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Roof Outer Panel Replacement - 5-Door Hatchback 68 > < Rocker Outer Panel Reinforcement Replacement

Astra J

Front Wheelhouse Panel Replacement


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.

           2191303



Note:  Front suspension strut housing reinforcement (1) remains to the body.
6. Locate and mark all the necessary factory welds of the front wheelhouse panel.

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7. Drill all factory welds (1). Note the number and location of welds for installation of the service assembly.

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8. Cut the adhesive in the front area (1) and where the front wheelhouse panel and the front compartment front rail overlap (2) with an appropriate tool.

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9. Remove the front wheelhouse panel (1).

Installation Procedure


           2027993


1. Remove the front suspension strut housing reinforcement (1) from service panel.

           2699394


2. Create slots for MIG-brazing to the front wheelhouse panel (1).
  •  5x 6x20 mm slots (2)
  •  12x 6x20 mm slots (3)
  •  1x 6x20 mm slot (4)
3. Clean and prepare the attaching surfaces for brazing and spot welding.

           2699395


4. Apply structural adhesive (1).

Note:  In MIG-brazing areas 50 mm (2 in) must be kept clear of structural adhesive.

           2191306


5. Position the front wheelhouse panel (1) on the vehicle.
6. Verify the fit of the front wheelhouse panel.
7. Clamp the front wheelhouse panel into position.

           2699396


8. Braze the front wheelhouse panel (1) accordingly.
  •  6x 6x20 mm slot brazes (2)
  •  11x 6x20 mm slot brazes (3)
  •  1x 6x20 mm slot braze (4)

Note:  Steps 9 to 12 only for vehicles with Liquefied Petroleum Gas (LPG).
9. Position the bracket for pressure relief valve.
10. Use the holes on the bracket to mark the positions on the front wheelhouse panel.

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11. Drill 2 x 9 mm holes to front wheelhouse panel.
12. Install 2 x 6 mm rivet nuts.

           2699397


13. Spot weld the front wheelhouse panel (1) accordingly.
  •  Strut housing (2) - 3 spot welds
  •  Side flange (3) - 5 spot welds
  •  Flange front compartment side rail (4) - 12 spot welds
  •  Flange drivetrain support (5) - 3 spot welds
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 .

Roof Outer Panel Replacement - 5-Door Hatchback 68 > < Rocker Outer Panel Reinforcement Replacement