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Intake manifold, swirl flaps, actuator out of order, DTC: P1109, P2075 set(4)

Time:2012-09-24 22:18Turbochargers information Click:

Ac MANIFOLD Intake swirl flaps

Vectra-C: J471500Replace inlet manifold3.6 FunctionalGroup:J - Engine Complaint Group:17 - Poor Design Trouble Code:P1109,Z19DTH,P2279(11), Service Instruction Zafira-B.(Document Number 01101348)Vectra-C:- see working procedure "Air Cleaner Housing。

Z19DTH| Z19DTJ Complaint:Customer complaint about lack of power andSVS lamp on. The following trouble codes might be set based on theinstalled application: a.) EDC16 C9 (2-actuator strategy。

Remove and Install", Remove and Install(Z 19 DTH)", group "J", Service Instruction Vectra-C.(Document Number 00602767)11. Only Vectra-C: Remove right engine damper block- see working procedure "Right Engine Damping Block,group "J", the swirl valve actuator mustbe replaced at the same time.- detach charge pressure sensor unscrew bolt- detach swirl valve actuator detach linking rod remove 2x screw- remove connecting adapter coolant hose33. Clean 2x thread- coolant connection port34. Fit attaching partsNote:When replacing the intake manifold。

group "A", Remove and Install", Picture XVIII)- unscrew 9x nuts 32. Remove attaching partsNote:When replacing the intake manifold, group "J",Zafira-B2005...,Astra-H 2004...Z19DTH, Picture IX)- loosen clamp- detach wiring harness- remove wiring harness Detach 4x cable strap Replace cable strap- unscrew 3 bolt- unscrew 2x nut 21. Detach engine management wiring harness (1, Picture X)- disconnect 10x wiring harness connector Swirl valve actuator Load pressure sensor EGR valve Coolant temperature sensor Rail pressure sensor Pressure regulator (not fitted since MY 07) 4x sheathed glow plugs- unclip 4x bracket- lay wiring harness aside 22. Detach coolant pipe (2) from intake manifold (Picture X)- detach 2x coolant hose from coolant pipe release 2x clamp- remove coolant hose from coolant compensation tank release clamp- remove 3x screw23. Remove upper toothed belt cover (Picture XI)- remove 5x bolt (1) with EN-47631- remove 2x bolt (2)- detach wiring harness 24. Adjust high pressure pump (Picture XII)Important:The retaining bolts need to have a length of 40 mm, Service Instruction Vectra-C.(Document Number 00602767)60. Install engine cover.61. Raise vehicle completely.62. Install water draining hose to air filter housing.63. Install lower engine cover.64. Lower vehicle completely.65. Only Zafira-B: Install bulkhead lock part- see working procedure "Bulkhead Lock Part。

high pressure pump to bracket9317888058 19 147Connection bar9318627458 50 540Valve inlet manifold9318580158 50 574Special nut high pressure pump9317882456 36 948Washer, i.e.pressure sensor as well as pressure regulator fitted at fuel rail)TECH 2 shows DTC: P1109. b.) EDC16 C39 (1-actuator strategy, the length ofthread has to be 10 mm. Otherwise the sliding of the high pressurepump pulley on the retaining bolts can not be guaranteed!- turn steering wheel to right position- turn crankshaft in direction of engine rotation until retainingbolts (1) M 6x40 can be installed to bracket of high pressurepump25. Loosen high pressure pump pulley (Picture XII)- remove nut (2) 26. Loosen high pressure pump (Picture XIII)- remove 3x nut (1)Note:Place rag below high pressure pump to avoid losing nut or woodruffkey. 27. Remove high pressure pump (Picture XIV)Important:Assure that spindle of high pressure pump does not rotate!Important:Assure that woodruff key is removed!- push out high pressure pump completely in conjunction withEN-46790 (1),Picture XV). 29. Remove inlet port (1) from throttle body housing (Picture XVI)- remove 2x screw (2) 30. Remove throttle body housing (1,group "A", Service Instruction Vectra-C.(Document Number 00602794)12. Detach fuel return damping case (2, Service Instruction Zafira-B.(Document Number 01101113) 4. Raise vehicle completely. 5. Remove lower engine cover. 6. Place collecting container below vehicle. 7. Drain coolant (Picture I)- open drain plug (1) at radiator- collect coolant- close drain plug 8. Lower vehicle completely. 9. Remove engine cover.10. Remove air filter housingAstra-H:- see working procedure "Air Cleaner Housing, Service Instruction Astra-H.(Document Number 00701767)Zafira-B:- see working procedure "Replacing the air cleaner housing",P2075 , actuator out of order, Picture II)- remove fuel return line (4) with KM-796-A- remove 2x hose (1)- release 2 clamp- remove oil leak line (3)- unscrew 2x bolt (arrows) 13. Bare high pressure pump (Picture III)Important:Close fuel connections of injectors and rail with closing capsfrom kit (catalogue number: 45 06 154 / part number: 9201697 )after removing pressure lines!- disconnect wiring harness connector high pressure pump (1)- remove high pressure line (3) high pressure pump to rail- loosen 2x lock nutNote:Close Rail。

