I noticed there was some confusion with the whole process which really is a simple task, but hard to explain with words. Did it on my drivers door to *Borat Voice* Great Success!!! Took pics to explain how2. May possibly be able to go in the relevant section? Save everyone a few quid
As said earlier in the thread, the rollers that run along the door stay are prone to wear down to a flat causing a clunking sound when opening the door. This can be replaced for around £20 however as there are 2 rollers in the housing and only one wears down, it is possible to swap them around and save yourself a replacement by using the 2nd roller.
1/4" Ratchet and extension
Torx 40 socket
Door stay part component requiring a persuasive adjustment. Why replace parts when you can re-use...
Start by using the Torx bit and the ratchet to undo the door stay from the front pillar. I used a 1/4" setup as I wanted to take a gentle approach as its easy to 'over-torque' the parts on the Vec/Sig.
Once the door stay is removed from the front pillar rotate the bar 180 degrees within its rollers. As its a well greased component I used pliers and rotated it 90 degrees at a time. Once complete it will be the wrong way round.
Using the 10mm socket and ratchet undo the two retaining nuts on the door to release the door stay from the door.
Once complete the whole component can be moved in and out of the door.
Using the door stay bar as a handle push the component inside the door housing until the mounting bolts are clear from the holes...
Whereas before you rotated the stay bar within the roller housing, This time you need to rotate the WHOLE component 180 degrees so that the bar is facing its original direction and the mounting bolts line up with the holes again.
I found that levering the bar upwards 45 degrees located an area large enough to rotate the component around.
Once lined up in the new position locate everything into position, re-tighten the mounting screw and nuts. If available I would probably re-grease the 'new' upper side of the stay bar.
The door clunking has now stopped (for a few years anyway) and you have saved a few pounds.
Big thanks to K4SYX for providing us with this how2 sourced from the Polish Vectra Club.
All in all, this took 10 minutes including taking pictures. It really is a very quick and effective repair.