Measurement Method - Use of Measuring and Alignment Systems.            5. MIG-Slot braze the front compartment side rail (1) - left side accordingly . 6. MIG-Butt weld (2) the front compartment side rail (1) - left side accordingly .            7. MIG-Slotbraze the front compartment side rail (1) - right side accordingly. 8. MIG-Buttweld (2) the front compartment side rail (1) - right side accordingly.            9. Spotweld the center reinforcement (1) - left side accordingly. 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 .

04 Body & interior