Field Service Remedies / Technical Safety Bulletins

[Robsey]

This thread gives a list of all Technical Safety Bulletins (TSBs) issued by Vauxhall / Opel to their dealership technicians.

I have kept them limited to Cavalier specific documents.

The discussion thread is here.

viewtopic.php?f=6&t=16813

I have done one post per TSB, so this is bound to be a long thread.

[Robsey]

BODY SECTION

TSB E0000796

Seat-belt joint - Crackling noise

Models: Cavalier 89...
Engines: All

Group: C - Equipment /Windows /Seats
Trouble code: None

Complaint:
Noises or Vibrations
Crackling noise of upper seat-belt joint at B-pillar.

Cause:
Disposal crackling noise from upper seat-belt joint:

Production Solution:
Spacer was altered and corrugated washer added.

Special part: No

Remedy:
- unscrew seat-belt at upper B-pillar.

- Install new spacer (1)
Cat. /Part No. 1 97 951 /(90 387 649) and

corrugated washer (2) Cat. /Part No. 1 98 964 /(90 449 717)

[Robsey]

BODY SECTION

TSB E0000909

Area of bulkhead - Knocking and chafing noise

Models: Cavalier 89-95
Engines: 2.5l
Option: X25XE
Group: A - Body

Trouble code: None

Complaint:
Noises or Vibrations

Knocking and chafing noise with load alteration of the engine from the area of bulkhead.

Cause:
Vacuum box knocks against bulkhead / cable duct.
As of CW 26 /95 modified intake manifold in production.

Special part: No

Production Solution:
Remedy:
Add two corner plates to the bottom of the vacuum box to enlarge the distance to the bulkhead.
Order corner plates from Serv.

[Robsey]

BRAKES SECTION

TSB E0000880

ABS - Brake pedal goes to the floor

Models: Cavalier 89...
Engines: All
Option: ABS

Group: H - Brakes
Trouble code: None

Complaint:
Poor Performance
Brake pedal goes to the floor.

Cause:
Air bubbles are trapped within the ABS unit.

Special part: No

Production Solution:
Remedy:
Use TECH1 to operate the ABS unit pump whilst simultaneously bleeding the system with a Pressure bleeder.

[Robsey]

BRAKES SECTION

TSB E0000954

ABS - Sporadically fails / telltale lights up

Models: Cavalier 89...
Engines: All
Option: ABS

Group: H - Brakes
Trouble code: None

Complaint:
Electrical failures, Loose or Comes off
ABS fails sporadically / telltale lights up. No diagnosis with TECH 1.

Cause:
Loose ground connection at end shield of transmission.

Special part: No

Production Solution:
Remedy:
Clean nut and fasten with specified torque at stud /ground connection.
Play of stud in the end shield has no impact to this fault.

[Robsey]

CLUTCH AND TRANSMISSION SECTION

TSB E0000838

Transmission - Hard 1-2 / 2-1 shifting

Models: Cavalier 1989..
Engines: All
Options: FWD,MT,F13,F15,F17

Complaint: Hard 1-2/2-1 shifting under cold conditions.

Functional Group: K - Clutch/Transmission
Complaint Group: 08 - Hard to operate
Trouble Code: None

Cause:
Unsuitable oil viscosity, reduced oil supply of the above Gearwheels on the
mainshaft, and/or burrs on the synchronising rings.

In no case did the problems result in a damaged transmission, nor is this to be expected.

Production: With MY 98 modified sliding gear will be introduced in production.

Remedy:
In case of complaint the following procedure will apply:

F13 - transmission: Up to MY 97, synchro-rings and gears have to be replaced.

F15 - transmission: Replace mainshaft, synchro-rings and 1. - 2. gearwheels.

F17 - transmission: Up to MY98 only the mainshaft is to be replaced.

For all above transmissions the following oil should be used: Cat.-/Part-Nr.: 19 40 764 / 90 540 998

The modified parts are not available through P&A.

Since the parts are available in limited numbers only, it should be ensured that the request for parts is issued in cases
of extreme customer complaint.

