vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Rough Idle > < Petrol engines - Refuelled with diesel fuel

Astra G

Field Remedy: 1316

Subject: Temperature sensor - None or insufficient function
Models: Engines: Option:
Astra-G 1998...2000,Corsa-B 1997,5...2000 X12XE,X10XE| X12XE
Complaint: While driving engine jerking may occur and in case of irregular idle speed, the engine may stall. The engine shows bad starting characteristics.
Cause: Relative movement in the area of the coolant temperature-sensor resulting in damaged contact pins.
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. Disconnect battery.
2. Disconnect wiring harness plug from coolant-temperature-sensor 
   (pic. I, 2).
3. Disconnect wiring harness plug from mass air flow meter (pic. 
   I, 4).
4. Remove cover wire channel (pic. I, 1).
5. Remove ribbed plastic tube from wiring harness (pic. I, 3).
Object Number: 2434863 Size: DEFAULT 

 6. Remove insulation tape from wiring harness.
 7. Cut sensor cable in cable duct (shifted cuts) and remove
    wiring harness plug sensor.
 8. Hold new wiring harness sensor temporarily into position new  
    wiring harness sensor and measure. 
    Minimum cable length from beginning of plug to exit of cable
    duct is 120 mm.
 9. Assign, mark cable and install new connector (pic II).
Object Number: 2434864 Size: DEFAULT 

10. Strip cable.
11. Slip heat-shrinkable tube on ground cable and crimp cable 
    ends with each other.
12. Slip heat-shrinkable tube on positive battery cable and crimp 
    cable ends with each other. Crimping connection of mass and
    plus cable shall not be on the same position (shifted
    position).
13. Slip heat-shrinkable tube on crimping ground cable and heat 
    up with hot air dryer.
14. Slip heat-shrinkable tube on crimping positive battery cable 
    and heat up with hot air dryer.
15. Route ribbed plastic tube from center cable duct around 
    wiring harness in direction cable branch sensor water  
    temperature approx. 30 mm. This is absolutely necessary since 
    the cable duct exit is sharply edged where it takes up the 
    ribbed plastic tube. Route wiring harness, insert ribbed 
    plastic tube into cable duct exit, install cover wiring 
    harness duct and secure with 2 cable binders. Minimum cable 
    length from beginning of plug to exit of cable duct is 120 mm 
    (maximum 140 mm). 
16. Insulate wiring harness completely new and connect wring 
    harness plug mass air flow meter. Cable length from exit
    cable duct to split coolant temperature-sensor shall not
    exceed 30 mm.
Object Number: 2434865 Size: DEFAULT 

17. Remove coolant-temperature-sensor and absorb draining coolant.
18. Install new coolant-temperature-sensor - torque to 18 Nm.
19. Connect new coolant-temperature-sensor electrically.
20. Check and correct coolant level.
21. Connect battery.
22. Program volatile memories.


Spare-Parts:                        Partnumber:        Catalognumber:


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          90542063           62 38 422


Labortimes:                         TC:                Hours:


T8 131 60                           92                 0.7 hrs.


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.
FunctionalGroup: J - Engine
Complaint Group: 13 - No/Poor Function
Trouble Code: None,P0115

Rough Idle > < Petrol engines - Refuelled with diesel fuel