Field Remedy: 2355

Remedy:

In case of customer complaint the studding bolts of exhaust manifold
have to be replaced.

Note:
Due to modified working procedures the vehicle has to stay in the
workshop for at least 24 hours in case of a reparature.

Working procedure:

 1. Remove exhaust manifold with turbocharger

    - see working procedure "Removing and installing exhaust manifold 
      with turbocharger", group "J", Service Instruction Astra-H.
      (Document Number 00501739)

    - see working procedure "Removing and installing exhaust manifold 
      with turbocharger", group "J", Service Instruction Zafira-B.
      (Document Number 01101619)

 2. Remove studding bolts (picture I)

    - Unscrew 10x studding bolt (arrows)

 3. Recut threads in cylinder head

    - Recut 10x thread with thread-endcutter (M8) and remove deposits

 4. Install new studding bolts

    - Apply high-temperature-resistant thread locking compound
      LOCTITE 620 on rear end of studding bolt (arrow, picture II)

    Note:
    Attend treatment notes on packing of thread locking compound.

    - Screw in studding bolt (1, picture III) into cylinder head until
      the excess length (2) is 30mm +1mm/-0mm.

    Note:
    Carry out procedure at all studding bolts.

 5. Let thread locking compound cure for at least 24 hours.

    Note:
    This time must be observed implicitly, otherwise a secure
    tightening cannot be guaranteed. In this time the studding
    bolts must not be strained anywise.

 6. Install exhaust manifold with turbocharger

    - see working procedure "Removing and installing exhaust manifold 
      with turbocharger", group "J", Service Instruction Astra-H.
      (Document Number 00501739)

    - see working procedure "Removing and installing exhaust manifold 
      with turbocharger", group "J", Service Instruction Zafira-B.
      (Document Number 01101619)

Spare-Parts:                            Part-No.:      Catalogue-No.:

Studding bolt M8 (10x included)         55355571       58 50 532
Gasket exhaust manifold                 90424422        8 49 522
Tightening nut M8 (5x included)         90424073       58 50 882
Thread locking compound LOCTITE 620     via LOCTITE retailer

Labour Times:                                TC:            Hours:

U3 235 50      Replacement studding bolt     92             2,2

The costs for this repair will be covered during the normal warranty.
The regular warranty procedure should be used for claiming Set-up-time.