In order to establish the correct relationship between mainshaft and transmission, it is essential to supply the full transmission-type number (i.e. A32971 F15 W419)

[Robsey]

CLUTCH AND TRANSMISSION SECTION

TSB E0000903

Transmission AF 13 - Heavy shifting of gear lever from position " P< >R "

Models: Cavalier 94...95
Engines: All
Option: AT AF 13
Functional Group: K - Clutch/Transmission
Complaint Group: 08 - Hard to operate
Trouble Code: None

Complaint: Heavy shifting of gear lever from position 'P R'.

Cause:
Modified selector lever unit.

Production:

Remedy:
In case of customer replace assembly selector lever according to service instruction.

[Robsey]

CLUTCH AND TRANSMISSION SECTION

TSB E0002130

Manual transmission - Clutch does not disengage and/or gears hard to engage

Models: All
Engines: All
Option: All

FunctionalGroup: K - Clutch/Transmission
Complaint Group: 08 - Hard to operate
Trouble Code: None

Complaint:
Clutch does not disengage and /or gears hard to engage.

Cause:
Toothing of the input shaft not greased (either forgotten in production or after
clutch replacement in service).

Remedy:
In case of customer complaint check first the greasing of the input shaft.

If necessary thinly grease gear teeth of input shaft with grease (part number: 90397024 / catalogue number: 19 48 568).

Please do not change any other parts.

[Robsey]

ELECTRICAL SECTION

TSB E0000728

Engine - Overheats

Models: Cavalier 93...
Engines: 2.5 l
Option: X25XE Motronic with A /C

Group: J - Engine,
N - Electrical Equipment

Trouble code: None

Complaint:
Electrical failures,
Poor Engine Driveability
Engine overheats when driving with air conditioning switched on.

Cause:
Fan motor runs at lowest speed due to failure of maxifuse (30 A). 30 A fuse is too weak.

Special part: No

Remedy:
Replace 30 A maxifuse with 40 A maxifuse.

[Robsey]

ELECTRICAL SECTION

TSB E0000824

Oil pressure warning light - constantly on

Models: Cavalier 89-94
Engines: 2.0 l
Option: C20LET
Group: N - Electrical Equipment
Troublecode: None

Complaint:
Chafing
Engine wiring harness damaged in starter motor area. Charge or oil pressure warning lights permanently on.

Cause:
Problem in routing of engine wiring harness in area of starter motor.

Production Solution:
Routing of engine wiring harness in area of starter motor changed since Nov.'94.
Strip added.

Special part: No

Remedy:
Fix engine wiring harness in area of starter motor with strip at the prop of the manifold intake to prevent damage caused by the plug connector.

[Robsey]

ELECTRICAL SECTION

TSB E000892

Radiator fan - Temp gauge in red area or fuse for fan blows.

Models: Cavalier 89...
Engines: All
Option: AT
Group: N - Electrical Equipment
Troublecode: None

Complaint:
Electrical failures
Temperature gauge in red area or fuse for radiator fan blows.

Cause:
High current consumption or failure of radiator fan due to pasted commutator.

Production Solution:
As of april `95 improved cooling fan is in production.

Special part: No

Remedy:
Replace radiator fan: Cat. /Part No.13 41 271 /(90 512 980)

[Robsey]

ELECTRICAL SECTION

TSB E0000954

ABS - Sporadically fails / telltale lights up

Models: Cavalier 89...
Engines: All
Option: ABS
Group: H - Brakes
Troublecode: Non

Complaint:
Electrical failures,
Loose or Comes off
ABS fails sporadically / telltale lights up. No diagnosis with TECH 1.

Cause:
Loose ground connection at end shield of transmission.

Special part: No

Remedy:
Clean nut and fasten with specified torque at stud /ground connection. Play of stud in the end shield has no impact to this fault.

[Robsey]

ELECTRICAL SECTION

TSB E0001090

Headlights - stay on after switch is turned off

Models: Cavalier 89-97
Engines: All
Option: All

Group:
N - Electrical Equipment
Troublecode: None

Complaint:
Electrical failures
After turning off the engine the low beam is still on. (Day driving light)

Cause:
Relay contacts sticking.
Production Solution:
From CW 02 /97 stronger relays are introduced in production.

