Astra G
Field Remedy: 1481
Remedy:In case of customer complaint repair the wiring harness of air mass meter and protect it with ribbed plastic tube. Install a plastic protection cap on the wiring harness connector air mass meter. Working Procedure: 1. Disconnect wiring harness plug from air mass meter. 2. Disconnect wiring harness plug from tank ventilation valve. 3. Clip off and expose wiring harness tank ventilation valve from air intake manifold. 4. Remove rubber sleeve from wiring harness connector air mass meter. 5. Remove insulation from wiring harness air mass meter up to cable branch. 6. Cut cable of wiring harness air mass meter one after the other and remove wiring harness connector. Note: Shifted cuts. 7. Install new plugs with cable in new wiring harness connector. Note: Plugs have to engage audible. 8. Hold new wiring harness into position, measure and shorten new wiring harness. Note: For measure of cable length hold wiring harness into later position. Cable length from exit wiring harness connector to cable branch - 220 mm (later position see picture II). 9. Strip cable. 10. Slip heat-shrinkable tube on cable and crimp cable ends with crimping tool MKM-923-31. Note: If necessary shorten heat-shrinkable tube. Crimping connections should not be on the same position (shifted position) (picture I). 11. Slip heat-shrinkable tube on crimping and heat up with hot air dryer. 12. Install ribbed plastic tube from cable branch to exit wiring harness connector. Note: Install ribbed plastic tube with second groove into protection cap of wiring harness connector. If necessary shorten ribbed plastic tube. 13. Install protection cap to wiring harness wiring harness connector air mass meter and fix it. 14. Fix ribbed plastic tube with customary textile stripe. 15. Route wiring harness tank ventilation valve and connect plug. 16. Clip on wiring harness tank ventilation valve to air intake manifold. 17. Route wiring harness air mass meter and connect plug (picture II). Note: Repair activities must NOT be claimed under warranty. Spare-Parts: Part-No.: Catalog-No.: 1 Kit, connector plug, ZFW4-7 9192615 62 86 086 Heat-shrinkable tube 90543875 12 86 666 (Package contains 50 pieces) 5m roll, tube grooved, 90443557 12 88 103 10mm outer diameter 1 Protection cap 13109073 90 12 042
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