Opel Astra J Manual Caroserie PDF

BACK TO FRONT PAGE ASRA J BODY REPAIR MANUAL 2011
ASTRA_J Title Section
PREFACE 00
BODY REPAIR MANUAL GENERAL INFORMATION 01
02
2011 BODY HARDWARE AND TRIM
BODY REPAIR 03
BODY SYSTEMS 04
ROOF 05
SEATBELTS 06
SEATS 07
RESTRAINTS 08
08
STEERING 09
SUSPENSION 10
HVAC SYSTEM 11
BACK TO FRONT PAGE ASRA J BODY REPAIR MANUAL 2011
ASTRA_J Title Section
PREFACE 00
BODY REPAIR MANUAL GENERAL INFORMATION 01
02
2011 BODY HARDWARE AND TRIM
BODY REPAIR 03
BODY SYSTEMS 04
ROOF 05
SEATBELTS 06
SEATS 07
RESTRAINTS 08
08
STEERING 09
SUSPENSION 10
HVAC SYSTEM 11
BACK TO CHAPTER INDEX ASRA J BODY REPAIR MANUAL 2011
TO MODEL INDEX
Caution Notices PREFACE Section 00
SIR Special Tool Warning

Warning: Failure to observe the special tool recommendations and instructions could cause SIR deployment, personal injury, or unnecessary SIR system
repairs.
TO MODEL INDEX
GENERAL INFORMATION Section 01
2. Position the stands as shown.
The water spray from the stands should overlap the vehicle as shown.
3. Have an assistant inside of the vehicle during the test in order to locate any leaks.
4. The water pressure at the nozzle should maintain a 155 kPa (22 psi), for at least 4 minutes.
5. In order to check the windscreen, aim the water spray 30 degrees down and 45 degrees toward the rear.
Aim the water towards the corner of the windscreen.
6. In order to check the side windows for leaks, position the water stand towards the centre of the rear quarter, aiming the water spray 30 degrees down
and 45 degrees toward the rear.
7. In order to check the back window, aim the water spray 30 degrees down and 30 degrees toward the front.
BACK TO MAIN INDEX ASRA J BODY REPAIR MANUAL 2011
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BODY HARDWARE and TRIM Section 02
Floor Coverings and Headlinings Interior Trim and Paneling

Instrument Panel and Console Trim Exterior Trim
TO MODEL INDEX
Floor Coverings and Headlinings BODY HARDWARE and TRIM Section 02
Front Floor Panel Carpet Replacement Rear Compartment Floor Panel Carpet Replacement - Estate
Headlining Trim Panel Replacement - Hatchback with Sunroof Floor Carpet Drying
Headlining Trim Panel Replacement - Hatchback without Sunroof Special Tools and Equipment
Rear Compartment Floor Panel Carpet Replacement - Hatchback
Floor Coverings And Headlinings
Front Floor Panel Carpet Replacement
Callout Component Name

Preliminary Procedure
1. Remove the front seats. Refer to Driver or Passenger Seat Replacement .

2. Remove the rear seat. Refer to Rear Seat Replacement : Back 60 Percent Seat Back 40 Pe rcent Seat .
3. Remove the front floor console. Refer to Front Floor Console Replacement .
4. Remove the front and rear side door sill trim plates. Refer to Front and Rear Side Door Sill Trim Plate Replacement .
Front Floor Panel Carpet Assembly

1 Tip
Loosen Transmission Control.
TO MODEL INDEX
Floor Coverings And Headlinings BODY HARDWARE and TRIM Section 02
Headlining Trim Panel Replacement — Hatchback without Sunroof

Preliminary Procedures
1. Disable the SIR system. Refer to SIR Disabling and Enabling .

2. Remove the sunshade supports. Refer to Sunshade Support Replacement .
3. Remove the assist handles. Refer to Assist Handle Replacement .
4. Remove the windshield side garnish molding. Refer to Windscreen Garnish Moulding Replacement .
5. Remove the centre pillar upper trim panels. Refer to Center Pillar Upper Garnish Molding Replacement .
6. Remove the body lock pillar upper trim panels. Refer to Body Lock Pillar Upper Trim Panel Replacement .
7. Loosen the rear seat shoulder belt retractor. Refer to Shoulder Belt Replacement - Rear : Hatchback
8. Remove the interior light assembly. Refer to Interior Lamp Replacement .
9. Remove the interior light wiring harness. Refer to Dome Lamp Wiring Harness Replacement .
Headliner Trim Panel Assembly
Procedure
1. Use care when removing the rear retainer.

2. When replacing the headliner transfer all the foams to the new headliner.
3. Install the interior light wiring harness. Refer to Dome Lamp Wiring Harness Replacement .
1 4. Before installing the headliner, fix the sunshades to the headliner. Refer to Sunshade Replacement .
Tip
Removal and installation of the headliner must be completed through the tailgate hatch opening. Always service with the aid of an assistant to prevent
kinking or damage to the headliner.
When installing a new headliner, tape any unused connector to the headliner with a high adhesive tape.
TO MODEL INDEX
Rear Compartment Floor Panel Carpet Replacement — Hatchback

1 Rear Compartment Floor Panel Carpet
TO MODEL INDEX
Rear Compartment Floor Panel Carpet Replacement — Estate

Remove the rear compartment stowage shelf. Refer to Rear Compartment Stowage Shelf Replacement .
1 Rear Compartment Floor Panel Carpet
TO MODEL INDEX
Floor Carpet Drying

If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components:
• For a 1-piece carpet assembly bonded to a cotton or a fibre padding, replace the entire assembly.
• For a 2-piece carpet assembly with a cotton or a fibre padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the
method described below.
• For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below.
• For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below.
Drying Method
1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture.
2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible.
3. Point a fan at the affected area and air dry the carpet.
TO MODEL INDEX
Special Tools
Illustration Tool Number/ Description
BO-347
KM-347
Installer
BO-569-A
KM-569-A
Plug Lifter
DT-6459-B
Torque Wrench
GE-604-D
MKM-604-D
TORX Bit and Socket Set

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Fastener Caution
Caution: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Do not use paints,
lubricants, or corrosion inhibitors on fasteners, or fastener joint surfaces, unless specified. These coatings affect fastener torque and joint clamping force and
may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
When using fasteners that are threaded directly into plastic, use extreme care not to strip the mating plastic part(s). Use hand tools only, and do not use any kind
of impact or power tools. Fastener should be hand tightened, fully seated, and not stripped.
TO MODEL INDEX
EL 47955
J 2534
Multi Diagnostic Interface MDI

TO MODEL INDEX
BODY HARDWARE and TRIM Section 02
Instrument Panel Outer Trim Cover Replacement - Right Side Instrument Panel Lower Centre Compartment Replacement
Front Floor Console Rear Cover Replacement Instrument Panel Compartment Door Replacement
Instrument Panel Wiring Harness Replacement Front Floor Console Front Ashtray Replacement
Front Floor Console Armrest Replacement Instrument Panel Outer Compartment Replacement
Instrument Panel Extension Replacement Headlamp Switch Molding Replacement
Front Floor Console Replacement Instrument Panel Lower Extension Compartment Panel Replacement
Instrument Panel Lower Extension Replacement Instrument Panel Instrument Cluster Hood Replacement
Instrument Panel Assembly Replacement Front Floor Console Compartment Replacement
Instrument Panel Centre Trim Panel Replacement Front Floor Console Rear Compartment Replacement
Steering Column Upper Trim Cover Replacement Instrument Panel Outer Trim Cover Replacement - Left Side
Steering Column Lower Trim Cover Replacement Roof Console Reading Lamp Bezel Replacement
Instrument Panel Compartment Replacement Roof Console Replacement - Assembly
Instrument Panel Lower Trim Panel Replacement - Left Side Specifications
Instrument Panel Tie Bar Replacement Special Tools and Equipment
Instrument Panel Upper Outer Trim Panel Replacement
Instrument Panel Upper Centre Trim Panel Replacement
TO MODEL INDEX
Instrument Panel and Console Trim BODY HARDWARE and TRIM Section 02
Instrument Panel Outer Trim Cover Replacement - Right Side

1 Instrument Panel Outer Trim Cover - Right Side
TO MODEL INDEX
Front Floor Console Rear Cover Replacement

1 Front Floor Console Rear Cover Assembly
TO MODEL INDEX
Instrument Panel Wiring Harness Replacement

Removal Procedure
1. Note: Arrange a place to embed the removed parts.
2. Install the MDI, turn on the ignition and read the diagnostic trouble codes.
• Delete all diagnostic trouble codes and read diagnostic trouble codes again.
• Notice ALL diagnostic trouble codes.
3. Open the bonnet and disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
4. Remove instrument panel assembly. Refer to Instrument Panel Assembly Replacement .
5. Remove the body control module (BCM). Refer to Body Control Module Replacement
6. Release all mass cables from the tie bar and body weld studs.
7. Release the instrument panel wiring harness.
Make pictures from the routing and fixing points of the instrument panel wiring harness for the orientation.
8. Disconnect all electrical connectors and unscrew the ground cables.