Special part: No

Remedy:
Install stronger relay:
Cat /Part-No. 62 38 559 /(90 532 627)

[Robsey]

ELECTRICAL SECTION

TSB E0001423

Cables damaged by Marten bite attacks

Models: All
Engines: All
Option: All

Functional Group: N - Electrical Equipment
Complaint Group: 01 - Broken or Cracked
Trouble Code: None

Complaint:
Cable damages with different origin

Cause:
Martenbites in engine compartment

Production:
Remedy:
In case of marten attacks it seems to be useful to wrap the replaced and likewise
other exposed cables with plastic grooved tubes.

Please see part
numbers below.
Parts:
Part-No.: Catalog.-Nr.:
5m roll, tube grooved, 90 443 557 12 88 103
10mm outer diameter

5m roll, tube grooved, 90 443 558 12 88 104
18mm outer diameter

[Robsey]

ELECTRICAL SECTION

This should be listed under interior body, however there is no such section, so TIS has it listed under electrics (?)

TSB E0001673

Interior Trim - Painted interior trim surfaces damaged by air refreshers

Models: All
Engines: All
Option: All

Functional Group: N - Electrical Equipment
Complaint Group: 07 - Foreign Material or Fluid
Trouble Code: None

Complaint:
Customer complains about loosing paint on interior trim components like
radio, dashboard, switches and the center console.

Cause:
Painted surfaces will be attacked and damaged by usage of air refreshers in
vehicles.
Air refreshers contain aggressive ingredients therefore it should be
avoid to get in direct contact with painted surfaces.

Production:
Remedy:
Customers have to be informed about this concern.
Often a hint is even printed
on the air refresher packaging that every contact with painted surfaces has to
be avoided.
Parts damaged by usage of air refreshers in the vehicle will not be accepted by warranty.

[Robsey]

ELECTRICAL SECTION

TSB E0002133

Battery - Battery leaky

Models: All
Engines: All
Option: All

Functional Group: N - Electrical Equipment

Complaint Group:
04 - Electrical failures,
10 - Leakages

Trouble Code: None

Complaint:
Battery leaky.

Cause:
Crack in battery housing etc.

Remedy:
In case of customer complaint remove both pole terminals from the battery. Clean and Check pole area with indicator paper

part number: 93173878

[Robsey]

ENGINE SECTION

TSB E0000750

Cylinder head - Oil leak

Models: Cavalier 93...
Engines: 1.8 l
Option: C18NZ Multec

Group: J - Engine
Trouble code: None

Complaint:
Leakages
Oil leak in cylinder head in area of 2nd cylinder intake pipe.

Cause:
Stud for intake pipe fastening in 2nd cylinder leaky.

Special part: No

Production Solution:
Remedy:
Unscrew stud. Clean threaded hole and stud.
Insert stud with Bolt Locking Paste
Cat /Part No. 15 10 177 /(90 167 347) and tighten.

[Robsey]

ENGINE SECTION

TSB E0000858

Crankcase ventilation hose - Chafes at hose clamp of pressure regulator.

Models: Cavalier 89...
Engines: 1.8 l, 2.0 l
Option: C18XEL, X20XEV Simtec

Group: J - Engine
Trouble code: None

Complaint: Chafing - Crankcase ventilation hose can chafe at hose clamp of pressure regulator.

Cause:
Position of clamp lock.

Special part: No

Remedy:

Rotate clamp lock about 180°, see illus . 1 and 2.



The angle (A) of the clamp lock has to be 45° + /- 10° when mounted.
If the crankcase ventilation hose is visibly damaged it has to be replaced.

illus. 1: clamp lock screw chafes at
crankcase ventilation hose.

illus. 2: clamp mounted by rotating 180°.

