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[howardmoon]

Hi guys. my drivers door made a horrible noise for a while and eventually something broke off and fell down the door. I found the guide on how to fit the reinforcing kit but i'm guessing mine is beyond that stage. has anybody else had this fixed by a bodyshop or managed to fix it themselves? I'm guessing that whatever the strap goes into inside the door fell off.

cheers, paul

[razzo]

you can get a replacement door stay all in from Vx for about £30

[Kevin Wood]

I think the reinforcement plate is designed to fix this very problem?

Kevin

[Andy B]

I think the reinforcement plate is designed to fix this very problem?

Kevin

Technically the reinforcment plate should be fitted before this happens. The bit that breaks is at the front edge of the door & the full repair should really use one of these:-
and the reinforcing plates sandwich it. If you go into Vauxhall & ask for the plate there is no reference to in EPC cos Vauxhall never had a problem with the door check straps  :-?

I can't now remember why I put the red circles on the picture ... plug welding perhaps?

[howardmoon]

Cheers kevin, i'll have to take a closer look and find out what it is that's actually broken. something definately fell out and is sat in the bottom of the door

[Andy B]

...... something definately fell out and is sat in the bottom of the door

Part of the check strap mechanism. IIRC about £20

[ians]

Paul - I would strip of the door card and see what you find.

Andy B - mine has just split as you described.   Are you saying that the reinforcing plate should be installed on all cars prior to this happening as a preventative maintenance measure?  Can it be used after the original plate has split?   Is the plate in your pic a weld on or bolt job?

Cheers,

Ian

[Andy B]

Paul - I would strip of the door card and see what you find.

Andy B - mine has just split as you described.   Are you saying that the reinforcing plate should be installed on all cars prior to this happening as a preventative maintenance measure?  Can it be used after the original plate has split?   Is the plate in your pic a weld on or bolt job?

Cheers,

Ian

This is the plate that if your car was within 3 yrs old & less than 100K kms  Vauxhall would have fitted for you. It's a welded in job. Mine has pulled completely throughon the driver's door & partially on the passenger side, but bolting the reinforcing plates on both sides  have done the trick. One of them has to be cutdown in length to make fit.

Extract starts here…………..

Field Remedy: 1291
Subject:      Front doors-Check link - pulls out of door panel
Models:      Engines:      Option:
Omega-B 1996...2000,Vectra-B 1996...2002      All,All      
Complaint:      Check link of front door cracked.
Cause:      Due to excess bending tension front check link bracket cracks.
Production:      Omega-B: Modified check links have been introduced in production as of the following VIN: W0L0VBP69Y1176008 (Rüsselsheim). Vectra-B: None.
Remedy:
There are 3 possibilities:
 I:   Installation of two reinforcement plates, only in case of
      cracks and WITHOUT strong deformation of the door body.
II:   Omega-B: Welding the check link - front door mounting bracket and
      installation of two reinforcement plates in case of cracks
      and strong deformation of the door body.
III:  Vectra-B: Welding the check link - front door mounting bracket
      WITHOUT installation of two reinforcement plates in case of cracks
      and strong deformation
Working Procedure:
Possibility I (Omega-B and Vectra-B):
 1. Disconnect battery.
 2. Remove inner panelling - front door
     - see working procedure ”Inner panelling – front door, Remove
     and Install”, unit ”C”, of the corresponding Service Instruction.
 3. Remove loudspeaker
     - see working procedure ”Loudspeaker - Front door, Remove and
     Install”, unit ”R”, of the corresponding Service Instruction.
 4. Separate wiring harness connector of front door.
 5. Remove check link - front door.
 6. Shorten and bevel the outer reinforcement plate on both sides by
    7.5 mm (Fig. I).  

 7. Paint the reinforcement plates in the colour of the car.
 8. Set original inner reinforcement plate onto the check link - front
    door and insert into front door.
 9. Install the modified outer reinforcement plate to the check link -
    front door with new fixing screws – use locking compound.
10. Install wiring harness connector of front door.
11. Install loudspeakers
     - see working procedure ”Loudspeaker - Front door, Remove and
     Install”, unit ”R”, of the corresponding Service Instructions.
12. Install inner panelling – front door
     - see working procedure ”Inner panelling – front door, Remove
     and Install”, unit ”C”, of the corresponding Service Instruction.
13. Connect battery.
14. Program volatile memories.
Possibility II (Omega-B):
 1. Remove inner panelling - front door
     - see working procedure, ”Inner panelling – front door, Remove
     and Install”, unit ”C”, Service Instruction Omega-B.
 2. Remove loudspeaker
     - see working procedure ”Loudspeaker - Front door, Remove and
     Install”, unit ”R”, Service Instruction Omega-B.
 3. Remove outside mirror
     - see working procedure ”Replace Outside Mirror”, unit ”R”,
     Service Instruction Omega-B.
 4. Open sash window.
 5. Partially loosen front door window guide seal.
 6. Remove guide rail of front door window.
 7. Close sash window.
 8. Disconnect battery.
 9. Remove front door
     - see working procedure ”Front or rear door, Remove and
     Install”, unit ”A”, Service Instruction Omega-B.
10. Set door to installation carrier.
11. Disconnect front door wiring harness up to loudspeaker area.
12. Remove check link - front door.
13. Remove front door gum seal in the front area.
14. Punch the welding points of the mounting bracket of the check
    link - front door (8 per door).
15. Drill through the welding points with a welding point drill
    (pic. II).
16. Remove drill chips completely.
17. Remove the check link - front door mounting bracket with a
    chisel and a drift punch from the front door.
18. Take off the check link - front door mounting bracket through
    the loudspeaker aperture.
19. Perform cleaning work.
20. Insert new check link - front door mounting bracket through the
    loudspeaker aperture (pic. III).
21. Fix the check link - front door mounting bracket with two drift
    punches.
22. Mark the welding points by drill holes in the new check link -
    front door mounting bracket (pic. IV).
23. Take off the check link - front door mounting bracket.
24. Grind the welding areas of the check link - front door mounting
    bracket with an angle grinder.
25. Insert the check link - front door mounting bracket and center
    it (pic. V). Centre the oval door aperture to the exterior sheet.
    Mark rectangular check link - front door aperture to the check
    link - front door mounting bracket, centred 6 mm.
26. Fix the check link - front door mounting bracket (2 fixing
    screws M5).
27. Protect water-repellent foil and inside of door from sparks.
28. Weld the check link - front door on mounting bracket.
29. Remove fixing screws M5.
30. Grind welding points with angle grinder.
31. Perform cleaning work.
32. Apply zinc spray paint to welding area.
33. Shorten the original outer reinforcement plate on both sides
    (see pic. I).
34. Paint the door with reinforcement plates.
35. Set modified inner reinforcement plate onto the check link -
    front door and insert into front door.
36. Install the outer reinforcement plate to the check link - front
    door with old fixing