8.1. Release all fixations.
8.2. Take care about destroyed cable straps and harness guidance regarding noises and rattles.
9. Remove instrument panel wiring harness (2) from instrument panel tie bar (1) and lay it on the floor.
Unpack the new instrument panel wiring harness and compare the old with the new harness concerning quantity of fixing points, cable straps, guides, part
numbers and pin assignments.
Installation Procedure
TO MODEL INDEX
1. 1. After comparing the new with the old harness (2) install the harness on the tie bar (1).
• Check if there is no twisting and bending and fix the new wiring harness.
• Use new cable straps and pins. Connect all electrical connectors.
• Take care for the correct counterpart and the pin assignment.
• Use the pictures for orientation.
Caution: Refer to Fastener Caution in the Preface section.
2. 2. Tighten all mass cables to the weld studs to 9 N·m (80 lb in) .
3. Install instrument panel assembly. Refer to Instrument Panel Assembly Replacement .
4. Install the body control module. Refer to Body Control Module Replacement
5. Install the instrument panel. Refer to Instrument Panel Assembly Replacement
6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
7. Close the bonnet.
8. Install the MDI, turn on the ignition and read the diagnostic trouble codes
Delete all diagnostic trouble codes and read trouble codes again.
9. Check all electrical functions and perform a test run.

TO MODEL INDEX
Front Floor Console Armrest Replacement

Remove the front floor console rear cover. Refer to Front Floor Console Rear Cover Replacement .
1 Front Floor Console Armrest Pin (Qty: 2)
2 Front Floor Console Armrest Assembly
TO MODEL INDEX
Instrument Panel Extension Replacement

Remove the instrument panel lower extension. Refer to Instrument Panel Lower Extension Replacement .
1 Instrument Panel Extension
Instrument Panel and Console Trim
Front Floor Console Replacement

1. Remove the instrument panel centre trim panel. Refer to Instrument Panel Centre Trim Panel Replacement .
2. Remove both instrument panel extensions. Refer to Instrument Panel Extension Replacement .
3. Remove both instrument panel lower extensions. Refer to Instrument Panel Lower Extension Replacement .
Front Floor Console Screw (Qty: 4)

1
Front Floor Console Assembly
2 Tip
Disconnect the electrical connections.
TO MODEL INDEX
SIR Seatbelt Pretensioner Handling Warning

Warning: When carrying an undeployed inflatable restraint seat belt retractor pretensioner:
• Do not carry the seat belt pretensioner by the seat belt webbing or pigtail connector, if equipped.
• Carry the seat belt pretensioner by the housing, keeping hands and fingers away from the seat belt webbing.
• Make sure the opening, from which the seat belt webbing extends, faces downward and the seat belt webbing hangs freely.
Failure to observe these guidelines may result in personal injury.
Instrument Panel and Console Trim
Instrument Panel Assembly Replacement

1. Disable the SIR system. Refer to SIR Warning .

2. Remove the front floor console assembly. Refer to Front Floor Console Replacement .
3. Remove the radio assembly. Refer to Radio Replacement .
4. Remove the heater and air conditioning control. Refer to Heater and Air Conditioning Control Replacement .
5. Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement .
6. Remove both instrument panel outer trim covers. Refer to Instrument Panel Outer Trim Cover Replacement - Left Side .
7. Remove the instrument panel compartment assembly. Refer to Instrument Panel Compartment Replacement .
8. Remove the instrument panel lower trim panel. Refer to Instrument Panel Lower Trim Panel Replacement - Left Side .
9. Remove the instrument cluster. Refer to Instrument Cluster Replacement .
10. Remove the radio front speakers. Refer to Radio Front Speaker Replacement .
Instrument Panel Assembly Fastener (Qty: 7)

1
Tighten
7 N·m (62 lb in)
Instrument Panel Assembly
Procedure
2
1. Disconnect the wiring harness from the I/P assembly.
2. With the aid of an assistant, remove the I/P assembly from the vehicle.
3. If replacing the I/P assembly, transfer all necessary components.
TO MODEL INDEX
4. Unclip the instrument panel centre trim panel on both sides.
M
TO MODEL INDEX
6. Unclip the instrument panel centre trim panel at both upper clip points in the direction shown (arrows).
TO MODEL INDEX
2. Install the instrument panel centre trim panel.

3. Clip in the instrument panel centre trim panel.
4. Install the instrument panel centre trim panel screws (1).
5. Clip in the transmission control lever boot (1).

Install the instrument panel lower centre compartment liner. Refer to Instrument Panel Lower Centre Compartment Replacement
TO MODEL INDEX
Steering Column Upper Trim Cover Replacement

Remove the headlamp switch moulding. Refer to Headlamp Switch Molding Replacement .
Steering Column Upper Trim Cover Fastener
1
2 Steering Column Upper Trim Cover
TO MODEL INDEX
Steering Column Lower Trim Cover Replacement

Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement .
Steering Column Lower Trim Cover Fastener (Qty: 3)
1
2 Steering Column Lower Trim Cover
TO MODEL INDEX
Instrument Panel Compartment Replacement

Remove instrument panel lower extension compartment panel. Refer to Instrument Panel Lower Extension Compartment Panel Replacement .
Instrument Panel Compartment Fastener (Qty: 4)

1
Procedure
Disconnect the electrical connections.

2 Instrument Panel Compartment Assembly
TO MODEL INDEX
Instrument Panel Lower Trim Panel Replacement - Left Side

1. Remove the instrument panel extension. Refer to Instrument Panel Extension Replacement .
2. Remove the instrument panel outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement - Right Side .
3. Remove the headlamp switch moulding. Refer to Liftgate Catch Striker Replacement .
Instrument Panel Lower Trim Panel Fastener (Qty: 5)

1
2 Instrument Panel Lower Trim Panel - Left Side
TO MODEL INDEX
Instrument Panel Tie Bar Replacement

Remove instrument panel wiring harness. Refer to Instrument Panel Wiring Harness Replacement .
Instrument Panel Tie Bar Assembly Fastener (Qty: 12)

1
Tighten
22 N·m (16 lb ft)
Heater and Air Conditioning Evaporator and Blower Module Fastener (Qty: 3)
2 Tighten
5 N·m (44 lb in)
Instrument Panel Tie Bar Assembly
Procedure
3
1. Note location and routing of the I/P wiring harness prior to removal of the I/P tie bar assembly to ensure proper reinstallation.
2. With the aid of an assistant, remove the I/P tie bar assembly from the vehicle.
3. If replacing the I/P tie bar assembly, transfer all necessary components.
TO MODEL INDEX
Cracked Window Warning

Warning: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury.
TO MODEL INDEX
Instrument Panel Upper Outer Trim Panel Replacement

Remove the windshield garnish moulding. Refer to Windscreen Garnish Moulding Replacement .
1 Instrument Panel Upper Outer Trim Panel
TO MODEL INDEX
Instrument Panel Upper Centre Trim Panel Replacement

Remove the radio control assembly. Refer to Radio Control Assembly Replacement .
Instrument Panel Upper Centre Trim Panel
Procedure
1
1. Disconnect the electrical connections.
2. When replacing the instrument panel upper center trim panel, transfer all necessary parts.
TO MODEL INDEX
Instrument Panel Lower Centre Compartment Replacement

Remove instrument panel centre trim panel. Refer to Instrument Panel Centre Trim Panel Replacement .
1 Instrument Panel Lower Centre Compartment
Instrument Panel Compartment Door Replacement

Remove the instrument panel compartment. Refer to Instrument Panel Compartment Replacement .
1 Instrument Panel Compartment Door Dampener Pin
2 Instrument Panel Compartment Door Dampener
3 Instrument Panel Compartment Door
TO MODEL INDEX
Instrument Panel Outer Compartment Replacement

1 Instrument Panel Outer Compartment
TO MODEL INDEX
Headlamp Switch Molding Replacement

Headlamp Switch
1 Procedure
Open instrument panel outer compartment and disconnect electrical connector.

