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Cold Driveability > < Tank Vent Valve, Remove and Install (X 18 XE1)

Vectra B

Field Remedy: 1437

Subject: Coolant Temperature Sensor - Wiring harness connector poor contact
Models: Engines: Option:
Astra-G 1998...2002,Corsa-C 2001...2002,Vectra-B 1998...2002,Vectra-C 2002,5,Zafira 1999...2002 X18XE1| Z14XE| Z16XE| Z18XE| Z18XEL,Z14XE| Z18XE,X18XE1| Y16XE| Z16XE| Z18XE| Z18XEL,Z16XE| Z18XE| Z18XEL,X18XE1| Z16XE| Z16YNG| Z18XE
Complaint: Engine jerking may occur while driving and while rough idling engine may stall. Engine - poor startability.
Cause: Vibrations at connector of coolant temperature sensor cause contact problems.
Production:

Remedy:

In case of customer complaint replace the wiring harness of  
coolant temperature sensor and replace mating connector on 
the wiring harness.

Working Procedure:

Note:

     On account of new gold contacts on the coolant temperature sensor,
     it is necessary to use gold plated connector contacts on the 
     mating connector.


 1. Remove upper engine compartment cover.


 2. Remove wiring harness connector of coolant temperature sensor 
    (under thermostat housing).   


 3. Remove insulating tape on the grooved tube and expose wiring harness
    coolant temperature sensor (picture I).

Object Number: 2435015 Size: DEFAULT 

 4. Hold the new wiring harness on the coolant temperature sensor harness
    and measure the length of the wiring harness. Lenght should be between 
    200 - 250 mm. Cut the cable on measured point (displaced intersections) 
    and replace wiring harness connector (picture II).

Object Number: 2435016 Size: DEFAULT 

 5. Allocate cable, mark and plug it on the new wiring harness connector 
    (picture III).

Note:

     At vehicles with dust cover on the wiring harness connector 
     coolant temperature sensor, reuse it for new wiring 
     harness connector.

Object Number: 2435017 Size: DEFAULT 

 6. Strip cable ends with crimping tool MKM-923-31.


 7. Put shrink sleeve over both cables and crimp cable ends
    with crimping tool MKM-923-31 (picture IV).
Object Number: 2435018 Size: DEFAULT 

 8. Put shrink sleeves over connections and heat it up with 
    hot-air blower (picture V).

Object Number: 2435019 Size: DEFAULT 

 9. Insulate complete wiring harness and put it in the grooved tube.


 10. Close grooved tube with insulating tape (picture VI).

Object Number: 2435020 Size: DEFAULT 

11. Replace coolant temperature sensor


     -see working procedure ”Coolant temperature sensor, remove and           
     install”, group "J", of the corresponding Service Instruction.


Spare-parts:                   Part-No.:               Catalog-No.:


Sleeve, cable, wire            90543865                12 86 663
connector                    


Hose, shrink, wire harness     90543875                12 86 666


Adapter kit, gold plated       93174557                62 86 420


Coolant temperature sensor     93174208                62 38 266
(Z14XE, Y16XE, Z16XE, Z16YNG)


Coolant temperature sensor     12992783                13 42 571
(X18XE-1, Z18XE, Z18XEL)
FunctionalGroup: J - Engine
Complaint Group: 18 - Poor Drivebility,19 - Poor Engine Driveability,21 - Poor Startability
Trouble Code: None,P0115

Cold Driveability > < Tank Vent Valve, Remove and Install (X 18 XE1)