Field Remedy: 1198
| Subject: | Engine - Stalling or bad idling |
| Models: | Engines: | Option: |
|---|---|---|
| Corsa-B 95...00,5,Tigra 95...00,5,Astra-F 95...00,5,Vectra-B 96...00,5,Astra-G 98...00,5,Zafira 99...00,5 | X14XE| X16XE,X14XE| X16XE,X14XE| X16XEL,X16XEL,X14XE| X16XEL,X16XEL |
| Complaint: | Stalling or bad idling 100-500 m after cold start by outer temperatures less than 10°C. Immediately after stalling serious or no restart possible, because the engine turns without compression. This affects vehicles on short distance journies in combination with regular low engine speed driving. Affected Engines: X14XE, X16XE and X16XEL. |
|---|---|
| Cause: | Loss of compression due to sticking exhaust valves. |
| Production: | In production a sintermetal valve guide has already been implemented as well as a clearance limitation. Breakpoints for sintermetal valve guides are: Szentgotthard: 20A69569 and Bochum: 02GR7584. The modified valve guide sealing cap will not be used in production. |
Remedy:
Attention: No TC’s are set! For an secure diagnosis, see diagnosis instruction
IMPORTANT: The herein described process affects only the exhaust valves.
To apply the field remedy, please proceed as described in the service instructions for Corsa-B/Tigra, Astra-F, Astra-G, Zafira, Vectra-B respectively:
- Remove the cylinder head. - Remove camshaft on the exhaust side only. - Dismantle cylinderhead on exhaust side only. - Rework valve guides with a handreamer (KM-6022).
Attention: Reaming only by hand, because of the coaxiality of the guides and shafts. Use the reamer for max. 10 cylinderheads. Regrind valve seats with paste. - Fit modified valve guide sealings on exhaust side. - Assemble cylinderhead and refit to engine.
Required parts: Valve guide sealings Cat.-/Part-No. 90 97 099 / 91 19 497
Labour times: TC Hours Modell Engine
T 0546 00 Remove and refit the cylinder head and rework valve guides 92 7.6 Corsa-B/ X14XE/ Tigra X16XE
T 0546 05 Remove and refit the cylinder head and rework valve guides 92 8.5 Corsa-B/ X14XE/ Tigra X16XE (AC 1)
T 0546 10 Remove and refit the cylinder head and rework valve guides 92 6.2 Astra-F X14XE
T 0546 20 Remove and refit the cylinder head and rework valve guides 92 6.3 Astra-F X16XEL
T 0546 30 Remove and refit the cylinder head and rework valve guides 92 6.4 Vectra-B X16XEL
T 0546 40 Remove and refit the cylinder head and rework valve guides 92 6.7 Astra-G X14XE/X16XEL
T 0546 50 Remove and refit the cylinder head and rework valve guides 92 6.7 Zafira X16XEL
(1) Important: The AC system for T 0546 05 remains closed!
Only one T-Number should be used. The regular warrenty procedure should be used for claiming Set-Up time.
Diagnosis-Instruction
After vehicle-takeover from the customer, ensure that the engine speed does not exceed over 3500 min/-1. Crosscheck driving with connected: Oil pressure manometer Measure point: Oil pressure switch Fuel pressure manometer Tech 1 / Tech Function: In snap shot mode trigger with F9, if engine dies press F9, then attempt re-start.
Data evaluation:
Oil pressure check: A oil pressure higher than 600 kPa by cold motor, can cause a trouble with the engine driveability. The rising of the oil pressure should be constant. Uneven pressure rise indicates a defect. The cause could be a sticking oil pressure regulator piston.
Fuel pressure check: Check the pressure values according to the following table
MPFI Pressure regulator controlled by intake pressure 240 up to 260 kPa
Pressure regulator controlled by throttle valve position 294 up to 306 kPa
TBI/Multec 70up to 79 kPa
The fuel pressure after engine off, shouldn’t fall by less than 50% in 10 minutes.
Possible remedy
Fuel forward hose /-reverse hose : Check hoses Fuel tank vent line: Check hoses Fuel pump: Check connections and voltage
Evaluate and save the snap shot data with a PC or Tech 15
Coolant temperature sensor: Values in F0 data list Intake air temperature sensor: Values in F0 data list -(approx. outer temp.) Exhaust gas recirculation (EGR-valve): Plan/actual- comparsion MAP-Sensor in case of restart: Constant under maximum value
Throttle valve position Injection impulse of the injection valves
Possible remedy
Plug intake pressure sensor: Optimise contacts EGR-valve: Check connections, if required replace part Intake air temperature sensor: Check connections, if required replace part Coolant temperature sensor: Check connections, if required replace part
If this check program indicates no failure, the cause could be mechanical.
| FunctionalGroup: | J - Engine |
|---|---|
| Complaint Group: | 19 - Poor Engine Driveability |
| Trouble Code: | Non |