vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

ABOUT US
Family 1 engine - EGR malfunction > < Petrol engines - Refuelled with diesel fuel

Corsa C

Field Remedy: 1779

Subject: Z17DTL/H Boost Pressure Sensor - FC P0105
Models: Engines: Option:
Astra-G 2003...2004,Astra-H 2004,Meriva 2004,Corsa-C 2004,Corsa-C Combo 2005 Z17DTL,Z17DTL| Z17DTH,Z17DTH,Z17DTH,Z17DTH None
Complaint: Sudden loss of power, engine stalling at 3. 000 rpm, SVS light on, FC P0105 set.
Cause: Vibrations cause contact problems between plug and sensor.
Production: As of engineno.: 1126120, (04.10.2004) an improved wiring harness plug has been introduced in production.

Remedy:


In case of customer complaint replace first wiring harness plug of load
pressure sensor.
Only if the problem reoccurs, replace the load pressure sensor in addition.




Note: 
     It is not necessary to replace the ECU in case of DTC: P0105.

Working Procedure:


 1. Disconnect battery.
 2. Remove air intake pipe with air mass meter (Picture I, 1).

Object Number: 8063961 Size: DEFAULT 


 3. Z17DTL: Remove pulsation damper with bracket and lay aside
    (Picture II, 1).




    - remove 2x nut (2)

Important


     Do not damage fuel lines.




    Z17DTH: Loosen oil leakage line (without picture).




    - remove nut

Object Number: 8063962 Size: DEFAULT 


 4. Remove vacuum reservoir for change-over flaps and lay aside
    (Picture III, 1)




    - remove vacuum hose (3)
    - remove 2x screw (2)

Object Number: 8063963 Size: DEFAULT 


 5. Remove wiring harness plug of load pressure sensor (Picture IV, 1).

Object Number: 8063964 Size: DEFAULT 


 6. Write down connector assignment of wiring harness plug chambers.
 7. Cut wiring harness plug of load pressure sensor.
 8. Shorten new wiring harness plug corresponding.
 9. Install new wiring harness plug load pressure sensor to wiring harness.




    - strip end of cables
    - slide heat shrinkable tubing over cable
    - crimp end of cables to each other

Important:


     Pay attention to chamber assignment.




    - slide heat shrinkable tubing over crimping and heat it up




10. Insulate wiring harness of load pressure sensor with textile band.
11. Install wiring harness plug to load pressure sensor.
12. Install vacuum reservoir for change-over flaps.
13. Z17DTL: Install pulsation damper with bracket. 
    Z17DTH: Fasten oil leakage line.
14. Install air intake hose with air mass meter.
15. Connect battery.
16. Program volatile memories.




Spare-Parts:                                Part-No.:      Catalogue-No.:




Wiring Harness Plug, Load Press. Sensor     93 184 531     62 86 663
(Cable cross-section 1 qmm / 2,5 qmm depents on model) 




Labour Times:                                       TC:       Hours:

Astra-G, Astra-H, Corsa-C, Combo-C:


U3 177 90  Replace wiring harness plug              90        0.8
           of load pressure sensor

Meriva:


U3 177 91   Replace wiring harness plug             90        0.9
            of load pressure sensor   




The costs for this repair will be covered during the normal warranty.
The regular warranty procedure should be used for claiming Set-up-time.
FunctionalGroup: J - Engine
Complaint Group: 20 - Poor Performance
Trouble Code: P0105

Family 1 engine - EGR malfunction > < Petrol engines - Refuelled with diesel fuel