Workshop Repair Manuals

Vauxhall Workshop Manuals

[PREV PAGE] [NEXT PAGE]

vauxhall Workshop Repair Guides


Astra G

J Engine and Engine Aggregates > DOHC Petrol Engine > Cylinder Head > Valves > Technical Service Bulletins > No Start > Engine - Stalling or worse Engine run

Field Remedy: 1198

Subject: Engine - Stalling or bad idling
Models: Engines: Option:
Corsa-B 95...00,5,Tigra 95...00,5,Astra-F 95...00,5,Vectra-B 96...00,5,Astra-G 98...00,5,Zafira 99...00,5 X14XE| X16XE,X14XE| X16XE,X14XE| X16XEL,X16XEL,X14XE| X16XEL,X16XEL
Complaint: Stalling or bad idling 100-500 m after cold start by outer temperatures less than 10°C. Immediately after stalling serious or no restart possible, because the engine turns without compression. This affects vehicles on short distance journies in combination with regular low engine speed driving. Affected Engines: X14XE, X16XE and X16XEL.
Cause: Loss of compression due to sticking exhaust valves.
Production: In production a sintermetal valve guide has already been implemented as well as a clearance limitation. Breakpoints for sintermetal valve guides are: Szentgotthard: 20A69569 and Bochum: 02GR7584. The modified valve guide sealing cap will not be used in production.

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.

FunctionalGroup: J - Engine
Complaint Group: 19 - Poor Engine Driveability
Trouble Code: Non

J Engine and Engine Aggregates > DOHC Petrol Engine > Cylinder Head > Valves > Technical Service Bulletins > No Start > Engine - Stalling or worse Engine run

[PREV PAGE] [NEXT PAGE]