Field Remedy: 1421
| Subject: | Engine - Cleaning Operation EGR / EGR-ports |
|---|
| Models: | Engines: | Option: |
|---|---|---|
| Astra-G 2001...2002,Corsa-C 2001...2002,Combo 2001...2002,Vectra-B 2000...2002,Zafira 2001...2002 | Z14XE| Z16XE| Z16SE,Z14XE| Z18XE,Z16SE,Z16XE| Y16XE,Z16XE |
| Complaint: | Engine poor idling. |
|---|---|
| Cause: | EGR-Valve contaminated with foreign particles. |
| Production: | As of 25.May 2002 modified parts have been used in production. Please refer also Technical Service Bulletin 1538. |
Remedy:
In case of customer complaint remove the EGR-Valve and the oxygen sensor and clean the EGR-Valve, EGR-ports and the catalytic converter.
Working Procedure:
1. Remove EGR-Valve
- see working procedure "Exhaust Gas Recirculation Valve, Remove and Install", group "L", of the corresponding Service Instruction.
2. Check EGR-Valve for contamination.
3. Only contaminated EGR-Valve: Remove contamination (picture I).
Attention:
Do not damage the EGR-Valve.
Note:
Clean EGR-Valve with a brass-brush or a wood-scraper.
4. Check function of the EGR-Valve.
5. Pin assignment of EGR-Valve:
1 = Pin "A".
2 = Pin "E".
6. Connect Pin "A" of the EGR-Valve to the negative pole of the battery.
7. Connect Pin "E" of the EGR-Valve several times to the plus pole of the battery (picture II).
Note:
Use special tool KM 609-10.
8. Remove oxygen sensor
- see working procedure "Oxygen Sensor - Mixture Regulation, Remove and Install", group "J", of the corresponding Service Instruction.
9. Remove contamination from both EGR-ports with a vacuum cleaner (picture III).
Note:
Set vacuum cleaner on maximum power.
10. Remove contamination from catalytic converter through opening for oxygen sensor with a vacuum cleaner (picture IV).
Note:
Set vacuum cleaner on maximum power.
11. Mark EGR-Valve on the underside in the represented area with a red color point (picture V, arrow).
12. Install EGR-Valve
- see working procedure "Exhaust Gas Recirculation Valve, Remove and Install", group "L", of the corresponding Service Instruction.
13. Install new oxygen sensor
- see working procedure "Oxygen Sensor - Mixture Regulation, Remove and Install", group "J", of the corresponding Service Instruction.
14. Read and delete troublecode
- see corresponding Checking Procedure.
Spare- parts: Part-No.: Catalog-No.:
Gasket, EGR-Valve
Corsa-C, Combo Z14XE, Z16SE, Z18XE 24 411 213 08 51 929
Astra-G Z14XE, Z16XE 24 411 213 08 51 929 Z16SE 24 411 213 08 51 929
Zafira Z16XE 24 411 213 08 51 929
Vectra-B Z16XE, Y16XE 24 411 213 08 51 929
Oxygen sensor
Corsa-C, Combo Z14XE 25 327 304 08 55 375 Z16SE 25 335 280 08 55 390 Z18XE 09 202 575 08 55 356
Astra-G Z14XE 25 327 304 08 55 375 Z16XE 25 327 304 08 55 375 Z16SE 25 323 632 08 55 366
Zafira Z16XE 25 327 304 08 55 375
Vectra-B Z16XE, Y16XE 25 324 206 08 55 360
Labour Times: TC: Hours:
T 8 142 10 Clean and check EGR 90 0.5
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.
| FunctionalGroup: | L - Fuel- and Exhaust System |
|---|---|
| Complaint Group: | 19 - Poor Engine Driveability |
| Trouble Code: | Non |