[Robsey]

ENGINE SECTION

TSB E0000883

Engine - Idle speed raises up after starting the engine

Models: Cavalier 89...
Engines: 1.4l, 1.6l
Option: X14XE, X16XE, X16XEL Multec

Group: J - Engine
Trouble code: None

Complaint:
Poor Engine Driveability
Idle speed raises up after starting the engine.

Cause:
Air induction hose between throttle body and intake manifold.

Production Solution:
As of CW 16 /95 spring clamps for production.

Special part: No

Remedy:
In case of repair replace the screwed clamps by spring clamps
Cat. /Part No.20 94 915 /(90 529 736)

[Robsey]

ENGINE SECTION

TSB E0001017

Engine - Bearing failure at the connecting rod bearing

Models: Cavalier 1989...
Engines: C25XE, X25XE,X30XE
Option: V6

Functional Group: J - Engine
Complaint Group: 01 - Broken or Cracked
Trouble Code: None

Complaint:
All models with V6 engine:
Bearing failure at the connecting rod bearing of 1st cylinder after replacing the oil pump or new gasket.

Cause:
When installing the gasket using silastic liquid gasket (against the service instruction) the liquid gasket can block the oil pressure bore of the 1st main
bearing.

Remedy:
The oil pump gasket must be installed dry, without any liquid gasket.
Torque the bolts M6: 8 Nm +/- 2 Nm.
In case of installing or refitting the oil pump use new bolts.

[Robsey]

ENGINE SECTION

TSB E0001029

Engine support - Noise from front of vehicle

Models: Cavalier 89...
Engines: 2.0l
Option: C20LET

Group: J - Engine

Trouble code: None

Complaint:
Noises or Vibrations
In fast left hand corners a noise can be heard from the front of the vehicle.

Cause:
Due to excessive tension in the engine supports the distance between engine support bracket and A /C compressor can be reduced to zero by certain loadings.

Special part: No

Remedy:
The engine supports should be realigned by releasing the left hand support.
Using the oval bolt holes in the left hand support.
The engine should be positioned to ensure 10 mm clearance on right side.

[Robsey]

ENGINE SECTION

TSB E0001082

Engine - Engine telltale comes on

Models: Cavalier 89...
Engines: 2.0l, 2.5l
Option: C20NE, X20XEV, X25XE

Group: J - Engine
Trouble code: 13

Complaint:
Failure Code Setting by Control Unit
Engine telltale comes on during cruising. TC 13 is set (Oxygen Sensor).

Cause:
There is no ground because of a corroded sensor.

Special part: No

Remedy:
In case of complaint fit a new sensor. Supplementary install a ground wire from the control unit to the sensor.

[Robsey]

ENGINE SECTION

TSB E0001415

Engine - Oil Heat Exchanger leaky

Models: Cavalier 1989...
Engines: C25XE, X25XE, Y26SE, X30XE
Option:

Functional Group: J - Engine
Complaint Group: 10 - Leakages

Complaint: Heat Exchanger is leaky, oil-water leakages.

Cause:
Heat Exchanger will be disintegrated by Electrolytic Corrosion.

Remedy:
In case of customer complaint replace Heat Exchanger through stainless steel Heat Exchanger.
Note:
For the repair of all Car lines should be proceed after the working procedure
"Heat Exchanger, Remove and Install" in the Service Instruction of the Omega-B.

Working Procedure:
1. Remove Heat Exchanger
– see working procedure "Heat Exchanger,
Remove and Install",
group "J", Service Instruction Omega-B.

2. Install stainless steel Heat Exchanger
– see working procedure "Heat Exchanger, Remove and Install",
group "J", Service Instruction Omega-B.

Note:
Use new banjo bolt.

