Roof Front Header Panel Replacement (Collision Repair)

Make: Vauxhall
Model: Astra J
Section: Collision Repair › Repair Instructions › Roof Front Header Panel Replacement

Body RepairRoof Front Header Panel Replacement

Roof Front Header Panel Replacement

Note: According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Warning: Refer to Approved Equipment for Collision Repair Warning .

Warning: Refer to Collision Sectioning 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.	Locate and mark all the necessary factory welds of the roof panel front bracket right (1).

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

8.	Remove the roof panel front bracket right (1).

9.	Proceed the same way with the roof panel front bracket left.

10.	Locate and mark all the necessary factory welds of the roof front header panel (1).

11.	Drill all factory welds. Note the number and location of welds for installation of the service assembly.

12.	Remove the damaged roof front header panel (1).

1.	Prepare all mating surfaces of the roof front header panel as necessary.

2.	Align roof front header panel.

3.	Spot weld the roof front header panel (1) accordingly with 10 spotwelds.

4.	Create 3 x 6 x 20 mm slots for MIG-brazing along the edges of the roof panel front bracket right (1).

5.	Clean and prepare the attaching surfaces for brazing.

6.	Position the roof panel front bracket right (1) on the vehicle.

7.	Verify the fit of the roof panel front bracket.

8.	Clamp the roof panel front bracket right into position.

9.	Braze roof panel front bracket right (1) accordingly with 3 x 6 x 20 mm slot brazes.

10.	Spot weld the roof panel front bracket right (1) accordingly with 10 spot welds.

11.	Proceed the same way with the roof panel front bracket left.

12.	Apply the sealers and anti-corrosion materials to the repair area, as necessary.

13.	Paint the repaired area.

14.	Install all related panels and components.

15.	Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

16.	Enable the SIR system. Refer to SIR Disabling and Enabling .

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