Field Remedy: 2199
| Subject: | Engine Z17DTH - Instable idle running or engine stalls in cold condition |
| Models: | Engines: | Option: |
|---|---|---|
| Meriva 2004......,Corsa-C 2004...2007,Corsa-C Combo 2004...2007 | Z17DTH,Z17DTH,Z17DTH |
| Complaint: | Engine stalls in cold condition and actuated clutch or during slowly approaching traffic lights. |
|---|---|
| Cause: | Contamination of suction control valve. |
| Production: |
Remedy:
In case of customer complaint replace the suction control valve (SCV) of the high pressure pump.
Important: - During the complete procedure it is obligated to work in a clean environment. - Prevent contamination at SCV area. Small contaminations, which cannot be seen by eye, can cause major problems on engine performance. Particle size of 0,3 mm, can be already critical! - Do not use gloves. - Do not use SCV in case it has been dropped. - Make sure that pressure in the system is dropped before loosening the pressure connection pipe between pump and rail. - Disconnect battery after failure checking procedure. Wait for a few minutes before starting SCV replacement procedure in order to prevent any system action.
Note: Technical Service Bulletin 2199 is only valid for engine Z17DTH not for engines Z17DT/Z17DTJ/Z17DTR.
Working Procedure:
1. Disconnect battery.
2. Remove air intake hose with air mass meter (Picture I)
- remove 2x clamp (1, 2) - disconnect wiring harness connector air mass meter (3)
3. Detach engine control wiring harness (1) from upper bracket (2) (Picture II)
- remove 5x cable strap
4. Remove upper bracket of wiring harness (2) (Picture III)
- remove 2x nut (1)
5. Raise vehicle.
6. Remove solenoid valve (2, Picture IV)
- remove 2x vacuum pipe (1) - disconnect wiring harness connector (3) - remove 2x screw (4)
Note: Mark vacuum pipes to prevent from interchanging pipes at assembly.
7. Detach engine control wiring harness from lower bracket
- remove 3x cable strap
8. Remove lower bracket of wiring harness (2, Picture V)
- detach wiring harness connector from rail-pressure sensor (1) - remove sensor ambient pressure - disconnect wiring harness connector - clip off sensor ambient pressure - remove 2x nut (3)
9. Disconnect wiring harness connector suction control valve.
10. Remove high pressure pipe (1, Picture VI)
- release 2x flared nut (2) - remove bracket - remove screw
11. Remove suction control valve (1, Picture VII)
- remove lower screw of suction control valve (3) - lower vehicle - remove upper screw of suction control valve (2)
Important: Be careful not to drop foreign material into pump supply.
12. Replace seal ring of suction control valve
- wet new seal ring with clean engine oil - pay attention to correct fit
Important: Be careful not to drop foreign material into pump supply.
13. Check 2x fuel feed holes (arrow) for contamination (Picture VIII).
14. Install suction control valve (Picture IX)
- apply clean engine oil to o-ring of suction control valve (1) - tighten upper screw of suction control valve to 10 Nm - raise vehicle - tighten lower screw of suction control valve to 10 Nm
15. Install high pressure pipe
- tighten 2x flared nut - install bracket - install screw
Note: Measure diameter of high pressure pipe before assembly. The correct tightening torque is defined dependent on the measurement result:
- diameter 6,00 mm – tightening torque 30 Nm - diameter 6,35 mm – tightening torque 25 Nm
16. Connect wiring harness connector of rail-pressure sensor.
17. Install lower bracket of wiring harness
- tighten 2x nut
18. Install sensor ambient pressure
- connect wiring harness connector
19. Connect wiring harness connector suction control valve.
20. Install 3x cable strap
- secure wiring harness with 3x cable strap to lower bracket
21. Install solenoid valve
- tighten 2x screw - install 2x vacuum pipe to solenoid valve
Note: Pay attention to allocation of vacuum pipes.
22. Lower vehicle.
23. Install upper bracket of wiring harness
- tighten 2x nut
24. Secure engine control wiring harness to bracket
- install 5x cable strap
25. Install air intake hose with air mass meter
- install 2x clamp - connect wiring harness connector air mass meter
26. Connect battery.
27. Programming high pressure pump with Tech2
- reset pump learning value with Tech2 - confirm question pump replaced with „OK“
28. Program volatile memories.
Spare-Parts: Part-No.: Catalogue-No.:
Kit - suction control valve 98043686 8 19 185
Labour Times: TC: Hours:
U3 219 90 Replace suction 90 1.3 control valve
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: | 19 - Poor Engine Driveability |
| Trouble Code: | P1190 |