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Removing/repairing door cards

Discussion in 'Omega How to and FAQ's' started by Hillper, Sep 27, 2005.

  1. Hillper

    Hillper Chews Werthers

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    Location:
    Aylesbury, Bucks.
    Car: 2.2CD (2000) facelift. Similar technique applies for other models.

    Lever out switch cluster and unplug. Lever out tweeter grill and tweeter and unplug.

    Remove screws. One screw on side by lock. Three screws on the bottom. Two screws on the front under covers in the oval shaped area where the dashboard side meets. One screw in the tweeter recess. And......the 'secret screw', the last one, is under a little pop off panel about 40mm square behind the flip down pocket. It's only visible when the pocket is pulled open. The panel levers off easily.

    It's easier to get the door card off if you pull off the 'triangle' where the door mirror adjuster would be. This takes a lot of pulling and is easier if you pull from the side nearest the door lock. When you do pull it off, you will probably find you've left one or both white plastic plugs which locate in the door frame. Remove them from the frame and re-insert in the 'triangle' before replacing. Pull the bottom of the card out about 3 inches and tap the card up from the bottom. The locating strip will pop out of the guide along the door top. Lift card over the lock pin and detach the curb light and speaker plug. The speaker plug is fiddly and requires three hands!

    The horizontal, plastic locating strip running along the top of the card often partly breaks off.
    Drill several screw holes along the base of the strip still on the card, holding it by hand in position on the card. (You can see the correct position by aligning the strip with the old glue mark). Drill smaller pilot holes through the strip holes and into the cardboardy stuff of the panel. When you've got enough holes (every 25mm), apply Araldite and screw the strip down. Let it dry thoroughly.

    Whilst the card is drying, the rattling lock pins can be silenced using small pieces of foam draft strip applied around hole in the door card where the pin comes through and by using the foam strip on the door itself by buiding up several layers behind the door push rod to help reduce the vibration.

    It's awkward getting the card back on. Locate card over lockpin. Re-attach speaker plugs, curb light plug tweeter plug and window plug. Pull the door card away from the door a bit at the bottom and knock down on the top of the trim, whilst pushing in at the top, the strip should locate! Refit tweeter and switches.
    Last point. Some of the self tappers in the door are different sizes, so remember where they go!
     
  2. JasonH

    JasonH Active Member

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    Location:
    Bristol, UK
    Absolutely excellent. Made the job almost easy.

    A couple of minor extras that might we worth adding are:

    The small triangle on the corner has a full length lip on the window side. Pull towards the window to free this then try and pull the whole thing up. This should pop the clips out nicely.

    You need to seal the plastic door liner when you're done. The airbag sensor relies on this being sealed. It detects pressure on a side impact.

    I popped the top edge off using a bolster. Wound the window down, lots of padding on the edge and levered up. Came off OK.
     
  3. Marks DTM Calib

    Marks DTM Calib Omega Tank Commander

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    Location:
    Nottingham
    THe easiest method for removing the door triangle is actualy to ease it away from the door metal at the door hinge end, this will release the two clips, then slide it towards the rear of the car to unclip the full length lip.
     
  4. markjay

    markjay Dakota

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    Location:
    London UK
    I was following Hillper’s notes above and took pictures as I went along.

    Please note that this is NOT a shortcut – you need to refer to Hillper’s text as it contains detailed instructions which are not obvious from the pictures alone.

    [​IMG]
     
  5. Marks DTM Calib

    Marks DTM Calib Omega Tank Commander

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    Location:
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    As a tip, you can leave the window switch in place and connected if only working on the door lock end etc.
     
  6. markjay

    markjay Dakota

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    Location:
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    Mark DTM's last point is a good one - the plastic 'shoulder' around the cluster that is used to lever it out seems very fragile, the less you take it out the better... And the cable feeding the cluster does have quite a lot of slack.
     
  7. taurean

    taurean New Member

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    Location:
    Manchester, England
    I have ordered the replacement plastic surrounds for both front doors (as they are scratched too death)

    I have followed the instructions above and got the card off (cheers for help as the secret screws didi my head in until I read hear)

    My next problem is that the trims appear to be held in place by what I can only described as plastic rivets. How do you remove these without breaking them - or is this impossible?? Can you get them from vauxhall to just pop back in, or do you have to cobble something together with self tapping screws???

    I would appreciate anyone's help.
     
  8. subliminal

    subliminal New Member

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    Location:
    England
    My apologies for reviving this aged thread, but can anyone shed any light on taurean's question regarding the "plastic rivets"? Does anyone have any more info about the "plastic seal" (water vapour barrier?) and wether it can just be undone and taped back up? Will this affect the airbag calibration (and thus need taking in to Vauxhall)?

    I've only bought the car last week and I'm already fixing bits :p (intermittent electronic/remote lock/unlock on driver side)

    Much appreciated!
     
  9. subliminal

    subliminal New Member

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    Location:
    England
    Update: (no post editing?) I replaced a central locking solenoid yesterday so thought I'd share my two bits:

    The rivets on the 'trim', e.g. the wood effect or the grey trim (mv6) will break if you remove the trim (no need to to remove the door card anyways).

    If you follow the instructions exactly you shouldnt have any problems - be patient releasing the last clips on the card (the bits that often end up breaking off) and they shouldnt :) (break off).

    The plastic seal or 'water vapour barrier' can, in most cases, be re-used - it just sticks back down if you peel it away carefully. There may be a small area that doesnt stick down properly (about 1cm in my case... I used some tape to sort that out).

    The airbag light did not come on - it doesnt look like its sensitive enough to be bothered by removing the vapour barrier.
     

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