Field Remedy: 1549

Remedy:

In case of customer complaint replace camshaft sensor and wiring
harness connector.

Working Procedure:

 1. Remove camshaft sensor

    - see working procedure "Camshaft Sensor, Remove and Install",
      group "J", of corresponding Service Instruction.

 2. Remove crankshaft housing ventilation hoses and cable trough     
    (see picture I, 1,2).

 3. Open cable trough cover.

    Note:
    Measure position of cut at the wiring harness by using the new
    harness.

 4. Cut wiring harness camshaft sensor on right length with suitable 
    tool (see picture II).

    Important:
    Don´t cut the new wiring harness. Position of the crimping should
    be inside the cable trough if possible.     

 5. Pull out the cut wiring harness of cable trough.
 6. Install new wiring harness in cable trough.
 7. Insulate cable wiring harness with MKM-923-31 (see picture III).

 8. Push three small shrink sleeves and big shrink sleeve over the 
    cables and crimp cable ends with crimping tool MKM-923-31 
    (see picture IV, 1).

 9. Push shrink sleeves over crimping areas and heat them up with 
    hot air blower (see picture V).

    Note:
    Push big shrinking sleeve over the three crimp connections and
    heat it up for insulation.

10. Install wiring harness finally.
11. Close cable trough cover and install cable trough.
12. Install crankshaft housing ventilation hoses.
13. Install camshaft sensor
    - see working procedure "Camshaft Sensor, Remove and Install", 
      group "J", of corresponding Service Instruction.

    Note:
    Apply grease (for contact connection) on contacts of camshaft
    sensor before installation of wiring harness connector.

14. Fix wiring harness on cable trough with straps.

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

Grease                                    9163339         19 48 877

Camshaft sensor                          24445139         62 38 187

Wiring harness connector                  9201903         62 86 198                       

Strap, Retaining, 255 mm long            90039907         12 88 900

Labour Times:                            TC:              Hours:

T 8154 90   Crimp wiring harness         92               0,8
            camshaft sensor
            - Astra-F C18XE- and
            C18XEL-engines

T 8154 91   Crimp wiring harness         92               0,7
            camshaft sensor
            - Astra-F X20XEV- and
            Calibra X20XEV-engines

T 8154 93   Crimp wiring harness         92               1,2
            camshaft sensor
            - Vectra-B X20XEV-engine

T 8154 94   Crimp wiring harness         92               0,7
            camshaft sensor
            - Omega-B X20XEV-engine

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
et-up-time.