Underbody Rear Side Rail Sectioning (Collision Repair)

Make: Vauxhall
Model: Astra J
Section: Collision Repair › Repair Instructions › Underbody Rear Side Rail Sectioning

Body RepairUnderbody Rear Side Rail Sectioning

Underbody Rear Side Rail Sectioning

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.	Create cut lines (1) on the underbody rear side rail.

Note: Do not damage any other panels or reinforcements.

7.	Cut the underbody rear side rail (1) where sectioning is to be performed.

8.	Locate and mark all the necessary factory welds of the underbody rear side rail (1).

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

10.	Remove the damaged underbody rear side rail (1).

1.	Cut the underbody rear side rail (1) in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of one-and-one-half-times the metal thickness at the sectioning joint.

2.	Prepare all mating surfaces as necessary.

3.	Align the rear side rail.

4.	Clean and prepare the attaching surfaces for brazing and spot welding.

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

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

6.	Position the underbody rear side rail (1) on the vehicle.

7.	Verify the fit of the underbody rear side rail.

8.	Clamp the underbody rear side rail into position.

9.	Braze accordingly (1).

10.	To create a solid braze with minimum heat distortion, make 25 mm (1 in) stitch brazes along the seam with 25 mm (1 in) gaps between them. Then go back and complete the stitch braze.

11.	Spot weld accordingly (1).

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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