2 Headlamp Switch Molding
TO MODEL INDEX
Instrument Panel Lower Extension Compartment Panel Replacement

Instrument Panel Lower Extension Compartment Panel Fastener
1
2 Instrument Panel Lower Extension Compartment Panel
TO MODEL INDEX
Instrument Panel Instrument Cluster Hood Replacement

Removal Procedure
1. Detach the instrument panel instrument cluster hood (1) with both hands in the direction shown.
TO MODEL INDEX
2. Pull the instrument panel instrument cluster hood (1) with both hands in the direction shown.
3. If equipped, remove the screw (1) of the cluster hood rebound strap.
1. If equipped, install the screw (1) of the cluster hood rebound strap.
TO MODEL INDEX
Defroster Outlet Warning

Warning: If broken glass falls into the defroster outlets, it can be blown into the passenger compartment and cause personal injury.
TO MODEL INDEX
2. Install the instrument panel instrument cluster hood (1) in the direction shown.
3. Install the instrument panel instrument cluster hood (1) in the direction shown.
TO MODEL INDEX
Front Floor Console Compartment Replacement

Remove front floor console armrest. Refer to Front Floor Console Armrest Replacement .
1 Front Floor Console Compartment
TO MODEL INDEX
Front Floor Console Rear Compartment Replacement

1 Front Floor Console Rear Compartment
TO MODEL INDEX
Instrument Panel Outer Trim Cover Replacement - Left Side

Instrument Panel Outer Trim Cover
1 Tip
Use a flat-bladed plastic trim tool to aid in the removal of the outer trim cover.
TO MODEL INDEX
Roof Console Reading Lamp Bezel Replacement

Roof Console Reading Lamp Bezel
1 Tip
Carefully use a flat-bladed tool to release the retainer from the roof console reading lamp bezel to the dome and reading lamp.
TO MODEL INDEX
Roof Console Replacement — Assembly

Remove the roof console reading lamp bezel. Refer to Roof Console Reading Lamp Bezel Replacement .
1 Roof Console Fastener (Qty: 2)
Roof Console Retainer (Qty: 4)
2 Tip
Carefully use a flat-bladed tool to release the retainer from the roof console to the headliner.
3 Roof Console
TO MODEL INDEX
Fastener Tightening Specifications

Specification
Application Metric English
Instrument Panel Tie Bar Brace 22 N·m 16 lb ft
Instrument Panel 7 N·m 62 lb in
TO MODEL INDEX
Special Tools
BO-347
KM-347
Installer
BO-569-A
KM-569-A
Plug Lifter
DT-6459-B
Torque Wrench
GE-604-D
MKM-604-D

TO MODEL INDEX
EL 47955
J 2534
Multi Diagnostic Interface MDI

Sunshade Replacement Rear End Trim Finish Panel Replacement - 35
Sunshade Support Replacement Luggage Shade Replacement - 35
Front Side Door Water Deflector Replacement Cargo Net Bracket Replacement
Rear Side Door Water Deflector Replacement Windscreen Garnish Moulding Replacement
Luggage Shade Retainer Replacement Centre Pillar Lower Garnish Moulding Replacement
Front Side Door Pull Handle Cover Replacement Center Pillar Upper Garnish Molding Replacement
Rear Side Door Pull Handle Cover Replacement Rear Side Door Trim Replacement
Front Side Door Window Frame Garnish Moulding Replacement Front Side Door Trim Replacement
Rear Side Door Window Frame Garnish Moulding Replacement Luggage Shade Replacement - 68
Body Lock Pillar Upper Trim Panel Replacement Luggage Shade Strap Replacement
Body Lock Pillar Lower Trim Panel Replacement Front and Rear Side Door Sill Trim Plate Replacement
Rear End Trim Finish Panel Replacement - Hatchback Rear Side Door Window Switch Opening Cover Replacement
Liftgate Window Side Garnish Moulding Replacement Liftgate Trim Finish Panel Replacement
Quarter Upper Trim Panel Replacement - Right Side Front Side Door Window Switch Opening Cover Replacement
Quarter Upper Trim Panel Replacement - Left Side Assist Handle Replacement
Quarter Inner Trim Finish Panel Replacement - Right Side Specifications
Quarter Inner Trim Finish Panel Replacement - Left Side Special Tools and Equipment
Rear Compartment Convenience Hook Replacement
TO MODEL INDEX
Collision Sectioning Warning

Warning: Sectioning should be performed only in the recommended areas. Failure to do so may compromise the structural integrity of the vehicle and cause
personal injury if the vehicle is in a collision.
TO MODEL INDEX
Interior Trim BODY HARDWARE and TRIM Section 02
Sunshade Replacement

Lower the front of the headliner to access the sunshade electrical connector, if necessary. Refer to Headlining Trim Panel Replacement : Hatchback without
Sunroof → Hatchback with Sunroof .
1 Sunshade Support Bolt Cover
2 Sunshade Retainer
Sunshade Assembly
Procedure
3
1. Disconnect the electrical connector.
2. Unclip the sunshade retainer from the headliner and sunshade.
TO MODEL INDEX
Sunshade Support Replacement

Remove sunshade assembly. Refer to Sunshade Replacement .

Sunshade Support Screw
1
2 Sunshade Support Assembly
TO MODEL INDEX
Front Side Door Water Deflector Replacement

Remove front side door trim. Refer to Front Side Door Trim Replacement .
Front Side Door Water Deflector
1 Procedure
Guide electrical connectors and door lock cable through the water deflector while removing it from the door.
TO MODEL INDEX
Rear Side Door Water Deflector Replacement

Remove rear side door trim. Refer to Rear Side Door Trim Replacement .
Rear Side Door Water Deflector
1 Procedure
Guide electrical connectors and door lock cable through the rear side door water deflector while removing it from the door.
TO MODEL INDEX
Luggage Shade Retainer Replacement

Release the luggage shade strap. Refer to Luggage Shade Strap Replacement .
1 Luggage Shade Retainer
TO MODEL INDEX
Front Side Door Pull Handle Cover Replacement

Front Side Door Pull Handle Cover
1 Tip
Use a small flat-bladed tool to release the front side door handle cover and start to unclip at the lower front edge with the cut out for tool access.
TO MODEL INDEX
Rear Side Door Pull Handle Cover Replacement

Remove the rear side door window switch opening cover. Refer to Rear Side Door Window Switch Opening Cover Replacement .
Rear Side Door Pull Handle Cover
1 Tip
Use a small flat-bladed tool to release the rear side door handle cover.
TO MODEL INDEX
Front Side Door Window Frame Garnish Moulding Replacement

Remove the front side door trim. Refer to Front Side Door Trim Replacement .
1 Front Side Door Window Frame Garnish Moulding Assembly
TO MODEL INDEX
Rear Side Door Window Frame Garnish Moulding Replacement

Remove the rear side door trim. Refer to Rear Side Door Trim Replacement .
1 Rear Side Door Window Frame Garnish Moulding Assembly
TO MODEL INDEX
Body Lock Pillar Upper Trim Panel Replacement

1. Remove the body lock pillar lower trim panel. Refer to Body Lock Pillar Lower Trim Panel Replacement .
2. Remove the quarter inner trim finish panel. Refer to Quarter Inner Trim Finish Panel Replacement - Right Side or Quarter Inner Trim Finish Panel
Replacement - Left Side .
Body Lock Pillar Upper Trim Panel Bolt (Qty: 2)

1
2 Body Lock Pillar Upper Trim Panel Retainer (Qty: 6)
3 Body Lock Pillar Upper Trim Panel
TO MODEL INDEX
Window Retention Warning

Warning: When replacing stationary windows, only use a single component adhesive kit, or an adhesive system meeting GM Specifications, to maintain original
installation integrity. Failure to use the single component adhesive kit will result in poor retention of the window, which may allow unrestrained occupants to be
ejected from the vehicle resulting in personal injury.
TO MODEL INDEX
Body Lock Pillar Lower Trim Panel Replacement

1. Remove the front and rear side door sill trim plate. Refer to Front and Rear Side Door Sill Trim Plate Replacement .
2. Remove the rear seat. Refer to Rear Seat Replacement : Back 60 Percent Seat → Back 40 Percent Seat .
1 Body Lock Pillar Lower Trim Panel

TO MODEL INDEX
Rear End Trim Finish Panel Replacement — Hatchback

1 Rear End Trim Finish Panel Retainer (Qty: 7)
2 Rear End Trim Finish Panel
TO MODEL INDEX
Liftgate Window Side Garnish Moulding Replacement

Remove tailgate trim finish panel. Refer to Liftgate Trim Finish Panel Replacement .
Liftgate Window Side Garnish Molding
1 Tip
Unclip luggage shade.
TO MODEL INDEX
Quarter Upper Trim Panel Replacement - Right Side

1. Remove the luggage shade. Refer to Luggage Shade Replacement : 35 → 68 .

Quarter Upper Trim Panel Replacement - Right Side

1
Tip
When replacing the quarter upper trim panel, release the seat belt.
TO MODEL INDEX
Quarter Upper Trim Panel Replacement - Left Side

1. Remove the luggage shade. Refer to Luggage Shade Replacement : 35 → 68 .

Quarter Upper Trim Panel Replacement - Left Side

1
Tip
When replacing the quarter upper trim panel, release the seat belt.
TO MODEL INDEX
Quarter Inner Trim Finish Panel Replacement - Right Side

1. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement : 35 → Hatchback .
2. Remove the quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement - Right Side .
1 Quarter Inner Trim Finish Panel - Right Side

TO MODEL INDEX
Quarter Inner Trim Finish Panel Replacement - Left Side

1. Remove the rear end trim finish panel. Refer to Rear End Trim Finish Panel Replacement : 35 → Hatchback .
2. Remove the quarter upper trim panel. Refer to Quarter Upper Trim Panel Replacement - Left Side .
1 Quarter Inner Trim Finish Panel - Left Side

TO MODEL INDEX
Rear Compartment Convenience Hook Replacement

1 Rear Compartment Convenience Hook
TO MODEL INDEX
Rear End Trim Finish Panel Replacement — 35

Remove the rear compartment floor panel carpet. Refer to Rear Compartment Floor Panel Carpet Replacement : Estate → Hatchback .
1 Rear End Trim Finish Panel Retainer (Qty: 9)
2 Rear End Trim Finish Panel
TO MODEL INDEX
Luggage Shade Replacement — 35

1 Luggage Shade Locking Lever
2 Luggage Shade
TO MODEL INDEX
Exhaust Flexible Pipe Bending Caution

Caution: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will
damage the exhaust flex decoupler.
TO MODEL INDEX
Cargo Net Bracket Replacement

Remove the headliner trim panel. Refer to Headlining Trim Panel Replacement : Hatchback without Sunroof → Hatchback with Sunroof .
Cargo Net Bracket Fastener

1
Tighten
20 N·m (15 lb ft)
2 Cargo Net Bracket
TO MODEL INDEX
Windscreen Garnish Moulding Replacement

1 Windscreen Garnish Moulding Clip
2 Windscreen Garnish Moulding Retainers
Windscreen Garnish Moulding Assembly
Procedure
3
1. Detach the windscreen garnish moulding.
2. For removal of the windscreen garnish moulding use a suitable tool to unlock the windscreen garnish moulding clip (arrows).
3. After removing of the windscreen garnish moulding, replace the windscreen garnish moulding clip.
Interior Trim
Centre Pillar Lower Garnish Moulding Replacement

1. Remove the front and rear side door sill trim plate. Refer to Front and Rear Side Door Sill Trim Plate Replacement
2. Move seat to full forward position.
Centre Pillar Lower Trim Panel Retainer (Qty: 4)
Procedure
1
1. Remove the center pillar trim panel.
2. Release the retainer on the rear side of the center pillar upper trim panel.
2 Centre Pillar Lower Trim Panel

TO MODEL INDEX
Rear Side Door Trim Replacement

1. Remove rear side door window switch opening cover. Refer to Rear Side Door Window Switch Opening Cover Replacement .
2. Remove rear side door pull handle cover. Refer to Rear Side Door Pull Handle Cover Replacement .
Rear Side Door Inside Handle Bolt

1
Tip
Pull handle back to remove cap. Use suitable tool to unsnap cover.
2 Rear Side Door Pull Handle Bolt (Qty: 2)
3 Rear Side Door Trim Clip-Green (Qty: 2)
4 Rear Side Door Trim Clip-Blue (Qty: 5)
Rear Side Door Trim Assembly
Procedure
5
1. Pull upwards on the door lock retainer cable to disengage.
2. Disconnect the electrical connectors.
TO MODEL INDEX
Front Side Door Trim Replacement

1. Remove front side door window switch opening cover. Refer to Front Side Door Window Switch Opening Cover Replacement .
2. Remove front side door pull handle cover. Refer to Front Side Door Pull Handle Cover Replacement .
Front Side Door Inside Handle Bolt

1
Tip
Pull handle back to remove cap. Use suitable tool to unsnap.
Front Side Door Pull Handle Bolt (Qty: 2)
2 Tip
It is not necessary to remove the three visible bolts at the handle.
3 Front Side Door Trim Clip-Green (Qty: 2)
4 Front Side Door Trim Clip-Blue (Qty: 5)
Front Side Door Trim Assembly
Procedure
5
1. Pull upwards on the door lock retainer cable to disengage.
2. Disconnect the electrical connectors.
TO MODEL INDEX
Luggage Shade Replacement — 68

Luggage Shade
Procedure
1
1. Release the luggage shade strap from the liftgate.
2. Remove the luggage shade from the supports.
TO MODEL INDEX
Luggage Shade Strap Replacement

Luggage Shade Strap
Procedure
1
1. Release the luggage shade strap from the liftgate.
2. Use a flat-bladed tool to release the two locking retainers from the bottom side of the luggage shade.
TO MODEL INDEX
Front and Rear Side Door Sill Trim Plate Replacement

1 Front and Rear Side Door Sill Trim Plate
TO MODEL INDEX
Rear Side Door Window Switch Opening Cover Replacement

Rear Side Door Window Switch Opening Cover
Procedure
1
1. Use a flat-bladed plastic trim tool to remove the rear side door window switch opening cover.
2. When replacing the rear side door window switch opening cover, remove the rear side door window switch Rear Side Door Window Switch
Replacement .
TO MODEL INDEX
Steering Angle Sensor Initialisation Warning

Warning: For vehicles with electric power steering (EPS) and without a vehicle stability enhancement program, the steering angle sensor MUST always be
initialised after the battery has been disconnected. Failure to initialise the steering angle sensor could limit the operation of the EPS system and result in personal
injury.
To ensure proper initialisation of the EPS system, do the following:
1. The engine should be running with the vehicle stationary.

2. Turn the steering wheel anti-clockwise until it stops.
3. Turn the steering wheel clockwise until it stops.
TO MODEL INDEX
Liftgate Trim Finish Panel Replacement

1 Liftgate Trim Finish Panel
TO MODEL INDEX
Front Side Door Window Switch Opening Cover Replacement

Front Side Door Window Switch Opening Cover
Procedure
1. Use a flat-bladed plastic trim tool to remove the front side door window switch opening cover.
1 2. To remove the front side door window switch opening cover, start to unclip at the front and remove the cover in forward direction.
3. When replacing the front side door window switch opening cover, remove the front side door window switch. Refer to Front Side Door Window
Switch Replacement - Left Side .
Tip
Do not scratch trim insert (especially leather) with front edge of cover window switch.
TO MODEL INDEX
Assist Handle Replacement

Assist Handle Screw (Qty: 2)
Procedure
1
1. Fold the assist handle downward and hold.
2. Use a small flat-bladed tool to open the assist handle covers to access the screws.
Tighten
6 N·m (53 lb in)
2 Assist Handle Assembly
TO MODEL INDEX

Specification
Assist Handle 6 N·m 53 lb in
Special Tools
BO-347
KM-347
Installer
BO-569-A
KM-569-A
Plug Lifter
DT-6459-B
Torque Wrench
GE-604-D
MKM-604-D

TO MODEL INDEX
Exterior Trim BODY HARDWARE and TRIM Section 02
Front Side Door Window Frame Rear Cover Replacement

Front Side Door Window Frame Rear Cover Bolt (Qty: 3)
1 Tip
Pull the window weatherstrip aside.
Tighten
2 N·m (18 lb in)
2 Front Side Door Window Frame Rear Cover
TO MODEL INDEX
Radiator Grille Moulding Replacement — Opel
Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement : Hatchback .
1 Radiator Grille Molding
TO MODEL INDEX
Radiator Grille Emblem/Nameplate Replacement

Remove the front bumper fascia upper moulding. Refer to Front Bumper Fascia Upper Moulding Replacement .
Radiator Grille Emblem
1 Procedure
Release the radiator grille emblem (arrows).

