Subject:
Engine replacement programme - Z22SE DOHC engine
Vehicles:
All Astra-G, Astra-G Coupe, Vectra-B, Speedster / VX220 and Zafira with Z22SE - DOHC engine
General:
This TI should serve to inform the dealership network of the procedure for complaints concerning the Z22SE engine.
1. Engine replacement programme
The engine replacement programme is applicable for customer complaints which result from engine problems. For this purpose, it must be noted that only the repair or replacement of certain engine components is permissible.
1.1 For the duration of the engine replacement programme, only the components listed below may be replaced:
- Drive chain tensioner
- Oil pump with gasket
- AC compressor
- Ribbed V-belt and automatic ribbed V-belt tensioner
- All engine sensors
- Block heater (if fitted)
- Engine / transmission brackets or mountings
- Cylinder head cover
- Coolant pump and gasket (without chain drive gear)
- Exhaust gas recirculation valve, exhaust gas recirculation valve gasket and exhaust gas recirculation pipe
- Exhaust manifold, exhaust manifold gasket and heat shields
- Intake manifold and intake manifold gasket
- Flywheel and ring gear disc
- Fuel distributor pipe
- Fuel injector nozzles and seals
- Fuel system
- Torsional vibration damper
- Heater hoses and seals
- Fuel injector nozzle wiring harness
- Oil filter, oil filter cover
- Oil dipstick guide tube and oil dipstick
- Crankcase ventilation hose
- Steering pump
- Engine control unit
- Engine wiring harness
- Starter
- Alternator
- Thermostat and seal ring
- Throttle valve and electronic accelerator pedal-related components
- Vacuum hoses
- Tank vent hoses and seals
- Ignition system with following components: Ignition module, spark plugs, high voltage switch
2. Procedure in case of oil leaks
In the case of oil leaks caused by one of the above-listed components, a repair by the Opel dealership without engine replacement is permissible. Oil leaks at the oil pan or at the front cover will be examined in each individual case. For this purpose, exact location of the leak point is required. After verification of the leak, the local TAC (Technical Assistant Centre) must be informed and consulted in deciding on the necessity of an engine replacement. If the leak is not at the oil pan, the front cover or at the non-replaceable components, then the engine must be replaced according to the procedure described under 4. In this case, the Opel dealership receives a fault description and leak designation form from their local TAC. This form must be filled in accordingly and enclosed with the returned engine. A copy of the fault description must be sent to the local TAC.
3. Repair of internal engine components
If the complaint indicates a fault caused by internal engine components, the engine must be replaced. Repairs to internal engine components are not permissible. The replacement engine is fitted with intake and exhaust manifolds, fuel distributor pipe, steering pump, ignition system, engine sensors, ring gear disc (for automatic transmissions), flywheel and clutch (for manual transmissions). Consequently, the engine to be replaced must also be fitted with these components when returned. This is necessary in order to perform an effective fault analysis. Components which were previously detached from the engine to be replaced, must be re-attached with the torques specified in the Service Instructions.
4. Procedure for engine replacement programme
In the case of a complaint which requires an engine replacement, the Opel dealership must contact the local TAC and submit an application for the delivery of a replacement engine. The TAC then organises the collection and the delivery of a new replacement engine to the relevant Opel dealership. Replacement engines are delivered to the dealerships without engine oil. The replacement engine must be filled with engine oil and coolant according to specifications, before commissioning.
The engine to be replaced must be furnished with the completed fault description form, the return form and the necessary freight documents.
Exceptions to this procedure are engines from the German and English dealership networks which must be sent to the responsible warranty claims centre in R�sselsheim or Birmingham.
5. Return
- The removed engine must be drained (engine oil, coolant) and fitted with closure plugs.
- The engine must be packed in the original transport frame.
- The dealership address and the TAC case number must be marked on the transport container. A copy of the fault description must be sent to the local TAC.
- The completed fault description form must be enclosed with the engine.
- With the exception of those from the German and English dealership networks, the removed engines must be sent via the responsible freight company, to the following address:
Adam Opel AG, Werk Kaiserslautern
FAO M. Becker or B. Wagner
Bau K30 S�ule C16
D-67653 Kaiserslautern
The copy of the freight documents, dated and signed by the responsible freight company, is intended for the Opel dealership and is valid as confirmation of return of the replaced engine, if required.
Time Allowances:
The time allowances remain unchanged and can be found in the current publications.