Vauxhall Workshop Service and Repair Manuals

Body And Chassis Sheet Metal Parts  

General Instructions  

Before beginning work on body sheet metal parts, remove body attaching parts, assemblies or fittings which interfere with the work. Disconnect battery ground strap. After carrying out repair work on the body, ensure that the ground connections are correct. Poor ground connections lead to faults in the system and, in extreme cases, to destruction of control units. To prevent danger of fire in connection with welding or grinding work on the body, the appropriate guidelines and regulations in particular related to accident prevention are to be followed. The same attention is to be devoted to following the environmental protection and health regulations.  

  Important!   

Since legal provisions differ in individual countries, it is not possible to provide such details in the workshop literature. Obtaining and observing the respective requirements are therefore an individual responsibility. The section repairs shown in the operations are the result of extensive tests. The welding procedures appearing in the various operations are identified by welding symbols. There is no difference between the welding of body untreated deep drawn sheet metal and of alloy-galvanised sheet metal. Preferably, alloy-galvanised sheet metal must be spot welded. Remove all paint layers completely from spot weld flanges.  

For corrosion-protection materials from the range of the "Aftersales" department, refer to the current "CORROSION PROTECTION leaflet" of "GMIO Aftersales".  

During any separation operations, grinding operations or welding operations, ensure that a suitable device for removing vapour is present and guard against sparks.  

Operations in this group are, on the whole, described and illustrated on left-hand drive vehicles. The operation processes on right-hand drive vehicles are generally a mirror image and analogous. The functions of the various systems are the same on both l hand and right-hand drive vehicles. Any basic deviations are accompanied by the appropriate information.  

The illustrated cutting sections and/or cutting lines are the result of comprehensive crash tests and examination of vehicles which have been involved in accidents. Body sheet metal parts and body members (underbody) are made of cold-workable, deep-drawn sheet steel in standard production. Consequently damaged parts must be cold when restoring them to their original shape. All operations are primarily shown as illustrations. Explanatory text has only been added at points where instructions are important to proper and appropriate repair. The sequence of the illustrations and the text occasionally included between them gives the sequence of labour operations. No reference is made in these labour operations to continually recurring standard operations, such as separation of parts or grinding mating surfaces, as these should be known sufficiently well in the service workshops. If the degree of damage does not permit restoration of the original shape, first straighten the mating surfaces. The damaged body section can then be replaced. The repair methods specified in this group must be used in those areas where both cutting and joining would have an effect on the strength and safety of the body.  

When delivered to the paint shop, the surface of the body parts must be satisfactorily prepared for painting. The surface is paintable when damaged sheet metal parts have been repaired (dents removed, seams welded and soldered, overlapping seams in cases of partial replacement) in such a way that the paint shop does not need to apply more than 3 thin filler coats. These operations belong to the sheet metal worker's working area and should be included in his specified repair time.  

After accidents indicating considerable stress on the chassis, the following components in particular should be checked, independently of checking axle alignment, which should be carried out in all cases:  

Check steering and steering linkage for correct operation through the complete turning circle, check visually for deformation and cracks. Check all components of the chassis for deformation and cracks, including spring strut, steering knuckle, control arm, axle body and stabiliser and their fastening parts. Test wheel rims and tyres for damage, examine tyres for cuts in the tread and the side walls and check for true running and balance.  

For special Service Tools, refer to the "Opel/Vauxhall Special Service Tools" catalogue, for all other necessary tools and equipment refer to the "Opel/Vauxhall Workshop Equipment" catalogue.