Vauxhall Workshop Service and Repair Manuals

Required commissioning routines for the Easytronic system for service/repair work

Note:   During vehicle repairs different system components have to be changed and repaired respectively. The following table lists the commissioning routines required after repair work so that all of the commissioning steps are carried out for the Easytronic system.

1. Changing the Easytronic control unit

• If an Easytronic service-control unit has been installed by aftersales service, the existing software has to be replaced in the service-control unit before commissioning. The software update is performed using the TIS 2000 "Service Programming System (SPS)" depending on the engine and/or vehicle type. The control unit is already locked Seed & Key.

2. Notes on servicing

Note:   Basic measures that should be taken into consideration when servicing to ensure optimisation of repair work:

• Obtain the version number of the most up to date TECH 2 software with the aid of Opel Service Information (TIS 2000) and if this does not correspond to the software version number present in the diagnostic unit, perform a software update on the TECH 2 software using the TIS 2000 "Transfer diagnostic software" system.
• When servicing or carrying our repair work with the TECH 2 perform "Read Control Unit Identification" from the menu and compare the Easytronic control unit software version with the current version in the Opel Service Information (TIS 2000). If a newer Easytronic software version is available in the TIS 2000, perform an update to the Easytronic software using the TIS 2000 "Service Programming System (SPS)".
• Delete the Easytronic error memory after each service/repair and perform a test drive. Then read out the error memory again and if necessary delete any remaining errors.
• If both brake lights fail, error code P1703 (8) "Brake Light Switch Signal Not In Target Range!" is generated. As a result, "F" is shown in the display and, because a brake light switch error has been detected, start approval is denied. The vehicle cannot be started and remains stationary. After the brake light is replaced, the brake must be fully operated so that the error is cleared and Easytronic can once again recognise valid brake light switch signals!

3. Possible error message and its remedy during initial use

The following error messages can appear in the TECH 2 display during initial use:

• Time out, check test conditions, transmission fault

Possible remedies:

• General
• Check battery voltage and connect battery charger if voltages of less than 12 V are present. If communication is interrupted during diagnosis, check connection between vehicle and TECH 2. Run through initial use menu for transmission several times.

• If the error message time out or transmission fault appears
• Detach transmission actuator and check transmission. Can the gears be engaged? Are the gear shift forks aligned? Is a gear engaged? Is the cut-out of the shifter rail for reverse gear aligned? Is there any play in the gear shift forks (transmission fault)?

• Check test conditions if there is an error message
• Disconnect hydraulic line from the MTA control unit and repeat test. If test is now OK, check clutch/release system, otherwise check fault memory entries and perform remedy in accordance with test instructions.

4. Parking the vehicle

To prevent the vehicle from rolling, the parking brake must be applied when the vehicle is parked.

5. Emergency clutch opening

• If the vehicle battery is discharged or there is a serious fault in the system, the clutch cannot be opened. If a gear is engaged at such a time, the vehicle cannot be moved. If the vehicle must be pushed away or moved out of the flow of traffic, the clutch can be opened. This emergency opening is only to be done in emergencies. Consult a workshop if emergency opening is used. When emergency opening the clutch, the ignition must be off and the foot brake must be depressed to prevent the vehicle from rolling away. Because the clutch actuator has no catch and the clutch can therefore close on its own, towing and starting are not permitted. An unfitted or incompletely fitted bearing cap could cause the brake actuator to malfunction. Do not switch on the ignition while the clutch is emergency opened as this could pose a danger or cause damage. The bearing cap must not be unintentionally pulled or twisted (no bracket). After emergency opening, a new bearing cap must be fitted.
• After emergency clutch opening on an MTA vehicle, the clutch actuator position may become displaced to >20.5 mm . If this happens, Tech 2 could fail to communicate with the Easytronic control unit after the ignition is switched on (Corsa Z12XE up to and including software edition 38) and/or it may only be possible to establish communication after clearing a Service, e.g. by clearing the error memory and thus performing a reset (Corsa Z10XE and Z10 XE ECO up to software edition 2). In both cases, the clutch control will be out of order. On these models, therefore, the actuator must be manually turned back a few turns after emergency clutch opening in order to reactivate the clutch control and enable diagnosis to take place.
• Additional information for mechanics to follow regarding emergency clutch opening can be found in operation "Emergency Clutch Opening (MTA)" .

6. Leaving the vehicle

Do not leave the vehicle if a gear is engaged or the engine is running. In such cases, a warning buzzer sounds when the driver's door is opened.

7. Service Vehicle Soon (SVS)

Some error memory entries generated by Easytronic in the event of an error result in activation of the SVS warning lamp. In such cases, continued driving is possible, but a workshop should be consulted immediately in order to have the error located and remedied.

8. Brake fluid for MTA release system

The brake fluid for the release system must be changed at the prescribed intervals. It is of the utmost importance to use the brake fluid specified by Opel/LUK: "BASF Hydraulan 404 DOT4+" or "Shell Brake Fluid DOT4+ LW". Even slight contamination of the brake fluid with grease or oil (e.g. grease on return hose to facilitate insertion or topping up brake fluid using a container contaminated with mineral oil) could cause a malfunction in the master cylinder and thereby clutch actuator failure!

9. Clutch overheating

When stopping on a hill, always apply the hand brake or depress the foot brake. If a gear is engaged, do not hold the vehicle stationary by increasing engine speed. Otherwise, the clutch could be damaged or overheat. Avoid depressing the accelerator pedal and foot brake simultaneously with a gear engaged as this could damage the clutch.

10. Not OK criterion after contact point determination

After determining contact point using TECH2, an evaluation must be undertaken as to whether initial use was successful. The following not OK criterion applies:

• Vehicle type, after determining contact point 2
• Z10XE contact point >14.0 mm
• Z10XE ECO contact point >14.0 mm
• Z12XE contact point >14.0 mm
• Z16XE contact point >14.0 mm

If the not OK criterion is exceeded after contact point determination 2, topping up/bleeding and contact point determination must be repeated. Erratic engine torque signals or air in the hydraulic lines of the release system could generate this error profile. This not OK criterion is obtained empirically by means of production data evaluation and is similarly implemented in production plants. Increased coolant temperature negatively affects contact point determination or is evidence of incorrect contact point determination.

11. Variant programming (ABS 5.3)

Variant programming may have to be carried out depending on the vehicle configuration. This notifies the control unit which additional consumers and/or signal emitters (e.g. ABS) should be installed in the vehicle. If the variant programming is incorrect, malfunctions and/or erroneous fault memory entries are likely to occur. The following sequence must be performed on MTA vehicles with Z10XE, Z10XE ECO, Z12XE, Z16XE motorization: Variant programming (00=without ABS, 01=with ABS); see test instructions!

12. CAN configuration programming (TCS 5.3/ABS 8.0)

CAN configuration programming is to be carried out on MTA vehicles with Z10XEP, Z14XEP, Z13DT, Z18XE motorization. Deactivation of ISM is necessary for correct initialisation of ISM during the subsequent reset; see test instructions!

13. Signal check using data list and additional data list

When an analysis is being performed in the Service department, various switches and signals relevant to MTA must be read out using TECH 2. The signals and their value ranges are described in the test instructions and compiled in a snapshot data block which provides information via the TECH 2 "Data List" and "Additional Data List" menus. See test instructions!