Field Remedy: 2592
Subject: |
Engine Z16XER, Coolant Temperatur Sensor -
SVS on , P2182(17) set |
Models: |
Engines: |
Option: |
Astra-H 2004...,Zafira-B 2005... |
Z16XER,Z16XER |
|
Complaint: |
Customer complain about SVS on, trouble code
P2182(17) set in ECU. |
Cause: |
Wiring harness of engine coolant temperature
sensor too short/incorrect routed and contamination of plug
connection |
Production: |
An improved software has been implemeted in
production in the production plants as of the following VIN's:
Antwerp: W0L0AHL35A5042356 Bochum: W0L0AHL48A2074366 Ellesmere
Port: Not affected. Gliwice: Zafira: W0L0AHM75AG060315 Astra H:
W0L0AHL69AG063302 |
Remedy:
In case of customer complaint, extend wiring harness and
correct routing of wiring harness.
Additionally an improved software will be available in
February 2010.
Working Procedure:
1. Disconnect battery
2. Drain coolant
3. Unlock and disconnect engine coolant sensor wiring harness
connector (Picture I, 2) from engine coolant temperature sensor
(Picture I, 1) and loosen wiring harness from engine coolant
hose
4. Remove insulation tape and cut lengthwise, bare the wiring harness
5. Cut engine coolant sensor wiring harness (Picture II)
6. Cut one cable to 50mm and the other
cable to approximately 85mm
Note:
Use cable with diameter of 1mm.
7. Bare both cable of wiring harness with MKM-923-31
8. Compare new wiring harness to engine coolant temperature sensor
wiring harness and cut to length (Picture III)
Note:
Use cable with diameter of 1mm.
9. Remove insulation from engine coolant temperature sensor
wiring harness with MKM-923-31
10. Move head shrink tube over both cables
11. Crimp new wiring harness to engine coolant temperature
sensor wiring harness with MKM-923-31 (Picture IV)
12. Move both shrink hoses over the crimps and heat with
hot air gun (Picture V)
13. Install wiring harness to rill tube and wrap with insulation tape
14. Install cable lug into new wiring harness connector
15. Remove engine coolant temperature sensor and install new engine
coolant temperature sensor
16. Lay wiring harness below coolant hose and clip in (Picture VI)
17. Connect wiring harness connector to engine coolant temperature
sensor
18. Fill up and bleed coolant system
- see working procedure "Cooling system charge and Bleed ",
group "J", Service Instruction Astra-H.
(Document Number 001001106)
or
- see working procedure "Cooling system charge and Bleed ",
group "J", Service Instruction Zafira-B.
(Document Number 001001582)
19. Connect battery
20. Program volatile memories
Spare-Parts: Part-No.: Catalogue-No.:
Water temperature sensor, 55353809 63 38 046
Engine Control, Radiator Assembly
Heat shrink tube, wiring harness, 90543875 12 86 666
1,0mm
Wiring harness, ZFW2 93189918 62 86 769
Tube, Cable, wire, adapter, 90543865 12 86 663
0,5mm to 1,0mm
Labour Times: TC: Hours:
U3 259 20 Extend Engine 90 0.7
temperature sensor
cable
001 Program Engine 90 0.3
Control Unit
The costs for this repair will be covered during the normal warranty.
The regular warranty procedure will apply.
FunctionalGroup: |
J - Engine |
Complaint Group: |
04 - Electrical failures,23 - Wrong
Indication |
Trouble Code: |
P2182(17) |
|