Vauxhall Workshop Service and Repair Manuals

Door and Tailgate Outer Panelling, Replace

Example - replace door outer panelling

  Remove

1.   Detach door •   Detach attaching parts •   Remove sealing compound •   Drill off welding points •   Grind flanged edges (1) all around •   Detach door outer panelling (2) from frame and remove remaining flange. •   Remove residual adhesive (3) on frame. Grind down adhesive flange to bare metal. •   Grind adhesive flanges (4) of the new component to bright metal Note:   Only grind to bright metal in the area of the spot welds, the new flanged seam adhesive bonds to the new part primer

  Install

2.   Restraighten panel frame Note:   If necessary 3.   Fit new part to frame and the cut sections. 4.   Apply activator from the adhesive kit •   To joint flanges, door frame, both sides (5) •   To outer panelling of door, on one side (6) 5.   Apply bead of adhesive ( 4 mm diameter) Note:   Insert adhesive cartridges from adhesive kit in BETAGUN 2000; apply 10 cm test bead (e.g. to cardboard) (7). •   To joint flange, door frame (8) •   To outer panelling of door (9)

6.   Align and fix door outer panelling on frame (10) 7.   Bend over flanged edges of door outer panelling Note:   (Body hammer and finishing hammer), support simultaneously with dolly or block (11). 8.   Apply adhesive as seam seal and corrosion protection •   Apply adhesive to all bright-ground areas with a spatula or flat paintbrush •   Remove surplus adhesive Note:   Additional sealing compound is not necessary 9.   Spot weld outer panel of door (12) Note:   Work with a copper plate to avoid marks in the outer panelling of the door Note:   Gas-shielded welding is used in the area of the separation points as before. The adhesive in the area of the separation point must be protected from burning with heat barrier paste •   Check visible area of surface and re-finish if necessary 10.   Seal cavities 11.   Fit attaching parts 12.   Attach door (12) Note:   Front door for model F08 & W5L, rear door for model F68 Note:   All dimensions shown in mm!

13.   Attach door (13) Note:   Front door and rear door for model F06, F25 Note:   All dimensions shown in mm!

14.   Attach rear door Note:   Rear doors left, right for model F06, F25 Note:   All dimensions shown in mm!

15.   Attach tailgate Note:   Tailgate for model F08, F68, F08 & W5L Note:   All dimensions shown in mm! •   Check visible area of surface and re-finish if necessary (16)