TO MODEL INDEX
Radiator Grille Replacement
Front bumper fascia upper moulding. Refer to Front Bumper Fascia Upper Moulding Replacement .
1 Radiator Grille
TO MODEL INDEX
Steering Angle Sensor Rotation Warning

Warning: Never rotate the steering angle sensor. Rotating the steering angle sensor could limit the operation of the electronic power steering (EPS) system,
and result in personal injury.
TO MODEL INDEX
Front Bumper Fascia Upper Moulding Replacement
Remove the radiator grille moulding. Refer to Radiator Grille Moulding Replacement : Vauxhall → Opel .
1 Front Bumper Fascia Upper Moulding
TO MODEL INDEX
Radiator Lower Grille Replacement — Hatchback
1 Radiator Lower Grille
TO MODEL INDEX
Tailgate Emblem/Nameplate Replacement — 1.6

Liftgate Emblem
Caution: Refer to Exterior Trim Emblem Removal Caution in the Preface section.
Procedure
1. The part and surface should be 21°C (70°F) prior to installation. The vehicle should remain 21°C (70°F) for one hour after assembly to allow
1 adhesive to develop sufficient bond strength.
2. Use a Heat Gun or equivalent to remove the old emblem. Clean all adhesive from the rear compartment panel and wipe the surface dry with a
clean lint-free towel prior to installing the new emblem.
3. When removing protective liners from the adhesive tape, be careful not to touch tape with hands and do not allow tape to come in contact with
dirt or any foreign matter prior to adhesion.
4. Close the rear compartment lid prior to adhesion.
5. Using the palm of the hand, wet out the emblem to the rear compartment lid to ensure full adhesion of the emblem is made.
TO MODEL INDEX
Tailgate Emblem/Nameplate Replacement — 1.7 CDTI

Liftgate Emblem
Procedure
TO MODEL INDEX
Tailgate Emblem/Nameplate Replacement — 2.0 CDTI

Liftgate Emblem
Procedure
TO MODEL INDEX
Tailgate Emblem/Nameplate Replacement — Astra

Liftgate Emblem
Procedure
TO MODEL INDEX
Tailgate Emblem/Nameplate Replacement — CDTI

Liftgate Emblem
Procedure
Tailgate Emblem/Nameplate Replacement — ECOFlex

Liftgate Emblem
Procedure
TO MODEL INDEX
Tailgate Emblem/Nameplate Replacement — Turbo

Liftgate Emblem
Procedure
TO MODEL INDEX
Safety Regulations for Paintshops Fuel and Evaporative Emission Pipe Warning
Express Window Down Warning Fuel Pipe Fitting Warning
Express Down Feature Warning SIR Inflator Module Handling and Storage Warning
Battery Disconnect Warning SIR Warning
Cleaning Solvent Warning Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution
Fuel Gage Leak Warning Tailgate Assist Rod Caution
Fuel Storage Warning Window Edge Damage Caution
SIR Special Tool Warning Exhaust Service Warning
Fastener Caution Protective Goggles and Glove Warning
SIR Seatbelt Pretensioner Handling Warning Definition of Danger, Warning, Caution, and Note
Cracked Window Warning Steering Wheel Straight and Column Locked Caution
Defroster Outlet Warning Bonnet Hold-Open Device Warning
Collision Sectioning Warning Actions to Take When Working with Fuel Warning
Window Retention Warning
Exhaust Flexible Pipe Bending Caution
Steering Angle Sensor Initialisation Warning
Steering Angle Sensor Rotation Warning
Handbrake and Drive Wheels Warning
Approved Equipment for Collision Repair Warning
Brake Fluid Irritant Warning
Eye Protection Warning
Foam Sound Deadeners Warning
Fuel Vapour in Evaporative Emission Components Warning
Gasoline/Gasoline Vapors Warning
Glass and Sheet Metal Handling Warning
Halogen Bulb Warning
Hot Exhaust System Warning
Moving Parts and Hot Surfaces Warning
Safety Glasses Warning
Safety Glasses and Compressed Air Warning
Safety Goggles and Fuel Warning
SIR Deployed Inflator Modules Are Hot Warning
SIR Inflatable Module Deployment Outside Vehicle Warning
SIR Inflator Module Disposal Warning
Avoid Chipping or Scratching the Coating Caution
Belt Dressing Caution
Brake Fluid Effects on Paint and Electrical Components Caution
Clearcoat/Ultraviolet Screeners Caution
Component Fastener Tightening Caution
Exterior Trim Emblem Removal Caution
Installing Hoses without Twists or Bends Caution
Steering Column in Lock Position Caution
Steering Wheel in the Full Turn Position Caution
Three-Way Catalytic Converter Damage Caution
TO MODEL INDEX
Handbrake and Drive Wheels Warning

Warning: Apply the handbrake and chock the drive wheels before performing this procedure in order to prevent bodily injury.
TO MODEL INDEX
Front Bumper Fascia Front Tow Eye Access Hole Cover Replacement

1 Front Bumper Fascia Front Tow Eye Access Hole Cover
TO MODEL INDEX
Rear Bumper Fascia Rear Tow Eye Access Hole Cover Replacement

1 Rear Bumper Fascia Rear Tow Eye Access Hole Cover
TO MODEL INDEX
Roof Panel Joint Finish Moulding Replacement

1 Roof Panel Joint Finish Moulding
TO MODEL INDEX
Front Wing Emblem/Nameplate Replacement — Elite

Front Wing Emblem
Procedure
1 1. The part and surface should be 21°C (70°F) prior to installation. The vehicle should remain 21°C (70°F) for one hour after assembly to allow
adhesive to develop sufficient bond strength.
2. Use a Heat Gun or equivalent to remove the old emblem. Clean all adhesive from the wing and wipe the surface dry with a clean lint-free towel
prior to installing the new emblem.
4. Using the palm of the hand, wet out the emblem to the wing to ensure full adhesion of the emblem is made.
TO MODEL INDEX
Front Wing Emblem/Nameplate Replacement — S

Front Wing Emblem
Procedure
TO MODEL INDEX
Front Wing Emblem/Nameplate Replacement — SE

Front Wing Emblem
Procedure
TO MODEL INDEX
Front Wing Emblem/Nameplate Replacement — SRi

Front Wing Emblem
Procedure
TO MODEL INDEX
Front Wing Emblem/Nameplate Replacement — SXi

Front Wing Emblem
Procedure
TO MODEL INDEX
Rear Side Door Window Frame Front Cover Replacement

Rear Side Door Window Frame Front Cover Bolt (Qty: 3)
1 Tip
Pull the window weatherstrip aside.
Tighten
2 N·m (18 lb in)
2 Rear Side Door Window Frame Front Cover
TO MODEL INDEX
Water Management Description and Operation

Plenum Water Flow Direction and Cleaning
A large percentage of water will flow off the windscreen area into the plenum chamber drain system and then down the outside on the plenum to the underside of
the vehicle. To ensure that the plenum chamber water management system performs properly, the air inlet grille panel, plenum chamber, and drains must not be
blocked with debris.
In the graphic below the grey arrows show the water flow direction in the plenum chamber and drains system.
Plenum Chamber and Drain Valve-Cleaning
The plenum chamber is located in front of the windscreen and below the air inlet grille panel.
1. Remove the air inlet grille panel. Refer to Plenum Water Deflector Replacement - Centre .
2. Clean the plenum chamber, drains and the air inlet grille panel of debris blockage.
3. Flush the plenum chamber, drains and the air inlet grille panel with clean water.
4. Install the air inlet grille panel. Refer to Plenum Water Deflector Replacement - Centre
TO MODEL INDEX
Approved Equipment for Collision Repair Warning

Warning: To avoid personal injury when exposed to welding flashes or to galvanized (Zinc Oxide) metal toxic fumes while grinding/cutting on any type of metal
or sheet molded compound, you must work in a properly ventilated area, wearing an approved respirator, eye protection, earplugs, welding gloves, and
protective clothing.
TO MODEL INDEX
Special Tools
BO-347
KM-347
Installer
BO-569-A
KM-569-A
Plug Lifter
DT-6459-B
Torque Wrench
GE-604-D
MKM-604-D

TO MODEL INDEX
BODY REPAIR Section 03
Bumpers and Fascias Frame and Underbody

Collision Repair Paint and Coatings
Bolted Exterior Body Panels and Closures
TO MODEL INDEX
Bumpers and Fascias BODY REPAIR Section 03
Front Bumper Fascia Replacement - Hatchback Rear Bumper Fascia Outer Guide Replacement - Estate
Rear Bumper Fascia Replacement - Hatchback Rear Bumper Fascia Lower Bracket Replacement - Estate
Rear Bumper Fascia Lower Bracket Replacement - Hatchback Rear Bumper Impact Bar Replacement - Estate
Rear Bumper Fascia Outer Guide Replacement - Hatchback Front Bumper Impact Bar Replacement
Front Bumper Fascia Guide Replacement - Inner Front Bumper Fascia Energy Lower Absorber Replacement
Front Bumper Fascia Guide Replacement - Outer Front Bumper Lower Impact Bar Replacement - Hatchback
Rear Bumper Fascia Inner Guide Replacement - Hatchback Front Bumper Fascia Centre Support Replacement - Hatchback
Front Bumper Lower Impact Bar Bracket Replacement Front Bumper Valance Panel Replacement
Rear Bumper Impact Bar Replacement - Hatchback Rear Bumper Fascia Rear Multifunction Carrier Opening Cover Support Replacement
Rear Bumper Fascia Replacement - Rear Multifunction Carrier Front Bumper Fascia Air Deflector Replacement
Rear Bumper Fascia Replacement - Estate Specifications
Rear Bumper Fascia Inner Guide Replacement - Estate Special Tools and Equipment
TO MODEL INDEX
Rear Bumper Fascia Replacement — Hatchback

Remove the tail lamps. Refer to Tail Lamp Replacement : 35 → Hatchback .

