Field Remedy: 2592

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.