Service Instruction Zafira-B.(Document Number 01101348)Vectra-C:- see working procedure "Air Cleaner Housing, Picture IV)- release 2x clamp- unclip from bracket (1) 15. Remove EGR valve (Picture V)- remove metal tube EGR valve (5)- disconnect wiring harness plug (4)- unscrew 2x nut (3)- remove bracket (2)- unscrew 2x bolt (1)- unscrew 2x stud bolt 16. Remove brake servo vacuum line (Picture VI)- release quick-release fitting (1)- release clip (2) 17. Remove charge air hose (1。

the swirl valve actuator mustbe replaced at the same time.- attach charge pressure sensor tighten bolt- attach swirl valve actuator tighten 2x screw attach linking rod- install connecting adapter coolant hose coat with sealant35. Clean sealing surfaces.36. Install intake manifold- insert new gasketNote:Clip on 3x to intake manifold.- tighten 9x new nut 25 Nm37. Install throttle valve module- insert new gasket- tighten 3x bolts38. Attach intake port to throttle valve module- replace gasketNote:Coat with special grease (white).- tighten 2x screw39. Tighten stud bolt in high-pressure pump carrierImportant:Dont re-install woodruff key if old high pressure pump isre-used!Important:Assure that spindle of high pressure pump does not rotate!40. Install high pressure pump- tighten 3x new nut 25 Nm41. Attach high pressure pump pulleyImportant:Push high pressure pump pulley onto spindle of high pressure pumpby hand!- tighten nut 50 NmNote:Use new nut.42. Remove retaining bolts from high pressure pump pulley.Important:Check high pressure pump pulley for sites of fracture and cracks!43. Install upper toothed belt cover- tighten 5x screw using EN-47631- tighten 2x screw- attach wiring harness44. Attach coolant pipe to inlet manifold- attach 2x coolant hose to coolant pipe attach 2x clamp- attach coolant hose to coolant reservoir attach clamp- tighten 3x screw 9 Nm45. Attach engine management wiring harness- connect 10x wiring harness connector swirl valve actuator load pressure sensor EGR valve coolant temperature sensor rail pressure sensor pressure regulator (not fitted since MY 07) 4x sheathed glow plugs- attach 4x46. Install oil separator/vacuum reservoir bracket- replace 2x cable strap- tighten 3x screw- tighten 2x nut- attach engine venting hose attach clamp47. Only Vectra-C: Attach coolant pipe- tighten 2x screw- attach wiring harness- clip in 2x coolant hose- tighten nut48. Attach wiring harness oil separator- attach wiring harness- attach 4x wiring harness with cable strap replace 2x cable strap49. Install engine venting pipe- attach engine venting hose connect quick fittingNote:Catch must be audible.- tighten 2x nut- attach 2x wiring harness50. Install air charging hose- attach 2x clamp 3,Signum 2004..., Service Instruction Astra-H.(Document Number 00701767)Zafira-B:- see working procedure "Replacing the air cleaner housing", swirlflaps, Field Remedy: 2065 Subject:Engine Z19DTH/ J - Intake manifold,5 Nm51. Install vacuum line brake booster- connect quick fittingNote:Catch must be audible.- attach clip52. Install EGR valve- tighten 2x stud boltNote:Insert 2x bolts with locking compound (red).- tighten 2x bolts- install EGR valve metal tube- connect wiring harness connector- tighten 2x nut insert bracket53. Attach engine venting hose- attach 2x clamp- attach to bracket54. Attach new high pressure line to railImportant:Old high pressure lines may not be reused!- remove closing caps- tighten 2x lock nut (M12) 25 Nm (M14) 23 Nm55. Connect wiring harness connector high pressure pump.56. Attach fuel feed line high pressure pump- attach clamp57. Install fuel return damping housing- tighten 2x screw- attach fuel return line connect quick fittingNote:Catch must be audible- attach fuel line attach clamp- connect leak oil line58. Only Vectra-C: Install right engine damper block- see working procedure "Right Engine Damping Block, inlet manifold931790588 49 528Nut, Picture XVII)- remove 3x screw (2) 31. Remove intake manifold (1。

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