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Subject:
Freewheel Lock Cylinder Assembly Repair, Front Door
(Driver’s Side), Luggage Compartment Lid and Tailgate
Vehicles:
Corsa-B, Tigra, Astra-F, Vectra-B,
Calibra, Omega-B
Condition
Previously, repair of the freewheel lock cylinder also
included the replacement of the bracket (handle recess).
Remedy:
The following operation describes the repair of the
freewheel lock cylinder along with the bracket, using the front door as an
example.
I Lock cylinder without freewheel
II Freewheel lock cylinder
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Operation; Example of Front Door:
Remove and install as specified in Service Instructions
Remove freewheel lock cylinder with bracket.
Detach freewheel casing (1) from bracket (2).
Remove roll pin (3) using drift Æ 2.5 mm.
The resulting hole (4) does not damage the component.
Unscrew freewheel casing from catch.
Insert new freewheel casing. Right bore (5) must align with
hole (4) in bracket.
Drive in new roll pin with drift.
Caulk roll pin on rear side of bracket with centre-punch
(6).
Assemble freewheel lock cylinder in bracket and install
handle unit.
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Parts:
The Service Department lists the parts shown in the survey
in the delivery range with the
part no. 90 . . . . . . cat. no. 01 33 . . .
Survey of Components, Front Door Freewheel Lock
Cylinder:
1 Roll pin
2 Casing
3 Lock cylinder (*)
4 Orifice sleeve
5 Ball
6 Coupling (*)
7 Bracket
8 Lock washer
9 Driver with lever
(central locking version)
10 Pivot spring
11 Thrust spring
(*) Always replace together
Important:
Only replace lock cylinder (3) and coupling (6)
together, in order to retain friction coefficient and optimal function
(break-in fit).
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Note:
1. For design reasons, the freewheel lock cylinders for the
luggage compartment lid and the tailgate are only available as assemblies in
the delivery range (replacement of individual parts not possible).
2. Lock Cylinder Spins (Coupling Engages)
- Insert ignition key into door lock
- Hold key vertically
- Turn key to left or right until slight resistance is
felt
- Turn key back
- Lock function (lock cylinder) operational
3. Lock Cylinder Spins (Coupling does NOT Engage)
- Remove freewheel lock cylinder with bracket
- Remove lock washer
- Remove driver
- Remove sheared-off cam of driver (plastic) from
coupling
- Install new driver
- Assemble lock cylinder and install
- Function check (note 2)
Time Allowance:
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Op. no.
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Operation
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Time allowance
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Lock Cylinder, Front Door - Replace
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TC: 01, 15, 24, 27, 54
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C 6221 00
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Driver’s side
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Time allowance
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C 6231 00
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Co-driver’s side
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remains
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unchanged
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Add:
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004
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For vehicles with freewheel lock cylinder
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.2 hrs. C
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(applies to Corsa-B, Tigra, Astra-F, Vectra-B, Calibra,
Omega-B)
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Driver for Freewheel Lock Cylinder - Replace
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TC: 01, 03, 71
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+: R + R door panelling, replace water vapour barrier
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C 6236 00
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Driver’s side
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.9 hrs.
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Corsa-B, Tigra,
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Vectra-B,
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Omega-B
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.7 hrs.
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Astra-F, Calibra
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1.0 hrs.
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Astra-F Convertible
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C 6237 00
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Co-driver’s side
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.9 hrs.
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Corsa-B, Tigra
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.7 hrs.
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Astra-F, Calibra
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1.0 hrs.
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Astra-F Convertible
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Important:
The specified time allowances do not include the time
allowance for the vehicle set-up of .2 hrs.
For reimbursement of the vehicle set-up time of .2 hrs in
warranty claims, enter the authorisation code ”T” and increase the main
operation time allowance by .2 hrs.
The authorisation code may only be used once per work
order. It may only be used more than once if the workplace and workteam are
changed at the same time.
