Field Remedy: 1265

Remedy:

Note:

For Astra-F (X20XEV) MY 1996 refer TSB 1523.

Installation of an additional oil separator and rotary idle actuation,
cleaning of charge control unit. For Omega-B: installation of an
additional oil separator, cleaning of idle speed stepper motor.
Replacement of connection piece for pre-heating hose.

There are two procedures A and B,

     procedure A applies to Astra-F Astra-G, Calibra
     procedure B applies to Omega-B

Working procedure A:

1. Disconnect battery.

2. Loosen engine-venthose clamps and remove hose.

3. Mount the two engine venthoses to the additional oil separator 
   (1+2) and fix them with hose clamps.

4. Install the additional oil separator - please consider that 
   the stell mesh inside the additional oil separator is directed 
   to the engine venting hose. Please consider the flow direction 
   marked on the oil separator.   

NOTE:
     When installing the oil separator the hoses have to be 
     disconnected, i.e. the necks of the oil separator must
     not come into contact with the necks of cylinder head (3)
     or the engine venting tube (4).

5. Removal of rotary idle actuation and charge control unit 

     - see working procedure "Idle Speed Stepper Motor, Remove
     and Install", unit "J" of the respective Service 
     Instruction.

6. Detach the solenoid valve (5) from the rotary idle actuation.

7. Clean the idle air control valve with cleaning gasoline and  
   dry it. Ensure absolute cleanliness.

8. Reattach the solenoid valve to the rotary idle actuation.
9. Installation of rotary idle actuation and charge control unit
     - see working procedure "Idle Speed Stepper Motor, Remove
     and Installt", unit "J" of the respective Service 
     Instruction.

Note:

     Consider the correct location of the gasket.

10.In case of impurities the secondary Blowby-Hose has 
   to be renewed.

11.Reconnect the battery.

12.Reprogram volatile memories.

Working Procedure B:

1. Disconnect battery.

2. Loosen the clamps of the egine venting hose an remove engine 
   vent hose.

3. Mount the two engine vent hoses to the additional oil 
   separator (1+2) and fix them with hose clamps.

4. Install the additonal oil separator please consider that the 
   steel mesh inside the addtional oil separator is directed to 
   the motor venting hose. Please consider the flow direction 
   marked on the oil separator.

NOTE:
     When installing the oil separator the hoses have to be 
     disconnected, i.e. the necks of the oil separator must
     not come into contact with the necks of cylinder head (3)
     or the engine venting tube (4).

5. Removal of neck of throttle valve

     - see working procedure "Removal and Installation neck of 
     throttle valve", unit "J", Service Instruction Omega-B.

6. Removal of idle speed stepper motor of neck of throttle valve.

7. Removal of solenoid valve (5) of idle speed stepper motor.

8. Cleaning of idle speed stepper motor with cleaning gasoline. 
   Ensure complete cleanliness.

9. Removal of connection piece for pre-heating hose.

10.Installation of connection piece (6) for pre-heating hose.

11.Mounting of solenoid valve to idle speed stepper motor.

12.Installation of idle speed stepper motor with new gasket to 
   neck of throttle valve.

Note:

     Consider the correct location of the gasket.

13.In case of impurities the secondary Blowby-Hose has 
   to be renewed.

14.Install neck of throttle valve.

15.Reconnect the battery.     

16.Reprogram volatile memories.

Parts:                                  Part-No.:      Catalog-No.

(Astra-F, Astra-G, Calibra)                              

Additional oil seperator                09201848       56 56 098 

Gasket, idle air control valve          09240103       08 37 302

2 x clamps                              90572595       20 94 004

Parts:                                  Part-No.:      Catalog-No.

(Omega-B)

Additional separator                    09201848       56 56 098

Connection piece,                       90322594       06 56 161
pre-heating hose                         

2x oil seals,                           11023582       20 91 046
connection piece                         

Gasket, throttle valve                  90412686       08 28 466
at intake hose

Gasket, adjuster                        90240103       08 37 302
rotary idle actuation
at intake hose  

Gasket, adjuster                        90466220       08 37 300
rotary idle actuation
at intake hose          

2x engine venting hose                  24421017       06 56 067

2x clamps                               90572595       20 94 004

Labor Time:                             TC:            Hours:

T8 126 50  Install additional oil                 
           separator and clean idle air control valve
           (For Omega-B: installation of additional oil 
           separator, cleaning of idle speed stepper motor and
           replacement of connection piece for pre-heating hose.)

           Omega-B                      92              0.9 hrs

           Astra-G                      92              0.9 hrs

           Astra-F                      92              0.7 hrs

The regular warranty procedure should be used for claiming Set-up-time.