Field Remedy: 1523

Remedy:

Note:

Astra-F (X18XE) valid as of MY 1996,5.

In case of customer complaint check the bore for crankcase ventilation in the
throttle housing, clean it if necessary and replace the idle air control valve.

At the Omega-B replace the connection piece for pre-heating if the bore for
crankcase ventilation is blocked.

Note:

     Working procedure I:   Applies to Astra-F, Vectra-B
                            (Software on TIS 2000 as of CD 39 available)
                            Applies to Astra-G
                            (Software on TIS 2000 as of CD 42 available)

     Working procedure II:  Applies to Omega-B
                            (Software on TIS 2000 as of CD 41 available)

Important:

     The conversion of the Omega-B can only be enforced with publication of
     the new software as of CD 41.

Working procedure I:

 1. Remove air intake hose from air filter housing and throttle housing.
 2. Remove hose for crankcase ventilation from throttle housing.
 3. Clean bore for crankcase ventilation in the throttle housing with
    a welding wire or a drill (diameter 1 mm) (Picture I, arrow).

 4. Install hose for crankcase ventilation to throttle housing.
 5. Remove idle air control valve from throttle housing (Picture II, 1).

 6. Clean gasket surface at throttle housing.
 7. Install new idle air control valve with new gasket to throttle housing.

Note:

     Observe installation position of gasket.

 8. Install adaptor wiring harness to idle air control valve and wiring
    harness plug idle air control valve.
 9. Fix wiring harness plug for idle air control valve with cable strap
    (Picture III, arrow).

10. Install air intake hose to air filter housing and throttle housing.
11. Program ECU with new software.

Working procedure II:

 1. Remove air intake hose from air filter housing and throttle housing.
 2. Bend a welding wire for checking the bore of the crankcase ventilation.

Note:

     Bend welding wire (diameter 1 mm) in an angel of 90°, Length 200x50 mm.

 3. Put throttle in position "full throttle" and block it with a suitable
    tool (Picture IV, 1).

 4. Check bore (arrow) for crankcase ventilation with welding wire for
    passage (Picture V, 1).

Note:

     If the bore of the crankcase ventilation is plugged, remove the tool for
     blocking the throttle in position "full throttle" and execute steps 5, 9
     and 10, working procedure B of the TSB 1265 "Engine Stalls – Idle Air
     Control dirty".

 5. Remove idle air control valve from throttle housing (Picture VI, 1).

 6. Clean gasket surface at throttle housing.
 7. Install new idle air control valve with new gasket to throttle housing.

Note:

     Observe installation position of gasket.

 8. Install adaptor wiring harness to idle air control valve and wiring
    harness
    plug idle air control valve.
 9. Fix wiring harness plug for idle air control valve with cable strap
    (arrow) (see Picture III).

10. Install air intake hose to air filter housing and throttle housing.
11. Program ECU with new software.

Spare-Parts:                                 Part-No.:        Catalog-No.:

Kit Idle Air Control Valve                   92066066         90 08 196
Connection piece, pre-heating hose           90322594         06 56 161
2x seal ring, connection piece               11023582         20 91 046

Labour Times:                                TC:              Hours:

Astra-F, Astra-G, Vectra-B

T8 152 30     Replace idle air control       90               0.6
              valve

Omega-B:

T8 152 31     Replace idle air control       90               0.6
              valve

Omega-B:

T8 152 32     Replace idle air control       90               0.8
              valve and Blow-By valve

          
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.