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).
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).
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.
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).
8. Put shrink sleeves over connections and heat it up with hot-air blower (picture V).
9. Insulate complete wiring harness and put it in the grooved tube.
10. Close grooved tube with insulating tape (picture VI).
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 |