Astra H
RemedyIn case of customer complaint the function of the turbocharger actuator rod has to be checked. Note: The following description is divided into 3 chapters: I: Check actuator rod Meriva II: Check actuator rod Astra-H, Corsa-D and Zafira-B III: Overhauling of the actuator rod, all above mentioned models Working Procedure: I: Meriva 1. Remove turbocharger - see working procedure "Replace Turbocharger", group "J", Service Instruction Meriva. (Document Number 01601646) 2. Clamp turbocharger in bench vice Important: Clamp turbocharger at exhaust flange. Use aluminium jaws for bench vice. 3. Connect minivac KM-667 to vacuum box and check actuator rod for proper function Note: In case the actuator rod works properly continue with chapter III. 4. If the actuator rod will not move or movement is restricted, apply rust solvent to actuator rod (Picture I, 1) Note: Application time for rust solvent must not be less than 12 hours in case linkage is completely stuck or might be less if movement is only restricted. 5. Connect minivac KM-667 to vacuum box and check actuator rod for proper function again Note: In case the actuator rod has now free movement proceed with chapter III. In case the actuator rod is still not moving or moving is still restricted apply again rust solvent. 6. Connect minivac KM-667 to vacuum box and check actuator rod for proper function Important: If necessary use in addition to minivac KM-667 an appropriate squared timber and push the actuator rod carefully in axial direction. Note: In case the actuator rod has now free movement proceed with chapter III. In case the actuator rod will still not move replace the turbocharger. II: Astra-H, Corsa-D and Zafira-B 1. Connect minivac KM-667 to vacuum box and check actuator rod for proper function Note: In case the actuator rod works properly continue with chapter III. 2. If the actuator rod will not move or movement is restricted apply rust solvent to actuator rod (Picture II, 1) Note: Application time for rust solvent must not be less than 12 hours in case linkage is completely stuck or might be less if movement is only restricted. 3. Connect minivac KM-667 to vacuum box and check actuator rod for proper function once again Note: In case the actuator rod has now free movement proceed with chapter III. In case the actuator rod is still not moving or moving is restricted apply rust solvent again and remove turbocharger. - see working procedure "Replace Turbocharger", group "J", Service Instruction Astra-H, Corsa-D and Zafira-B. (Document Number 01701224, 01501911 and 01801316) 4. Clamp turbocharger in bench vice Important: Clamp turbocharger at exhaust flange. Use aluminium jaws for bench vice. 5. Connect minivac KM-667 to vacuum box and check actuator rod for proper function Important: If necessary use in addition to minivac KM-667 an appropriate squared timber and push the actuator rod carefully in axial direction. Note: In case the actuator rod has now free movement proceed with chapter III. In case the actuator rod will still not moving replace the turbocharger. III: Overhauling of the actuator rod 1. Loosen the actuator rod from turbocharger with suitable tool (Picture III, 1), handle with care - Remove snap ring Note: If necessary spray actuator rod again with rust solvent and try to release manually by hand. 2. Grind the pin carefully with sand paper 400 grain size (Picture IV, 1) 3. Grind the inner surface of the pin hole carefully with sand paper 400 grain size (Picture V, 1) Note: Pin hole and groove must be made completely free of rust by using sand paper. 4. Lubricate the pin with special oil partno.: 93165293 / catalogueno.: 19 48 335 Important: While lubricating the pin with special oil use gloves and observe the safety security data sheet. 5. Install actuator rod to turbocharger - Install new snap ring and check for proper fitment Note: After rework apply minivac KM 667 again in order to guarantee free movement of the actuator linkage. 6. Install Turbocharger Note: Only when turbocharger is removed - see working procedure "Replace Turbocharger", group "J", Service Instruction Astra-H, Corsa-D, Meriva-A and Zafira-B. (Document Number 01701224, 01501911, 01601646 and 01801316) Note: In case the turbocharger must be replaced by a new unit apply special oil partno.: 93165293 / catalogueno.: 19 48 335 as described in chapter III also to new turbocharger. In that case the snap ring must not be removed neither must the actuator rod be removed or any sandpaper operation carried out. Spare-Parts: Part-No.: Catalogue-No.: Snap ring 95507727 90 08 005 Special oil 93165622 19 48 002 Labour Times: TC: Hours: U3 265 10 Actuator rod turbocharger overhauling Corsa-D, Astra-H, Zafira-B 90 0,3 U3 265 11 Turbocharger - remove and install overhaul actuator rod, or turbocharger replace Astra-H 90 2,9 Corsa-D 90 2,5 Meriva 90 3,8 Zafira-B 90 3,0 U3 265 11 001 Additional work for vehicles with air conditioning 90 0,3 The costs for this repair will be covered during the normal warranty. The regular Warranty Procedure will apply.
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