Field Remedy: 1356
Subject: |
Throttle Valve Adjuster - Voltage
high |
Models: |
Engines: |
Option: |
Corsa-B 97...2000,Astra-G 98...2000 |
X10XE| X12XE,X12XE |
None |
Complaint: |
The Engine management light comes on and the
engine runs rough and stalls. TECH2 test showed stored Trouble Code
of P0505 "present idle air control voltage high". |
Cause: |
Voltage of air control valve high. |
Production: |
|
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
FunctionalGroup: |
J - Engine |
Complaint Group: |
19 - Poor Engine Driveability |
Trouble Code: |
None |
|