[Andy B]

37. Apply cavity protection in the repair area.
38. Lay and fix front door wiring harness.
39. Install door and attaching parts as mentioned above, in
    reversed order.
40. Install outside mirror
     - see working procedure ”Replace Outside Mirror”, unit ”R”,
     Service Instruction Omega-B.
41. Install loudspeaker
     - see working procedure ”Loudspeaker - Front door, Remove and
     Install”, unit ”R”, Service Instruction Omega-B.
42. Install inner panelling - front door
     - see working procedure ”Inner panelling – front door, Remove
     and Install”, unit ”C”, Service Instruction Omega-B.
43. Connect battery.
44. Program volatile memories.

Parts:                                   Part-No.:       Catalog.-No.:
Possibility I:
Omega-B:
2 reinforcement plates                   09 195 961      90 97 309
2 Fastening screws                       13 104 167      20 03 001
Vectra-B:
2 reinforcement plates                   09 195 961      90 97 309
2 Fastening screws                       13 104 167      20 03 001
Possibility II:
Omega-B:
1 front door stop mounting bracket,      90 458 147      90 97 293
  left side
1 front door stop mounting bracket,      90 458 148      90 97 294
  right side
2 reinforcement plates                   09 195 961      90 97 309
2 Fastening screws                       13 104 167      20 03 001
Possibility III:
Vectra-B:
1 front door stop mounting bracket,      90 507 501      90 01 077
  left side
1 front door stop mounting bracket,      90 507 502      90 01 076
  right side
Labour Times:                            TC:          Hours:
T 8 129 10    Repair with                92           0.6 (Omega-B)
              reinforcement                           0.9 (Vectra-B)
              plates without
              side bag
T 8 129 11    Repair with                92           0.7 (Omega-B)
              reinforcement                           1.1 (Vectra-B)
              plates with
              side bag
T 8 129 12    Repair with                92           3.2 (Omega-B)
              bracket front                           3.2 (Vectra-B)
              check link
              without side bag
T 8 129 13    Repair with                92           3.4 (Omega-B)
              bracket front                           3.4 (Vectra-B)
              check link
              with side bag
T 8 129 14    Painting and               92           1.3 (Omega-B)
              finishing work                          1.3 (Vectra-B)
The costs for this repair will be covered for vehicles not older than
3 years and a mileage lower than 100.000 km.
The regular warranty procedure should be used for claiming Set-up-time.

[Bo Bo]

Cheers kevin, i'll have to take a closer look and find out what it is that's actually broken. something definately fell out and is sat in the bottom of the door

Exact same happened to mine, the mechanism went back together & all repaired with the kit....

[howardmoon]

mine is totally gone, guess i'll live with it until the car goes in for a service in the summer

[ians]

Well my door body hasn't deformed as far as I know so hopefully will be ok with the plates.

Regarding
Shorten and bevel the outer reinforcement plate on both sides by
   7.5 mm (Fig. I).  

Is this the top and bottom its referring to (ie short edges) ('sides' makes it sound like the long edges..).

Cheers
Ian

[Andy B]

Well my door body hasn't deformed as far as I know so hopefully will be ok with the plates.

Regarding
Shorten and bevel the outer reinforcement plate on both sides by
   7.5 mm (Fig. I).  

Is this the top and bottom its referring to (ie short edges) ('sides' makes it sound like the long edges..).

Cheers
Ian

Yes. When you get the plate(s) you'll find they're too long to fit into the hole at the front of the door.

[Mike Collins]

It's not too difficult to replace the bracket that Andy posted a picture of, you need to drill out five, from memory, spot welds. At least one is hidden under a sealing strip.

I found 3/16 or thereabouts pop rivets adequate for it's refitting, I did not want the paint destruction and subsequent corrosion of welding.
It's lasted a year so far with signs of failure.

Removing the door is essential, as is the front window guide, needs to be done with power on to move glass.

Don't unplug the door with the battery connected in case of airbag trouble.

Somewhere I have some pictures taken during the process, if anyone wants them, let me have your email address.

[Mike Collins]

That should read NO signs of failure.