Rear Bumper Fascia Bolt (Qty: 8)
1
2 Rear Bumper Fascia Retainer (Qty: 2)
Rear Bumper Fascia
3 Procedure
Unclip rear bumper fascia from rear bumper fascia guides.

TO MODEL INDEX
Rear Bumper Fascia Lower Bracket Replacement — Hatchback

Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement : Estate → Rear Multifunction Carrier → Hatchback .
Rear Bumper Fascia Lower Bracket Rivet (Qty: 2)
1 Special Tools
BO‐594‐A Hand Rivet Tongs For equivalent regional tools, refer to Special Tools .
2 Rear Bumper Fascia Lower Bracket
TO MODEL INDEX
Rear Bumper Fascia Outer Guide Replacement — Hatchback

Rear Bumper Fascia Outer Guide Rivet (Qty: 6)
1 Special Tools
BO‐594‐A Hand Rivet Tongs For equivalent regional tools, refer to Special Tools .
2 Rear Bumper Fascia Outer Guide
Bumpers and Fascias
Front Bumper Fascia Guide Replacement — Inner

Front Bumper Fascia Guide Rivet (Qty: 2)
1 Special Tools
BO 594 A Hand Rivet Tongs For equivalent regional tools, refer to Special Tools .
Front Bumper Fascia Guide
2 Procedure
Unclip front bumper fascia guide inner from front bumper fascia guide outer.
Front Bumper Fascia Guide Replacement — Outer

Front Bumper Fascia Guide Rivet (Qty: 4)
1 Special Tools
BO 594 A Hand Rivet Tongs For equivalent regional tools, refer to Special Tools .
Headlamp Bracket Bolt (Qty: 1)
2
Front Bumper Fascia Guide
3 Procedure
Unclip front bumper fascia guide - outer from front bumper fascia guide - inner.
TO MODEL INDEX
Brake Fluid Irritant Warning

Warning: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
• Eye contact--rinse thoroughly with water.
• Skin contact--wash with soap and water.
• If ingested--consult a physician immediately.

TO MODEL INDEX
Front Bumper Lower Impact Bar Bracket Replacement

Remove the front compartment insulator or front compartment splash shield if needed. Refer to Front Compartment Insulator Replacement or Front
Compartment Splash Shield Replacement .
Drivetrain and Front Suspension Frame Bolt

1 Tighten
160 N·m (118 lb ft)
Note: Do NOT reuse the old bolt.

Front Bumper Lower Impact Bar Bracket Bolt
Tip
2 For removal only loosen the bolt.
Tighten
25 N·m (19 lb ft)
Front Bumper Lower Impact Bar Bracket
3
Note: Secure the drivetrain and front suspension frame with hydraulic jack.
TO MODEL INDEX
Rear Bumper Impact Bar Replacement — Hatchback

Rear Bumper Impact Bar Nut (Qty: 6)

1
Tighten
40 N·m (30 lb ft)
2 Rear Bumper Impact Bar
TO MODEL INDEX
Rear Bumper Fascia Replacement — Rear Multifunction Carrier

1. Remove the rear bumper rear multifunction carrier opening cover support. Refer to Rear Bumper Fascia Rear Multifunction Carrier Opening Cover
Support Replacement .
2. Remove the tail lamps. Refer to Tail Lamp Replacement : 35 → Hatchback .
Rear Bumper Fascia Bolt (Qty: 8)

1
Rear Bumper Fascia
4 Procedure
Unclip rear bumper fascia from rear bumper fascia guides.

TO MODEL INDEX
Rear Bumper Fascia Replacement — Estate

1. Remove the rear bumper fascia extension. Refer to Rear Bumper Fascia Extension Replacement : Estate → Hatchback .
2. Remove the tail lamps. Refer to Tail Lamp Replacement : 35 → Hatchback .
Rear Wheelhousing Panel Liner Bolt (Qty: 6)

1
2 Rear Bumper Fascia Bolt (Qty: 2)
Rear Bumper Fascia
3 Procedure
Unclip the rear bumper fascia from the rear bumper fascia guides.
TO MODEL INDEX
Rear Bumper Fascia Inner Guide Replacement — Estate

Rear Bumper Fascia Inner Guide Rivet (Qty: 5)
Special Tools
1
BO‐594‐A Hand Rivet Tongs
For equivalent regional tools, refer to Special Tools .

2 Rear Bumper Fascia Inner Guide
Rear Bumper Fascia Outer Guide Replacement — Estate

Remove the rear bumper fascia. Refer to Rear Bumper Fascia Replacement : Estate : Rear Multifunction Carrier : Hatchback .
Rear Bumper Fascia Outer Guide Rivet (Qty: 6)
Special Tools
1
BO 594 A Hand Rivet Tongs

2 Rear Bumper Fascia Outer Guide
Rear Bumper Impact Bar Replacement — Estate

Remove the front bumper fascia. Refer to Rear Bumper Fascia Replacement : Estate : Rear Multifunction Carrier : Hatchback .
Rear Bumper Impact Bar Nut (Qty: 6)

1
Tighten
40 N·m (30 lb ft)
2 Rear Bumper Impact Bar
TO MODEL INDEX
Front Bumper Fascia Energy Lower Absorber Replacement

1 Front Bumper Fascia Energy Lower Absorber
TO MODEL INDEX
Eye Protection Warning

Warning: Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury.
Front Bumper Lower Impact Bar Replacement — Hatchback

1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement : Hatchback .
2. Remove the front fog lamp. Refer to Front Fog Lamp Replacement : Hatchback .
Front Bumper Lower Impact Bar Bolt (Qty: 3)

1
2 Front Bumper Lower Impact Bar
TO MODEL INDEX
Front Bumper Valance Panel Replacement

2. Remove the front bumper fascia lower impact bar. Refer to Front Bumper Lower Impact Bar Replacement : Hatchback .
1 Front Bumper Valance Panel Retainer (Qty: 12)

Front Bumper Valance Panel
2 Procedure
Unclip front bumper valance panel from front bumper.

Front Bumper Valance Panel Replacement

2. Remove the front bumper fascia lower impact bar. Refer to Front Bumper Lower Impact Bar Replacement : Hatchback .
1 Front Bumper Valance Panel Retainer (Qty: 12)

Front Bumper Valance Panel
2 Procedure
Unclip front bumper valance panel from front bumper.

TO MODEL INDEX
Front Bumper Fascia Air Deflector Replacement

1 Front Bumper Fascia Air Deflector Retainer (Qty: 2)
2
Front Bumper Fascia Air Deflector Bolt (Qty: 2)
3 Front Bumper Fascia Air Deflector
TO MODEL INDEX

Specification
Drivetrain and Front Suspension Frame Bolt Front 160 N·m 118 lb ft
Front Bumper Lower Impact Bar Bracket Bolt 25 N·m 18 lb ft
Rear Bumper Impact Bar Nut 40 N·m 30 lb ft
TO MODEL INDEX
Special Tools
BO-594-A
MKM-594-A
Hand Rivet Tongs

Replacement of Parts of the Outer Skin/Doors, Tailgates and Front Compartment Side Rail Sectioning - Long
Luggage Compartment Lids, and Hoods with Folded Edges Front Compartment Side Rail Sectioning - Short
Quarter Outer Panel Sectioning Headlamp Mount Panel Replacement
Rocker Outer Panel Sectioning - Complete Front Wheelhouse Front Panel Replacement
Rocker Outer Panel Sectioning - Front Front Wheelhouse Panel Rear Reinforcement Replacement
Rocker Outer Panel Sectioning - Rear Underbody Rear Side Rail Reinforcement Replacement
Front Side Door Outer Panel Replacement Rear Bumper Fascia Energy Absorber Bracket Anchor Plate Replace
Rear Side Door Outer Panel Replacement Front Bumper Impact Bar Replacement
Underbody Rear Side Rail Sectioning Centre Pillar Inner Panel Replacement
Centre Pillar Sectioning - Outer Front End Upper Tie Bar Support Replacement
Front End Upper Tie Bar Support Sectioning Rear Floor Rear Panel Replacement - Rear Multifunction Carrier
Centre Pillar Reinforcement Replacement Front Wheelhouse Panel Brace Replacement
Rear Floor Rear Panel Replacement - Standard Rocker Inner Panel Replacement
Body Hinge Pillar Outer Panel Sectioning Rear Wheelhouse Panel Replacement
Front Wheelhouse Panel Brace Sectioning Rocker Outer Panel Reinforcement Replacement
Body Side Outer Panel Extension Replacement Front Wheel housing Panel Replacement
Body Side Inner Panel Sectioning Roof Outer Panel Replacement
Body Hinge Pillar Reinforcement Replacement Roof Rear Header Panel Replacement
Mechanical Measuring Method - Body Measuring Rod Body Repair Systems
Computerized Measurement Method - Use of Measuring and Alignment Systems
Roof Front Header Panel Replacement
Tail Lamp Pocket Replacement
Rear End Lower Panel Replacement
Rear End Lower Panel Reinforcement Replacement - Standard Special Tools and Equipment
Rear End Lower Panel Reinforcement Replacement - Rear Multifunction Carrier
Collision Repair
Replacement of Parts of the Outer Skin/Doors, Tailgates and Luggage Compartment Lids, and
Hoods with Folded Edges
Special Tools
• BO 6392 Flanging Tool Kit

