Field Remedy: 1421

Subject: Engine - Cleaning Operation EGR / EGR-ports

Models: Astra-G 2001...2002,Corsa-C 2001...2002,Combo 2001...2002,Vectra-B 2000...2002,Zafira 2001...2002

Engines: Z14XE| Z16XE| Z16SE,Z14XE| Z18XE,Z16SE,Z16XE| Y16XE,Z16XE

Option:

Complaint: Cause:

Engine poor idling. EGR-Valve contaminated with foreign particles. As of 25.May 2002 modified parts have been used in production. Please refer also Technical Service Bulletin 1538.

Production:

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. Spareparts: Gasket, EGR-Valve Corsa-C, Combo Z14XE, Z16SE, Z18XE Astra-G Z14XE, Z16XE Z16SE Zafira Z16XE Vectra-B Z16XE, Y16XE Oxygen sensor Corsa-C, Combo Z14XE Z16SE Z18XE Astra-G Z14XE Z16XE Z16SE Zafira Z16XE Vectra-B Z16XE, Y16XE Labour Times: T 8 142 10 Clean and check EGR

Part-No.:

Catalog-No.:

24 411 213

08 51 929

24 411 213 24 411 213

08 51 929 08 51 929

24 411 213

08 51 929

24 411 213

08 51 929

25 327 304 25 335 280 09 202 575

08 55 375 08 55 390 08 55 356

25 327 304 25 327 304 25 323 632

08 55 375 08 55 375 08 55 366

25 327 304

08 55 375

25 324 206 TC: 92

08 55 360 Hours: 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: Complaint Group: Trouble Code:

L - Fuel- and Exhaust System 19 - Poor Engine Driveability Non