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Rear Bumper Fascia Energy Absorber Bracket Anchor Plate Replacement - 5-Door Hatchback 68 > < Front Wheelhouse Panel Rear Reinforcement Replacement

Astra J

Underbody Rear Side Rail Reinforcement 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.

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6. Locate and mark all the necessary factory welds of the underbody rear side rail reinforcement (1).
7. Drill all factory welds.

Note:  Note the number and location of welds for installation of the service assembly.

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8. Remove the underbody rear side rail reinforcement (1).

Installation Procedure


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1. Create 8 x 24 mm (5/16 x 15/16 in) slots for MIG-Brazing along the edges of the underbody rear side rail reinforcement (1) as noted from the original panel.
2. Clean and prepare the attaching surfaces for brazing.

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3. Position the underbody rear side rail reinforcement (1) on the vehicle.
4. Verify the fit of the underbody rear side rail reinforcement.
5. Clamp the underbody rear side rail reinforcement into position.

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6. Braze accordingly (1).

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7. Spot weld accordingly (1).
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
9. Paint the repaired area.
10. Install all related panels and components.
11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
12. Enable the SIR system. Refer to SIR Disabling and Enabling .

Rear Bumper Fascia Energy Absorber Bracket Anchor Plate Replacement - 5-Door Hatchback 68 > < Front Wheelhouse Panel Rear Reinforcement Replacement