• BO 6392 1 Flanging Tool Kit
• BO 6396 Bending Pliers
Mode of Procedure for Removal
As a matter of principle, it is necessary to remove the component, on which the outer skin is to be replaced, from the vehicle and to remove any attaching parts
present (on rear end doors this includes windows attached with adhesive).
Outer skins are normally partially replaced (upper or lower half) A dividing point is provided for this in the area of the window line.
Adhesive bonds between the outer skin and the inner frame are cut with flat scrapers or glass removal tools.
Spot welds are drilled out in the conventional way.
Two possibilities are available for the removal of outer skins with folded edges:
Method Tool Area of Application

Chiselling off Folded edge toolkit BO 6392 On straight or slightly curved folded joints
Grinding through Grinding disc On straight and angled folded joints
Mode of Procedure with BO 6392
Two chisels are included in the folded edge toolkit for use from both sides
The chisels BO 6392 1 flanging tool kit and BO 6392 2 flanging tool kit should only be used manually as a matter of principle and not in a compressed air chisel.
It is necessary to remove the seam sealant to reach the raised seam more effectively.
The blade of the BO 6392 1 flanging tool kit (or BO 6392 2 flanging tool kit) is pressed under the flanged folded joint with a suitable hammer. The outer plastic
jaw serves as a guide and should be run along the outside on the edge of the component.
The blade opens the folded edge joint if the user hammers evenly on the handle of the chisel.
The opened edge can then be opened up completely with a pair of pliers and the outer skin removed from the frame.
Mode of Procedure with Grinding Disc

TO MODEL INDEX
Foam Sound Deadeners Warning

Warning: Foam sound deadeners must be removed from areas within 152.4 mm (6 in) of where flame is to be used for body repairs. When reinstalling foam
sound deadeners, avoid inhaling fumes as bodily injury may result.
TO MODEL INDEX
Collision Repair BODY REPAIR Section 03
Use an angle grinder with a grinding or toothed grinding disc.
Note: Do not damage the sheet metal lying in the folded edge joint.
Cut through edge of component slowly and carefully applying a low level of pressure evenly (1).
A sufficient cutting depth has been reached when individual layers of sheet metal become visible on the cut open edge.
Cut the individual layers of sheet metal with a flat chisel and remove from the framework (2).
Mode of Procedure for Installation
Remove residual sealant from panel frame. Grind welding flanges on panel frame and new part down to bright metal. Cut down beads of adhesive from inner
framework to outer skin. Straighten panel frame if necessary. Grind residues of spot welds smooth. If necessary, work in dividing point between new part and
outer skin.
Applying 1-Component Glass Adhesive
Clean surfaces of new component to be bonded using the cleaning material from the kit, apply primer and allow to air dry.
Apply 1-component glass adhesive to cut down beads of adhesive

TO MODEL INDEX
Applying 2-Component Body Structural Adhesive (93 160 535/15 05 000)
Clean the flanges to be bonded on the new component and the frame with the cleaning material from the kit.
Note: Only use the adhesive cartridge in a suitable cartridge gun.
Lay a test bead (approx. 20 cm long), until the adhesive is evenly mixed through.
Note: Leave at least 40 mm free in adhesive zones within the connection area of any MIG-brazed seams which may be present.
Apply a bead of adhesive around the circumference of folded edge joint and welding flanges.
Aligning the New Outer Skin Component
Lay new part on frame and align. Fix, e.g. with locking pliers. Fit component on vehicle and align outer skin. Then remove component from vehicle again.
Note: To prevent indentations, place an underlay between the locking pliers and the new outer skin component.
Several possibilities exist for making the folded edge joint on the new outer skin.
Method Tool Area of application

Pre-prepare the folded edge seam Hammer-headed chisel BO-6392-4 Straight, flat, slightly arched folded edge folded joint
Close fold Folded joint pliers BO-6396 Only flat, unarched folded joints
Entire folded joint and align subsequently Hammer and pad All folded edge joints
Pre-prepare Joint With Hammer-Headed Chisel BO-6392-4

TO MODEL INDEX
Note: Do not tilt hammer-headed chisel to avoid damage.
Position hammer-headed chisel BO‐6392‐4 flanging tool kit and bend folded edge joint evenly around the circumference within the working area provided by
striking the handle with a hammer.
Close Fold with Folded Joint Pliers BO-6396
Note: Do not tilt folded joint pliers to avoid damage to the outer skin.
Position folded joint pliers BO‐6396 bending pliers with the inner working jaw on the outer skin. Close partially bent folded edge joint by pressing closed with the
folded joint pliers completely and evenly around the edge.
Course of Fold with Hammer and Pad
Pre-fold folded flange with a suitable hammer whilst simultaneously counterholding with a pad or block.
Complete folding of folded flange around the circumference with hammer and block.
Resistance Spot Welding
Note: In the edge area, the outer skin is only butt spot-welded from behind in some places along the fold.
Position spot welds as on old part.

TO MODEL INDEX
MIG-Brazing Butt Welds
MIG-braze joints when replacing tailgate outer skins and grind down.
Aligning Folded Joint
Align and smooth flanged folded joint and outer skin with hammer and block. If necessary, finish outer skin with body file to produce a surface suitable for
applying paint.
Sealing Folded Joint and Assembly
Paint on surface adhesive with a spatula or flat paintbrush as a seam sealant and corrosion protection and allow to cure.
Prime folded joint
Note: Comply with air-drying time for primer.
Apply body sealing compound around the circumference of the folded edge. If necessary cut tip of cartridge to size and make a spacer from wire to guide the
cartridge tip along the edge of the component and attach.
Note: Apply the seam sealant as evenly as is undertaken in the works. Only brush in the corner areas.
After completion of painting, fit attaching parts and apply corrosion protection wax in the cavities.
TO MODEL INDEX
Quarter Outer Panel Sectioning

Note: According to different corrosion warranties, only the regional mandatory joining methods are allowed.
Special Tools
• BO‐6396 Bonding Pliers

• BO‐6392 Flanging Tool Kit.
Removal Procedure
Warning: Refer to Approved Equipment for Collision Repair Warning in the Preface section.
Warning: Refer to Collision Sectioning Warning in the Preface section.
Warning: Refer to Glass and Sheet Metal Handling Warning in the Preface section.
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 on the quarter outer panel (1).
Note: Do not damage any inner panels or reinforcements.

TO MODEL INDEX

7. Cut the quarter outer panel (1) where sectioning is to be performed.
8. Open the wheelhouse flanging.
9. Locate and mark all the necessary factory welds of the quarter outer panel (1).
10. Drill all factory welds. Note the number and location of welds for installation of the service assembly.
11. Remove the damaged quarter outer panel (1).
TO MODEL INDEX
1. Cut the quarter outer panel 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 quarter outer panel.
4. Clean and prepare the attaching surfaces for spot welding.
5. Create 5 x 18 mm (4/16 x 11/16 in) slots for MIG-brazing spaced 40 mm (1 1/2 in) apart where the spotwelder is not applicable.
TO MODEL INDEX
6. Apply structural adhesive (1) to all attaching surfaces.
Note: In MIG-brazing areas 50 mm (2 in) must be kept clear of structural adhesive.
7. Position the quarter outer panel (1) on the vehicle.

8. Verify the fit of the quarter outer panel.
9. Clamp the quarter outer panel into position.
TO MODEL INDEX
10. Spot weld the quarter outer (1) accordingly.
11. Braze the quarter outer panel (1) accordingly.

12. 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.
13. Pre-flanging the flange with BO‐6396 pliers and BO‐6392 tool kit.
TO MODEL INDEX
14. Finish closing the wheelhouse flanging.

15. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
16. Paint the repaired area.
17. Install all related panels and components.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
19. Enable the SIR system. Refer to SIR Disabling and Enabling .
TO MODEL INDEX
Fuel Vapour in Evaporative Emission Components Warning

Warning: Do not breathe the air through the EVAP component tubes or hoses. The fuel vapours inside the EVAP components may cause personal injury.
TO MODEL INDEX
Rocker Outer Panel Sectioning — Complete

Special Tools

• BO‐6396 Bonding Pliers.
For equivalent regional tools, refer to Special Tools
Removal Procedure

6. Create cut lines on the rocker outer panel (1).
7. Cut the rocker outer panel (1) where sectioning is to be performed.

