Field Remedy: 1590

Remedy:

In case of customer complaint drill out the primary blow by bore in throttle
body up to 2mm and program the ECU with a modified software.

Note:

     Is there a white colour dot at the throttle body, the TSB 1590 is
     already performed (see Picture IV, arrow).

Working Procedure:

 1. Remove throttle body

     - see working procedure “Throttle Body (Throttle Valve Adjuster),
     Remove and Install (X18XE1) Management System Simtec 70 (X18XE1),
     group “J”, of the corresponding Service Instruction.

 2. Clamp throttle body carefully into vice (Picture I).

Important:

     For protection against damage of the sealing surface use a cloth (1)
     for clamping.

 3. Clamp drill into drill chuck (Picture II).

Note:

     Use a new 2mm drill (or if available a new long 2mm drill).
     The length of drill has to be at least 45mm from drill chuck
     up to drill peak.
     Check straight running of drill.

 4. Drill out primary blow by bore in the throttle body up to 2mm
    (Picture III, arrow).

 5. Clean primary blow by bore and throttle body with a cloth without fluff.
 6. Check the cleanness of primary blow by bore.

Note:

     Primary blow by bore and throttle body have to be free from chips.

 7. Install throttle body

     - see working procedure ”Throttle Body (Throttle Valve Adjuster),
     Remove and Install (X18XE1) Management System Simtec 70 (X18XE1),
     group ”J”, of the corresponding Service Instruction.

 8. Mark throttle body with a white colour dot, to document the 2mm primary
    blow by bore (Picture IV).

 9. Program ECU with modified software.

Note:

     The modified software on TIS 2000 is available as of CD 42 and can
     be used for all X18XE1 engines.

10. Learn throttle body adaptation.

     - Engine operating temperature
     – Ambient temperature higher +5°C
     - Ignition on for 15 seconds
     – Ignition off

Spare-Parts:                                     Part-No.:      Catalog-No.:

Gasket, Throttle Valve Body                      90543950       08 25 508
to induction manifold

Labour Times:                                    TC:            Hours:

T8 159 00  Drill out Primary Blow By Bore        90             0.9
           in the Throttle Body

The costs for this repair will be covered for vehicles not older than
3 years and a mileage lower than 100.000 Km.
The regular warranty procedure should be used for claiming Set-up-time.