Field Remedy: 1356

Remedy:

In case of customer complaint, replace Throttle Valve Adjuster and Adapter
Cable by modified parts.

1. Open three screws on the top of the air intake cover
   (pic. I, 1) and remove air intake cover (pic. I, 2).

2. Install new Throttle Valve Adjuster
      - see working procedure "Throttle Valve Adjuster, Remove and
        Install", Unit "J", in the corresponding Service
        Instructions.

   Note:
   When replacing the Throttle Valve Adjuster, it is essential
   that the adaptation values for the throttle valve in EPROM of
   the engine control unit are deleted using TECH2.

3. Wind fiber-reinforced adhesive tape at the area of the holder 
   round the water hose to protect the water hose against wear or 
   damages. Put cable tie (pic. II, 1) diagonal against holder 
   (pic. II, 2) of water hose. Tighten cable tie until water hose 
   (pic. II, 3) is jammed and fixed at the holder. Cut cable tie 
   at the water hose.

   Caution:
   Do not damage anything during cutting.

4. Disconnect plug connection of the Throttle Valve Adjuster,
   positioning the adapter cable (pic. III, 1).

   Connect adapter plug, male (pic. III, 2) to unplugged original
   Throttle Valve Adjuster cable, female (pic. III, 3).

   Position cable tie between plug, male and the flex tube of the
   adapter and between plug, female and the flex tube of the
   adapter, between grommet and plug housing (pic. III, 4).

   Tighten both cable ties until plug connection is jammed. Cut
   cable ties.

   Caution:
   Do not damage anything during cutting.

5. Bring adapter into end position, connect adapter plug, female,
   to the Throttle Valve Adjuster, male (pic. IV, 1) and fit two
   plastic clips on the water hose (pic. IV, 2). If necessary
   locate position of clips upwards.

6. Installation step only 4-cyl. vehicles:
   Fix the original Throttle Valve Adjuster cable (pic. V, 2) at
   the flex tube of the adapter cable (pic. V, 3).

   Position cable tie and tighten until plug connection is jammed.
   Cut cable ties.

   Caution:
   Do not damage anything during cutting.

7. Installation step only 3-cyl. vehicles:
   Fix the original Throttle Valve Adjuster cable with a cable tie
   at the flex tube of the adapter cable (pic. VI, 1).

   Position the original Throttle Valve Adjuster cable parallel to
   the cable with the flex tube. Position a cable tie and tighten
   until plug connection is jammed. Cut cable ties.

   Caution:
   Do not damage anything during cutting.

Parts:                               Part-No.:      Catalog-Nr.:

Throttle Valve Adjuster              09199907       90 08 977

Adapter cable                        93170485       90 12 037

Labour Times:                             TC:               Hours:

T 8 135 60     Replace Throttle           92                0.8
               Valve Adjuster and
               set throttle valve
               0-degree position.
               Install adapter cable.
               Corsa-B X10XE LHD/RHD

T 8 135 61     Replace Throttle           92                0.9
               Valve Adjuster and
               set throttle valve
               0-degree position.
               Install adapter cable.              
               Corsa-B X12XE LHD/RHD

T 8 135 62     Replace Throttle           92                0.9
               Valve Adjuster and
               set throttle valve
               0-degree position.
               Install adapter cable.              
               Astra-G X12XE LHD/RHD

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.

Please note:

Only in cases where the above procedure does not mend the problem proceed as
follows:

1. Check if ECU is dated before or after breakpoint check ECU-labeling or
engine-number.

ECU breakpoints: 
Corsa-B X10XE - FD 966113, 
Corsa-B X12XE - FD 966114, 
Astra-G X12XE - FD 082119.
The 1st digit indicates the production year 9=1999.
The 3rd digit indicates the production month 6=June.
For example: 966113 = June 1999
             082119 = Feb. 2000

If ECU is dated before breakpoint, ECU has to be changed.

2. Install new ECU
      - see working procedure "Engine Control Unit, Remove and
        Install", Unit "J", in the corresponding Service
        Instructions.

Parts:                               Part-No.:      Catalog-Nr.:

ECU Corsa-B (X10XE)                  09164450       62 37 039

ECU Corsa-B (X12XE)                  09164454       62 37 040

ECU Astra-G (X12XE)                  09131795       62 37 765