TO MODEL INDEX

8. Locate and mark all the necessary factory welds of the rocker outer panel (1).
9. Drill all factory welds.
10. Remove the damaged rocker outer panel (1).
TO MODEL INDEX
1. Cut the rocker outer panel 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. Create 5 x 18 mm (4/16 x 11/16 in) slots (1) for MIG-brazing.
3. Align the rocker outer panel.
5. Apply structural adhesive(1) to the attaching surfaces.

TO MODEL INDEX
6. Position the rocker outer panel (1) on the vehicle.

7. Verify the fit of the rocker outer panel.
8. Clamp the rocker outer panel into position.
9. Spot weld the rocker outer panel (1) accordingly.

TO MODEL INDEX
10. Braze the rocker outer panel (1) accordingly.

Rocker Outer Panel Sectioning — Front

Removal Procedure

6. Create cut lines on the rocker outer panel - front (1).
7. Cut the rocker outer panel - front (1) where sectioning is to be performed.

TO MODEL INDEX
1. Cut the rocker outer panel - front 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.
3. Align the rocker outer panel - front.

TO MODEL INDEX
6. Position the rocker outer panel - front (1) on the vehicle.

7. Verify the fit of the rocker outer panel - front.
8. Clamp the rocker outer panel - front into position.
9. Spot weld the rocker outer panel - front (1) accordingly.

TO MODEL INDEX
10. Braze the rocker outer panel - front (1) accordingly.

TO MODEL INDEX
Gasoline/Gasoline Vapors Warning

Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an
open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
TO MODEL INDEX
Rocker Outer Panel Sectioning — Rear

Special Tools

• BO‐6396 Bonding Pliers.
For equivalent regional tools, refer to Special Tools
Removal Procedure

6. Create cut lines on the rocker outer panel - rear (1).

TO MODEL INDEX
7. Cut the rocker outer panel - rear (1) where sectioning is to be performed.
8. Locate and mark all the necessary factory welds of the rocker outer panel - rear (1).
9. Drill all factory welds.
TO MODEL INDEX
10. Remove the damaged rocker outer panel - rear (1).
1. Cut the rocker outer panel - rear in corresponding locations to fit the remaining original panel. The sectioning joint should be trimmed to allow a gap of
3. Align the rocker outer panel - rear.
TO MODEL INDEX
6. Position the rocker outer panel - rear (1) on the vehicle.

7. Verify the fit of the rocker outer panel - rear.
8. Clamp the rocker outer panel - rear into position.
TO MODEL INDEX
9. Spot weld the rocker outer panel - rear (1) accordingly.
10. Braze the rocker outer panel - rear (1) accordingly.

TO MODEL INDEX
TO MODEL INDEX
Front Side Door Outer Panel Replacement

Special Tools

• BO‐6392 Flanging Tool Kit
Removal Procedure

3. Remove the front side door. Refer to Front Side Door Replacement .
4. Remove the front side door outside handle. Refer to Front Side Door Outside Handle Replacement .
5. Remove the outside rearview mirror. Refer to Outside Rearview Mirror Replacement .
7. Grind the edges of the front side door outer panel(1) to separate the outer door panel from the door shell.
8. Remove the front side door outer panel (1).

10. Straighten the edges of the door shell.
TO MODEL INDEX
1. Apply structural adhesive (1) on the flanges of the front side door inner panel where the front side door outer panel bears on.
2. Apply urethane adhesive (1) to the front side door outer panel reinforcement and the front side door outer panel bar.
TO MODEL INDEX
3. Position the front side door outer panel (1) to the front side door.
4. Verify the fit of the front side door outer panel.
5. Clamp the front side door outer panel into position.
7. Continue to hammer in stages along the hem flanges (1).

9. Install the outside rearview mirror. Refer to Outside Rearview Mirror Replacement .
10. Install the front side door outside handle. Refer to Front Side Door Outside Handle Replacement .
11. Install the front side door. Refer to Front Side Door Replacement .
TO MODEL INDEX
Rear Side Door Outer Panel Replacement

Special Tools

• BO‐6392 Flanging Tool Kit
Removal Procedure

3. Remove the rear side door. Refer to Rear Side Door Replacement .
4. Remove the rear side door outside handle. Refer to Rear Side Door Outside Handle Replacement .
6. Grind the edges of the rear side door outer panel (1) to separate the outer door panel from the door shell.
7. Remove the rear side door outer door panel (1).

9. Straighten the edges of the door shell.
TO MODEL INDEX
Glass and Sheet Metal Handling Warning

Warning: When working with any type of glass or sheet metal with exposed or rough edges, wear approved safety glasses and gloves in order to reduce the
chance of personal injury.
TO MODEL INDEX
1. Apply structural adhesive(1) on the flanges of the rear side door inner panel where the front side door outer panel bears on.
2. Apply urethane adhesive (1) to the rear side door outer panel reinforcement and the rear side door outer panel bar.
TO MODEL INDEX
3. Position the rear side door outer panel (1) to the rear side door.
4. Verify the fit of the rear side door outer panel.
5. Clamp the rear side door outer panel into position.
7. Continue to hammer in stages along the hem flanges (1).

9. Install the rear side door outside handle. Refer to Rear Side Door Outside Handle Replacement .
10. Install the rear side door. Refer to Rear Side Door Replacement .
TO MODEL INDEX
Underbody Rear Side Rail Sectioning

Removal Procedure

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.
TO MODEL INDEX
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
3. Align the rear side rail.
4. Clean and prepare the attaching surfaces for brazing and spot welding.
5. Apply structural adhesive (1) to all attaching surfaces.

TO MODEL INDEX
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).

TO MODEL INDEX
11. Spot weld accordingly (1).

Collision Repair
Centre Pillar Sectioning - Outer

Removal Procedure

5. Remove the sealers and anti corrosion materials from the repair area, as necessary.
6. Create cut lines on the centre pillar outer panel (1).
7. Cut the panel (1) where sectioning is to be performed.

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BACK TO FRONT PAGE ASRA J BODY REPAIR MANUAL 2011

ASTRA_J Title Section

ASTRA_J Title Section

Caution Notices PREFACE Section 00

SIR Special Tool Warning

GENERAL INFORMATION Section 01

2. Position the stands as shown.

Aim the water towards the corner of the windscreen.

BODY HARDWARE and TRIM Section 02

Floor Coverings and Headlinings Interior Trim and Paneling

Floor Coverings and Headlinings BODY HARDWARE and TRIM Section 02

Front Floor Panel Carpet Replacement

Callout Component Name

1. Remove the front seats. Refer to Driver or Passenger Seat Replacement .

Front Floor Panel Carpet Assembly

Floor Coverings And Headlinings BODY HARDWARE and TRIM Section 02

Headlining Trim Panel Replacement — Hatchback without Sunroof

Callout Component Name

1. Disable the SIR system. Refer to SIR Disabling and Enabling .

Headliner Trim Panel Assembly

1. Use care when removing the rear retainer.

Floor Coverings And Headlinings BODY HARDWARE and TRIM Section 02

Rear Compartment Floor Panel Carpet Replacement — Hatchback

Callout Component Name

Floor Coverings And Headlinings BODY HARDWARE and TRIM Section 02

Rear Compartment Floor Panel Carpet Replacement — Estate

Callout Component Name

Floor Coverings And Headlinings BODY HARDWARE and TRIM Section 02

Floor Carpet Drying

Floor Coverings And Headlinings BODY HARDWARE and TRIM Section 02

TORX Bit and Socket Set

Caution Notices PREFACE Section 00

Floor Coverings And Headlinings BODY HARDWARE and TRIM Section 02

Multi Diagnostic Interface MDI

BODY HARDWARE and TRIM Section 02

Instrument Panel Outer Trim Cover Replacement - Right Side

Callout Component Name

Front Floor Console Rear Cover Replacement

Callout Component Name

Instrument Panel Wiring Harness Replacement

1. Note: Arrange a place to embed the removed parts.

8. Disconnect all electrical connectors and unscrew the ground cables.

• Use the pictures for orientation.

Caution: Refer to Fastener Caution in the Preface section.

9. Check all electrical functions and perform a test run.

Front Floor Console Armrest Replacement

Callout Component Name

Instrument Panel Extension Replacement

Callout Component Name

Front Floor Console Replacement

Callout Component Name

Front Floor Console Screw (Qty: 4)

Caution Notices PREFACE Section 00

SIR Seatbelt Pretensioner Handling Warning

Instrument Panel Assembly Replacement

Callout Component Name

1. Disable the SIR system. Refer to SIR Warning .

Instrument Panel Assembly Fastener (Qty: 7)

Caution: Refer to Fastener Caution in the Preface section.

4. Unclip the instrument panel centre trim panel on both sides.

2. Install the instrument panel centre trim panel.

Caution: Refer to Fastener Caution in the Preface section.