Vauxhall Workshop Service and Repair Manuals

Remedy

In case of customer complaint the function of the turbocharger
actuator rod has to be checked.

Note: The following description is divided into 3 chapters:

I: Check actuator rod Meriva

II: Check actuator rod Astra-H, Corsa-D and Zafira-B

III: Overhauling of the actuator rod, all above mentioned models

Working Procedure:

I: Meriva

 1. Remove turbocharger

    - see working procedure "Replace Turbocharger",
      group "J", Service Instruction Meriva.
      (Document Number 01601646)

 2. Clamp turbocharger in bench vice

    Important:
    Clamp turbocharger at exhaust flange.
    Use aluminium jaws for bench vice.

 3. Connect minivac KM-667 to vacuum box and check actuator rod for
    proper function

    Note:
    In case the actuator rod works properly continue with chapter III.

 4. If the actuator rod will not move or movement is restricted, 
    apply rust solvent to actuator rod (Picture I, 1)

    Note:
    Application time for rust solvent must not be less than 12 hours 
    in case linkage is completely stuck or might be less if movement
    is only restricted.

 5. Connect minivac KM-667 to vacuum box and check actuator rod for
    proper function again

    Note:
    In case the actuator rod has now free movement proceed with
    chapter III.
    In case the actuator rod is still not moving or moving is 
    still restricted apply again rust solvent.

 6. Connect minivac KM-667 to vacuum box and check actuator rod for
    proper function

    Important:
    If necessary use in addition to minivac KM-667 an appropriate
    squared timber and push the actuator rod carefully in axial
    direction.

    Note:
    In case the actuator rod has now free movement proceed with
    chapter III.
    In case the actuator rod will still not move replace the
    turbocharger.

II: Astra-H, Corsa-D and Zafira-B

 1. Connect minivac KM-667 to vacuum box and check actuator rod for
    proper function

    Note:
    In case the actuator rod works properly continue with chapter III.

 2. If the actuator rod will not move or movement is restricted
    apply rust solvent to actuator rod (Picture II, 1)

    Note:
    Application time for rust solvent must not be less than 12 hours 
    in case linkage is completely stuck or might be less if movement
    is only restricted.

 3. Connect minivac KM-667 to vacuum box and check actuator rod for
    proper function once again

    Note:
    In case the actuator rod has now free movement proceed with
    chapter III.
    In case the actuator rod is still not moving or moving is 
    restricted apply rust solvent again and remove turbocharger.

    - see working procedure "Replace Turbocharger",
      group "J", Service Instruction Astra-H, Corsa-D and Zafira-B.
      (Document Number 01701224, 01501911 and 01801316)

 4. Clamp turbocharger in bench vice

    Important:
    Clamp turbocharger at exhaust flange.
    Use aluminium jaws for bench vice.

 5. Connect minivac KM-667 to vacuum box and check actuator rod for
    proper function

    Important:
    If necessary use in addition to minivac KM-667 an appropriate
    squared timber and push the actuator rod carefully in axial
    direction.

    Note:
    In case the actuator rod has now free movement proceed with
    chapter III.
    In case the actuator rod will still not moving replace the
    turbocharger.

III: Overhauling of the actuator rod

 1. Loosen the actuator rod from turbocharger with suitable
    tool (Picture III, 1), handle with care

    - Remove snap ring

    Note:
    If necessary spray actuator rod again with rust solvent and
    try to release manually by hand.

 2. Grind the pin carefully with sand paper 400 grain size 
    (Picture IV, 1)

 3. Grind the inner surface of the pin hole carefully with 
    sand paper 400 grain size (Picture V, 1)

    Note:
    Pin hole and groove must be made completely free of rust
    by using sand paper.

 4. Lubricate the pin with special oil 
    partno.: 93165293 / catalogueno.: 19 48 335

    Important:
    While lubricating the pin with special oil use gloves and observe
    the safety security data sheet.

 5. Install actuator rod to turbocharger

    - Install new snap ring and check for proper fitment

    Note:
    After rework apply minivac KM 667 again in order to guarantee
    free movement of the actuator linkage.

 6. Install Turbocharger

    Note:
    Only when turbocharger is removed

    - see working procedure "Replace Turbocharger",
      group "J", Service Instruction Astra-H, Corsa-D, 
      Meriva-A and Zafira-B.
      (Document Number 01701224, 01501911, 01601646 and 01801316)

    Note:
    In case the turbocharger must be replaced by a new unit apply
    special oil partno.: 93165293 / catalogueno.: 19 48 335 as 
    described in chapter III also to new turbocharger.
    In that case the snap ring must not be removed neither must
    the actuator rod be removed or any sandpaper operation
    carried out.

Spare-Parts:                              Part-No.:     Catalogue-No.:

Snap ring                                 95507727      90 08 005
Special oil                               93165622      19 48 002

Labour Times:                             TC:           Hours:

U3 265 10      Actuator rod                            
               turbocharger overhauling 

Corsa-D, Astra-H, Zafira-B                90            0,3

U3 265 11      Turbocharger - remove and install 
               overhaul actuator rod,
               or turbocharger replace      

Astra-H                                   90            2,9

Corsa-D                                   90            2,5

Meriva                                    90            3,8

Zafira-B                                  90            3,0

U3 265 11 001  Additional work for 
               vehicles with 
               air conditioning           90            0,3

The costs for this repair will be covered during the normal warranty.
The regular Warranty Procedure will apply.