Parts:
Part-No.: Catalog-No.:
1 Heat Exchanger (Stainless Steel) 13 101 668 90 06 313

2 Banjo bolt 90 424 578 13 36 977

1 Sealing 09 163 307 15 03 301

4 Seal ring 11 076 852 20 91 055

2 Seal ring 90 409 175 06 50 760

[Robsey]

ENGINE SECTION

TSB E0001463

Toothed belt diagnosis - Possible causes and remedys

Models: All
Engines: All
Option: All

FunctionalGroup: J - Engine
Complaint Group:
01 - Broken or Cracked,
05 - Excessive wear,
14 - Noises or Vibrations,
24 - Wrong or not mounted

Trouble Code: None

Complaint: Excessive drive noise from toothed belt drive (picture I)



Problem: belt whines / squeals
cause: Side tension too high
Remedy: Adjust to correct tension

Problem: belt strikes against cover
cause: Side tension too low
Remedy: Adjust to correct tension

Complaint: Excessive edge wear (picture II)



Problem: Belt not running parallel to axis and impacting against flanged pulley
Remedy: Align Correctly

Problem: Defective flanged pulley
Remedy: Replace sprocket

Problem: Belt cannot run true
Cause: Gearwheel misaligned
Remedy: Align correctly

Complaint: Excessive fabric wear at base (picture III)



Problem: Belt operating in excessive heat
Remedy: Identify problem and recify

Problem: Side tension too high
Remedy: Adjust to correct tension

Problem: Worn sprocket
Remedy: Replace sprocket

Complaint: Tooth flank wear / roof fractures and tooth shear (picture IV)



Problem: Side tension too high / low, leading to incorrect pitch ratios
Remedy: Adjust to correct tension

Problem: Belt does not comply with permissible length tolerance
Remedy: Replace Sprocket

Problem: Action of external media(e.g. oil)
Remedy: Identify problem and recify

Problem: Sprocket / pulley jammed
Remedy: Identify problem and recify

Complaint: Separation of teeth and fabric from belt body (tension member) (picture V)



Problem: Fabric damaged during installation
Remedy: Fit new belts carefully

Problem: Action of external media
Remedy: Check cover if seated properly

Complaint: Damage on pulley side of belt (picture VI)



Problem: Foreign object caught in belt drive
Remedy: Remove foreign object, check cover if seated properly

Problem: Damage to gearwheel teeth caused by foreign object or installation tool
Remedy: Replace sprocket

Problem: Belt damaged prior to / during installation
Remedy: Fit new belts carefully / Ensure proper installation

Complaint: Cracks in backing (picture VII)




Problem: Exposure to excessive heat
Remedy: Identify problem and recify

Problem: Exposure to excessive low temperature
Remedy: Identify problem and recify

Problem: Action of external media
Remedy: Check cover if seated proberly

Complaint: Tearing of the belt (picture VIII)



Problem: Foreign object caught in drive
Remedy: Check cover if seated properly

Problem: Action of external media
Remedy: Check cover if seated properly

Problem: Initial tension too high
Remedy: Adjust to correct tension

Problem: Belt crimped prior to / during installation
Remedy: Observe handling instruction

Complaint: Faulty system component (picture IX)



Problem: Bearing play
Remedy: Substitute idler pulley, tension coil and/or guide roller

Problem: Damaged bearing surface
Remedy: Substitute idler pulley, tension coil and/or guide roller

Complaint: Fracture on fixing spot tension coil-oil pump (1,4 - 2.2 litre engines)
(picture X)



Problem: Wrong torque of tension coil on fixing spot of oil pump
Remedy: Replace oil pump

Important:
- check the oil pump on each toothed belt check or each replace
interval and each toothed belt damage for cracks (arrows).

[Robsey]

ENGINE SECTION

TSB E0001510

Engine or drivetrain - Damaged due to Tuning

Models: All
Engines: All
Option: All

FunctionalGroup: J - Engine
Complaint Group: 13 - No/Poor Function
Trouble Code: None

Complaint:
Engine or drivetrain damage.

Cause:
Tuning of petrol and diesel engines.

Remedy:
The number of offers for engine tuning kits for petrol and diesel engineswith electronic injection is growing.

An increasing number of engine damages as well as damages of the drivetrain have been caused by engine tuning.

We have to point out that such manipulated vehicles will be taken out of
warranty immediately.

Repair works have to be paid by the customer.

Furthermore we have to stress that manipulated vehicles do not fulfill the type approval requirements as well as the vehicle insurance will expire.