vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

No Start > < Engine Z20LEH, Z20LER - Exhaust manifold leaky

Field Remedy: 2405

Subject: Diesel engines, AC condenser, charge air cooler - Get loose
Models: Engines: Option:
Astra-H 2004...2009,Zafira-B 2005...2009 Diesel Engines,Diesel Engines Diesel Engines with MT/MTA,but not Z19DTH
Complaint: AC condenser, charge air cooler get loose, sometimes radiator damaged by fixing screws.
Cause: Fixing screws become loose.
Production: New fixing system has been introduced in production: Bochum: W0L0AHL3592110607, 20-May-2009 Gliwice: W0L0AHL699G076488, 19-May-2009, Antwerp: W0L0AHL4895063962, 19-May-2009 Ellesmere Port: W0L0AHL4898061764, 15-Jun-2009

Remedy:

In case of complaint check and if necessary correct the installation 
sequence of the charge air cooler fixation. 

The correct sequence is:

1. Radiator; the charge air cooler is mounted to the radiator
2. Charge air cooler bracket; the condensator is mounted on the 
   charge air cooler 
3. Condensator bracket

Install new AC condenser/charge air cooler fixing screws
(Part-No: 11099561/Catalogue-No: 20 48 759) 
with self locking nuts
(Part-No: 90424093 / Catalogue-No: 13 41 713) 
and apply a tightening torque of 5 Nm.

FunctionalGroup: D - Heating/Ventilation/Air conditioning,J - Engine
Complaint Group: 11 - Loose or Comes off
Trouble Code: None

No Start > < Engine Z20LEH, Z20LER - Exhaust manifold leaky