Vauxhall Workshop Service and Repair Manuals

Front Side Door Outer Panel Replacement

Note :  According to different corrosion warranties, only the regional mandatory joining methods are allowed.

Special Tools

For equivalent regional tools, refer to Special Tools .

Removal Procedure

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 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 .
6. Remove the sealers and anti-corrosion materials from the repair area, as necessary.





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).
9. Remove the sealers and anti-corrosion materials from the repair area, as necessary.
10. Straighten the edges of the door shell.

Installation Procedure

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.





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.
6. Pre-flanging the flange with  BO-6396 pliers and  BO-6392 tool kit.





7. Continue to hammer in stages along the hem flanges (1).
8. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
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 .
12. Paint the repaired area.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
14. Enable the SIR system. Refer to SIR Disabling and Enabling .