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Front Wheelhouse Panel Brace Replacement > < Rear Floor Rear Panel Replacement - 5-Door Hatchback 68 with Rear Carrier

Astra J

Rear Floor Rear Panel Replacement (5-Door Hatchback 68 Standard)


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.

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6. Locate and mark all the necessary factory welds of the rear floor rear panel (1).
7. Note the number and location of weld studs for installation of the service assembly.
8. Drill all factory welds.

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9. Remove the damaged rear floor rear panel (1).

Installation Procedure


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1. Position the rear floor rear panel on the vehicle (1).
2. Align the rear floor rear panel.

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3. Drill 4 mm (3/16 in) every 100 mm (4 in) for rivets along the attaching flanges of the rear floor rear panel were a resistance spot welder can not be applied (1).
4. Remove the new rear floor rear panel.
5. Clean and prepare the attaching surfaces for spot welding and riveting.

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6. Apply structural adhesive (1) to all attaching surfaces.

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7. Position the rear floor rear panel (1) on the vehicle.
8. Verify the fit of the rear floor rear panel.
9. Clamp the rear floor rear panel into position.
10. Rivet the rear floor rear panel.

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11. Spot weld accordingly (1).
12. Weld accordingly the weld studs as noted.

Note:  Steps 13 to 15 only for vehicles with Liquefied Petroleum Gas (LPG).
13. Position the bracket for LPG tank.
14. Use the holes on the bracket to mark the positions on the rear floor rear panel.

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15. Drill holes to rear floor rear panel
  •  Diameter: 52 mm (1)
  •  Diameter: 12 mm (2)
16. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
17. Paint the repaired area.
18. Install all related panels and components.
19. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
20. Enable the SIR system. Refer to SIR Disabling and Enabling .

Front Wheelhouse Panel Brace Replacement > < Rear Floor Rear Panel Replacement - 5-Door Hatchback 68 with Rear Carrier