Field Remedy: 1291

Remedy:

There are 3 possibilties:

 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 color 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 Instructionne.

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). Center the oval door aperture to the exterior sheet.
    Mark rectangular check link - front door aperture to the check
    link - front door mounting bracket, centered 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 screws – use locking compound.
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.

Possibility III (Vectra-B):

 1. Remove inner panelling – front door

     - see working procedure ”Inner panelling – front door, Remove
     and Install”, unit ”C”, Service Instruction Vectra-B.

 2. Remove loudspeaker

     - see working procedure ”Loudspeaker - Front door, Remove
     and Install”, unit ”R”, Service Instruction Vectra-B.

 3. Remove exterior rear view mirror

     - see working procedure ”Outside rear
     view mirror, Remove and Replace”, unit ”R”, Service Instruction
     Vectra-B.

 4. Open sash window.
 5. Partially loosen front door window guide seal.
 6. Close sash window.
 7. Disconnect battery.
 8. Remove front door

     - see working procedure ”Front or rear door, Remove and
     Install”, unit ”A”, Service Instruction Vectra-B.

 9. Set door to installation carrier.
10. Disconnect front door wiring harness up to loudspeaker area.
11. Remove check link - front door.
12. Straighten the deformation of the check link - front door
    mounting bracket.
13. Punch the welding points of the mounting bracket of the check
    link - front door (pic. VI, 1).
14. Punch new fixing points in the area of the check link - front
    door mounting bracket (pic. VI, arrows).

15. Drill through the welding points and the fixing points with
    a 5 mm drill.
16. Debur drill holes.
17. Remove drill chips completely.
18. Clean the inner check link - front doorop mounting bracket and
    remove cavity protection.
19. Adapt new check link - front door mounting bracket (pic. VII). 

20. Insert new check link - front door mounting bracket from the
    inside into the front door and fix it with 2 fixing screws and
    fixing nuts M5.
21. Mark the welding points by drill holes in the new check link -
    front door mounting bracket.
22. Remove the check link - front door mounting bracket (2 fixing
    screws and fixing nuts M5).
23. Grind the welding areas of the check link - front door mounting
    bracket with an angle grinder.
24. Insert the check link - front door mounting bracket and fix it
    with 2 fixing screws and fixing nuts M5.
25. Grind the front door in the area below the inner panelling for
    ground contact for welding purposes.
26. Protect water-repellent foil and inside of door from sparks.
27. Weld the check link - front door on mounting bracket.
28. Remove fixing screws and fixing nuts M5.
29. Grind welding points with angle grinder.
30. Perform cleaning work.
31. Apply zinc spray paint to welding area.
32. Paint the door with reinforcement plates.
33. Install check link - front door (outside use washers with diameter 20mm).

Note:

    Heed weldingpoints - washers may not support.

34. Apply cavity protection in the repair area.
35. Lay and fix front door wiring harness.
36. Install the front door

     - see working procedure ”Front or rear door, Remove and
     Install”, unit ”A”, Service Instruction Vectra-B.

37. Connect battery.
38. Open sash window.
39. Install front door window guide seal.
40. Close sash window.
41. Disconnect battery.
42. Install exterior rear view mirror

     - see working procedure ”Outside rear view mirror, Remove
     and Install”, unit ”R”, Service Instruction Vectra-B.

43. Install loudspeakers

     - see working procedure ”Loudspeaker - Front door, Remove
     and Install”, unit ”R”, Service Instruction Vectra-B.

44. Install inner panelling – front door

     - see working procedure ”Inner panelling – front door, Remove
     and Install”, unit ”C”, Service Instruction Vectra-B.

45. Connect battery.
46. 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           0.7 (Omega-B)
              reinforcement                           1.0 (Vectra-B)
              plates without
              sidebag

T 8 129 11    Repair with                92           0.8 (Omega-B)
              reinforcement                           1.2 (Vectra-B)
              plates with
              sidebag 

T 8 129 12    Repair with                92           3.3 (Omega-B)
              bracket front                           3.3 (Vectra-B)
              check link
              without sidebag

T 8 129 13    Repair with                92           3.5 (Omega-B)
              bracket front                           3.5 (Vectra-B)
              check link
              with sidebag

T 8 129 14    Painting and               92           1.4 (Omega-B)
              finishing work                          1.4 (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.