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Backfires, Misfires > < Coolant Temperature Sensor - Wiring harness connector poor contact

Astra G

Field Remedy: 1481

Subject: Wiring Harness Connector Air Mass Meter - Marten Bite Attacks
Models: Engines: Option:
Astra-G 1998...,Zafira 1999... Z18XE| X18XE1,Z18XE| X18XE1 None
Complaint: Engine warning light illuminates. Engine jerking. Engine poor idling.
Cause: Damaged wiring harness of air mass meter caused by marten bite.
Production: As of autumn 2002 all vehicles are equipped with modified protection caps at the connector air mass meter and insulation of wiring harness with ribbed plastic tube.

Remedy:

In case of customer complaint repair the wiring harness of air mass 
meter and protect it with ribbed plastic tube. Install a plastic 
protection cap on the wiring harness connector air mass meter.

Working Procedure:

 1. Disconnect wiring harness plug from air mass meter.
 2. Disconnect wiring harness plug from tank ventilation valve.
 3. Clip off and expose wiring harness tank ventilation valve from air
    intake manifold.
 4. Remove rubber sleeve from wiring harness connector air mass meter.
 5. Remove insulation from wiring harness air mass meter up to cable
    branch.
 6. Cut cable of wiring harness air mass meter one after the other and
    remove wiring harness connector.

Note:

     Shifted cuts.


 7. Install new plugs with cable in new wiring harness connector.

Note:

     Plugs have to engage audible.


 8. Hold new wiring harness into position, measure and shorten new
    wiring harness.

Note:

     For measure of cable length hold wiring harness into later
     position. Cable length from exit wiring harness connector to
     cable branch - 220 mm (later position see picture II).


 9. Strip cable.
10. Slip heat-shrinkable tube on cable and crimp cable ends with crimping   
    tool MKM-923-31.

Note:

     If necessary shorten heat-shrinkable tube. Crimping connections
     should not be on the same position (shifted position) (picture I).

Object Number: 2435086 Size: DEFAULT 

11. Slip heat-shrinkable tube on crimping and heat up with hot air dryer.
12. Install ribbed plastic tube from cable branch to exit wiring harness
    connector.

Note:

     Install ribbed plastic tube with second groove into protection cap of
     wiring harness connector. If necessary shorten ribbed plastic tube.


13. Install protection cap to wiring harness wiring harness connector air
    mass meter and fix it.
14. Fix ribbed plastic tube with customary textile stripe.
15. Route wiring harness tank ventilation valve and connect plug.
16. Clip on wiring harness tank ventilation valve to air intake manifold.
17. Route wiring harness air mass meter and connect plug (picture II).

Object Number: 2435087 Size: DEFAULT

Note: Repair activities must NOT be claimed under warranty.

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


1 Kit, connector plug, ZFW4-7           9192615           62 86 086


Heat-shrinkable tube                    90543875          12 86 666
(Package contains 50 pieces)


5m roll, tube grooved,                  90443557          12 88 103
10mm outer diameter


1 Protection cap                        13109073          90 12 042
FunctionalGroup: J - Engine,N - Electrical Equipment
Complaint Group: 04 - Electrical failures,13 - No/Poor Function,18 - Poor Drivebility,19 - Poor Engine Driveability,20 - Poor Performance,21 - Poor Startability
Trouble Code:

Backfires, Misfires > < Coolant Temperature Sensor - Wiring harness connector poor contact