The steps below are shortened from the Vauxhall TIS pages for the Speedster. The VX220 shares the same engines and most of the car, but check anything unusual against your own car. The TIS pictures and the full wording aren't reproduced, so use the workshop manual if you are doing the job. We haven't seen owners' accounts of this job, so there are no owner tips here.
Both are body repair jobs. The crashbox is a structural part and needs a second person for some steps. The partial body assembly page is only a checklist of what to transfer, and points to the individual TIS operations.
Crashbox replacement
The TIS steps are the same for the Turbo and the NA.
For what owners added on removing the old box, the adhesive, clamping and which crashbox to buy, see Crashbox replacement: removing the old one, adhesive and which to buy.
Remove
- Remove radiator. Note: Includes detaching front clamshell. (see "Radiator, Remove and Install")
- Detach left radiator hose from coolant pipe
- Detach right radiator hose from coolant pipe
- Remove towing device
- Drill out rivets from left and right gussets (Remove gussets)
- Detach threaded clamps from crashbox (10x)
- Cut off flange from crashbox at top (using a pneumatic saw)
- Make cut in side of crashbox on left
- Make cut in side of crashbox on right
- Roughly cut out crashbox (using a pneumatic saw)
- Cut off flange from crashbox at bottom
- Cut off residues
- Trim down adhesive beads
- Clean crashbox
- Clean adhesive points on vehicle
- Apply primer to crashbox (Shake primer for 1 minute; 15 minutes drying time)
- Using primer, make good the adhesive points on the vehicle
- Apply adhesive to crashbox
Install
- Place crashbox in position
- Align crashbox
- fix in place with strap pliers and tensioning strap
- Remove strap pliers
- Rivet on right gusset (Drill 2 holes; 3 rivets)
- Rivet on left gusset (Drill 2 holes; 3 rivets)
- Fit threaded clamps (12x)
- Install towing device (Coat screws with locking compound)
- Apply primer to crashbox (to coolant pipe)
- Fit right radiator hose (to coolant pipe)
- Install radiator (see "Radiator, Remove and Install")
Partial body assembly replacement
The TIS steps are the same for the Turbo and the NA.
Disassemble
- The following components should be removed from the original vehicle, inspected for damage where applicable and stored for installation to the new partial body in a logical sequence. Refer to individual component instructions for more information (additional technicians may be required)
Assemble
- The following list outlines only the major components that need to be installed to the new partial body. All required components should be transferred as necessary. Components should be installed to the new partial body assembly in a logical sequence. Refer to individual component instructions for more information
Adjust
- Front and rear suspension - see relevant operations
Inspect
- Fill and bleed coolant system - see “Cooling System, Drain, Fill and Bleed”
- Bleed brake system - see “Brake System, Bleed”
- Bleed clutch - see “Hydraulic Clutch, Bleed”
- Add fuel and check for leaks
- Program all volatile memories
Adjust
- Where body components such as front or rear clamshell have been repaired due to accident damage, then minor adjustment or alignment of the new panels by elongating the mounting holes will be required. Align body parts to specification, see “Body Panel Alignment Values”. Only the areas detailed in this section are adjustable. All further gaps align as a consequence of these adjustments as the body panels are formed from common moulds