Field Remedy: 1897
| Subject: | Z16XE engine - EGR malfunction |
|---|
| Models: | Engines: | Option: |
|---|---|---|
| Astra-G 2002...2004,Meriva 2003...2004,Vectra-C 2002...2004,Zafira 2002...2004 | Z16XE,Z16XE,Z16XE,Z16XE | MT,MTA |
| Complaint: | Telltale on, driveabilty complaints, jerking, trouble code P0400 set |
|---|---|
| Cause: | Deposits in EGR between pintle and guide |
| Production: | As of engine number 20BY2510 (10 October 2003) a stepped pintle EGR valve with several design improvements has been introduced. |
Remedy:
This remedy is valid for the following models only:
Engine Model Transmission Modelyear until Engine-BP Z16XE Astra-G MT 2002 - 2004 20CK1163 Z16XE Meriva-A MT & MTA 2003 - 2004 20CF5854 Z16XE Vectra-C MT 2002 - 2004 20CR2606 Z16XE Zafira-A MT 2002 - 2004 20CF5860 Please refer to QI 1899, TSB 1900, QI 1953 or Special Policy Program 05-P-25 for other models with family 1 engine.
In case of customer complaint replace EGR gasket and reprogram engine ECU with software as of TIS 2000 CD 64 or later:
1. Replace EGR gasket by the new version (Part No. 55 560 700, with flag) before reprogramming the ECU.
- see working procedure „Exhaust Gas Recirculation Valve, Remove and Install”, Group „L“ of the corresponding Service Instruction.
Note: The new version of the gasket (1-bore version) can be identified by a ‘flag’ at the outer side of the gasket.
2. Reprogram engine ECU with modified software (Software Version available as of TIS 2000, CD 64) to deactivated the EGR valve function.
Spare-Parts: Part-No.: Catalogue-No.:
Gasket 55 560 700 91 06 319
Labour Times: TC: Hours:
U3 189 71 Replace Gasket and 90 0,3 reprogram engine ECU
The costs for this repair will be covered for vehicles not older than 6 years and a mileage lower than 100.000 km.
The regular warranty procedure should be used for claiming Set-up-time.
| FunctionalGroup: | J - Engine,L - Fuel- and Exhaust System |
|---|---|
| Complaint Group: | 13 - No/Poor Function,19 - Poor Engine Driveability,20 - Poor Performance |
| Trouble Code: | P0400 |