Field Remedy: 1198

Remedy:

Attention: No TC’s are set! For an secure diagnosis, see diagnosis instruction

IMPORTANT: The herein described process affects only the exhaust valves.

To apply the field remedy, please proceed as described in the 
service instructions for Corsa-B/Tigra, Astra-F, Astra-G, Zafira, Vectra-B 
respectively:

- Remove the cylinder head.
- Remove camshaft on the exhaust side only.
- Dismantle cylinderhead on exhaust side only.
- Rework valve guides with a handreamer (KM-6022).

Attention: Reaming only by hand, because of the coaxiality of the guides and
shafts. 
Use the reamer for max. 10 cylinderheads.
Regrind valve seats with paste.
- Fit modified valve guide sealings on exhaust side.
- Assemble cylinderhead and refit to engine.

Required parts: Valve guide sealings        Cat.-/Part-No. 
                                       90 97 099 / 91 19 497

Labour times:                TC  Hours    Modell    Engine

T  0546 00 Remove and refit 
           the cylinder head 
           and rework valve 
           guides            92  7.6      Corsa-B/  X14XE/
                                          Tigra     X16XE

T  0546 05 Remove and refit 
           the cylinder head 
           and rework valve 
           guides            92  8.5      Corsa-B/  X14XE/
                                          Tigra     X16XE
                                          (AC 1) 

T  0546 10 Remove and refit 
           the cylinder head 
           and rework valve 
           guides            92  6.2      Astra-F   X14XE

T  0546 20 Remove and refit 
           the cylinder head 
           and rework valve 
           guides            92  6.3      Astra-F   X16XEL

T  0546 30 Remove and refit 
           the cylinder head 
           and rework valve 
           guides            92  6.4      Vectra-B   X16XEL

T  0546 40 Remove and refit  
           the cylinder head 
           and rework valve 
           guides            92  6.7      Astra-G    X14XE/X16XEL

T  0546 50 Remove and refit  
           the cylinder head 
           and rework valve 
           guides           92   6.7      Zafira     X16XEL 

(1) Important: The AC system for T 0546 05 remains closed!

Only one T-Number should be used.
The regular warrenty procedure should be used for claiming
Set-Up time.

Diagnosis-Instruction

After vehicle-takeover from the customer, ensure that the engine speed does
not exceed over 3500 min/-1. 
Crosscheck driving with connected:
Oil pressure manometer
Measure point: Oil pressure switch
Fuel pressure manometer
Tech 1 / Tech
Function: In snap shot mode trigger with F9, if engine dies press F9, then
attempt re-start.

Data evaluation:

Oil pressure check:
A oil pressure higher than 600 kPa by cold motor, can cause a trouble with
the engine driveability. The rising of the oil pressure should be constant.
Uneven pressure rise indicates a defect. The cause could be a sticking oil
pressure regulator piston.

Fuel pressure check:
Check the pressure values according to the following table

MPFI  Pressure regulator controlled by intake pressure
      240 up to 260 kPa

      Pressure regulator controlled by throttle valve position
      294 up to 306 kPa

TBI/Multec 70up to 79 kPa

The fuel pressure after engine off, shouldn’t fall by less than 50% in
10 minutes.

Possible remedy

Fuel forward hose /-reverse hose : Check hoses
Fuel tank vent line:               Check hoses
Fuel pump:                         Check connections and  
                                   voltage

Evaluate and save the snap shot data with a PC or Tech 15

Coolant temperature sensor:     Values in F0 data list
Intake air temperature sensor:  Values in F0 data list -(approx. outer temp.)
Exhaust gas recirculation (EGR-valve):     Plan/actual- 
                                           comparsion
MAP-Sensor in case of restart:  Constant under maximum value

Throttle valve position
Injection impulse of the injection valves

Possible remedy

Plug intake pressure sensor:   Optimise contacts
EGR-valve:                     Check connections, 
                               if required replace part
Intake air temperature sensor: Check connections, 
                               if required replace part
Coolant temperature sensor:    Check connections, 
                               if required replace part

If this check program indicates no failure, the cause could be mechanical.