Vauxhall Workshop Service and Repair Manuals

Door Outer Panelling, Replace

 

Tailgate Outer Panelling, Replace

 

Remove

 

Remove door/tailgate.

Remove attaching parts.

 

Drill off welding points.

 

1     Grind down flanged edges all round.

 

2     Remove outer panelling from frame.

       Remove any residual flange.

 

3     Remove residual cement from frame.

       Grind cement flange bare.

 

 

 

 

Install

 

Install new part to frame and fit to cut edges - if necessary realign frame.

 

4     Grind cement flange of new part bare.

 

Clean cement surfaces.

 

Prepare two component cement for use - note leaflet in packing.

 

5     Apply two component cement evenly (at least 1 mm/0.04 in. thick) to cement flange of frame.

 

6     Place outer panelling on frame, align and fasten.

 

7     Bead bordering flange of outer panelling (dinging or straightening hammer).

       At the same time counterhold with fist.

 

Remove surplus cement with putty knife.

 

 

 

 

Weld on outer panelling.

 

Welding points:

 

1     Front door, model 91, 92, 93, 94

 

2     Front door, model 96, 97, 98, 99

 

3     Rear door

 

4     Tailgate

 

 

Control surface of outer panelling in visual range and - if necessary - rework.
Apply sealing compound. lt can be applied directly to remainder of "wet" cement and can be painted.   After painting, apply wax to cavities.   Install attaching parts.   Install door/tailgate.