Thread: 2065 - Engine Z19DTH/ J - Intake manifold, swirl flaps, actuator DTC: P1109, P2075

Field Remedy: 2065

Subject:

Engine Z19DTH/ J - Intake manifold, swirl flaps, actuator out of order, DTC: P1109, P2075 set

Models:

Vectra-C 2004...,Signum 2004...,Zafira-B 2005...,Astra-H 2004...

Complaint:

Customer complaint about lack of power and SVS lamp on. The following trouble codes might be set based on the installed application: a.) EDC16 C9 (2-actuator strategy, i.e. pressure sensor as well as pressure regulator fitted at fuel rail) TECH 2 shows DTC: P1109. b.) EDC16 C39 (1-actuator strategy, i.e. only pressure sensor fitted at fuel rail). TECH 2 shows DTC: P2075.

Cause:

Problem might be caused due to sticking swirl flap or due to malfunction from swirl flap actuator.

Production:

Several modifications introduced since SOP. Latest improvement was a design change at the swirl flaps itself in order to make the flaps more robust and to prevent them from sticking. Engine-BP: Z19DTH17228334 (28.02.2007).

Remedy:

In case of customer complaint perform TECH 2 swirl flap actuator test in order to evaluate the problem. Recommendation: Remove upper beauty cover in order to see the swirl flap linkage mechanism. Switch on ignition (no need to start the engine) take TECH 2 out of the vehicle to the engine bay. Change into swirl flap actuator test and perform test. If linkage does not move at all but the actuator motor itself is working (audible) it might be that: --->>> either the internal actuator motor mechanism is faulty --->>> or the pin ball from the actuator lever has come off, the lever is bent or has just slipped off from the actuator joint. In this case the actuator needs to be replaced. Note: If the modified intake manifold (=swirl flaps) is already installed please replace only the actuator. In any other case it might be that the swirl flap linkage got stuck during the actuator test or does not move completely from one end to another. If this happens the intake manifold needs replacement together with actuator. The procedure for replacement of the intake manifold has been changed and will be published on TIS 2000 as soon as possible. In Advance the new procedure is given below in this document. Working Procedure: Note: It is not necessary to disassemble the toothed belt. Important: When working on the fuel system it is essential to pay attention to cleanliness as even the smallest dirt particles can lead to faults in engine operation or in the fuel system. Open fuel connections must be sealed with appropriate plugs from the Opel Parts Catalogue (catalogue number: 45 06 154 / part number: 9201697). Sealing plugs are only intended to be used once. 1. Open bonnet. 2. Disconnect battery - detach ground clamp – loosen nut 3. Only Zafira-B: Remove bulkhead lock part - see working procedure "Bulkhead Lock Part, Remove and Install", group "A", 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 Attachment 53 8. Lower vehicle completely. 9. Remove engine cover. 10. Remove air filter housing Astra-H: - see working procedure "Air Cleaner Housing, Remove and Install", group "J", Service Instruction Astra-H. (Document Number 00701767) Zafira-B: - see working procedure "Replacing the air cleaner housing", group "J", Service Instruction Zafira-B. (Document Number 01101348) Vectra-C: - see working procedure "Air Cleaner Housing, 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, Replace (Z 19 DTH)", group "J", Service Instruction Vectra-C. (Document Number 00602794) 12. Detach fuel return damping case (2, 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) Attachment 54 13. Bare high pressure pump (Picture III) Important: Close fuel connections of injectors and rail with closing caps from 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 nut Note: Close Rail, high pressure pump and high pressure line with closing caps from kit (catalogue number: 45 06 154 / part number: 9201697 ). - Remove fuel feed line (2) high pressure pump - Loosen clamp Attachment 55 14. Detach engine vent hose (2, Picture IV) - release 2x clamp - unclip from bracket (1) Attachment 56 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 Attachment 57