Subject:
Supplement to Service Instructions and Labour Time Guides.
Vehicles:
Vectra-B with X 20 DTL / X 20 DTH engine.
Condition:
The following operations are not contained or are incomplete
in the Vectra-B Service Instructions, KTA-1768/1, published 9/96:
Piston Protrusion, Check; Transverse Fuel Injectors, Remove
and Install; Fuel Injection Pump, Remove and Install; Glow Plugs,
Remove and Install; Exhaust Gas Recirculation Valve, Remove
and Install; Fuel Filter, Replace.
The changes will be introduced in the next revision of the
Service Instructions and Labour Time Guides.
Note:
All other new features relating to direct injection engines
can be found in the ”New Technical Features, Model Year ´98” brochure.
Remedy:
Check protrusion of the piston
Check the piston protrusion using the Measurement Bridge
KM-301 and the
Dial Gauge KM-571-B.
The corresponding cylinder head gasket is subsequently
selected.
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Piston Protrusion
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Cylinder Head
Thickness
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Designation
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0.40 - 0.50 mm
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1.2 mm
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None
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0.51 - 0.60 mm
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1.3 mm
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1 Notch
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0.61 - 0.70 mm
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1.4 mm
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2 Notches
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The designation (notch) is located in position (1).
Note:
If a cylinder head gasket is no longer available, use the
next thicker cylinder
head gasket.
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Traverse Fuel Injectors, Remove and Install
In future, in order to prevent damage during installation, the
cam shaft
must be removed when replacing the upper seal ring
(1).
Fuel Injector Pump, Remove and Install
Use the Special Service Tool MKM-604-30 to remove and
install the
4 fastening bolts (2) for the fuel injection pump.
Glow Plugs, Remove and Install
As of Model Year ’98, use the Special Service Tool KM-980
to remove and install the glow plugs.
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Exhaust Gas Recirculation, Remove and Install
As a result of repeated complaints in dealerships regarding
soiling as a result of oil mist in the vicinity of the exhaust gas
recirculation valve (1) some related information is provided below:
The soiling resulting from the oil mist is not a technical
problem and therefore harmless. As a result of the large exhaust gas
recirculation rate a tiny amount of mixed exhaust gas and engine oil emerges
from two vent holes on the bottom of the exhaust gas recirculation valve
(arrow).
In contradiction to the previously published operation
method, the exhaust gas recirculation valve must not be separated from
the upper section of the intake manifold (2). If either one of the two
components is defective, the complete assembly must be replaced.
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Fuel Filter, Replace
Comprehensive trials have determined that an excessive
tightening torque applied to the central bolt (1) of the fuel filter housing
(2) can result in leaks.
As a result, it is important to observe the specified
tightening torque of 6 Nm.
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Parts:
|
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Part No.
|
Catalogue No.
|
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Cylinder head gasket - no notch
|
90 540 459
|
56 07 421
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Cylinder head gasket - one notch
|
90 540 460
|
56 07 422
|
|
Cylinder head gasket - two notches
|
90 540 461
|
56 07 423
|
|
Exhaust gas recirculation valve with upper section of
intake manifold (X 20 DTL)
|
9 117 505
|
8 49 104
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Exhaust gas recirculation valve with upper section of
intake manifold (X 20 DTH)
|
9 118 573
|
8 49 105
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Time Allowances:
|
J 4860 00
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One Sheathed Glow Plug, Replace
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Time allowance unchanged
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X 20 DTL
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TC: 86, 87
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J 4917 00
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Diesel Fuel Injection Pump, Replace
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Time allowance unchanged
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X 20 DTL
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TC: 56, 61
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J 4945 00
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Fuel Filter Element, Replace
|
.2 hr
|
X 20 DTL
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TC: 12
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J 4964 00
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Transverse Fuel Injector, Replace
|
2.9 hrs
|
X 20 DTL
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TC: 01, 06, 12, 42
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+ : Programme volatie memory
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- : Bleed fuel system
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J 9825 00
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Exhaust Gas Recirculation Valve, Replace
|
.7 hr
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X 20 DTL
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TC: 01, 15, 27, 42
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+ : Disconnect and reconnect battery
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The time allowances for additional operations remain
unchanged and can be found in the current Labour Time Guide publications.
Important:
The specified time allowances do not include the time
allowances for the vehicle set-up time of .2 hr.
The vehicle set-up time of .2 hr is claimed by entering
the authorisation code ”T” and increasing the operation time allowance by .2
hr.
The authorisation code can be entered once per work
contract. Further entries are only permitted if the workplace or team is
changed.
