Check control on Zafira B

[cross-keys]

In order to do this modification on the Zafira B, the following parts are required:

93183141 - Coolant Header Tank with inbuilt float
£22.45 +VAT from Vauxhall

93179551 - Sensor for coolant level (fits to tank above)
£13.05 +VAT from Vauxhall

90346055 - Washer sensor
£6.59 + £1.39 delivery from eBay seller 'hook4920'
http://cgi.ebay.co.uk/ws/eBayISAPI.d...m=200507701220

90276310 - Grommet for washer sensor
£1.84 +VAT from Vauxhall

The front bumper needs to come off to fit the washer sensor and this is done as follows:

Firstly, remove the front grille by removing the four torx bolts which hold it to the slam panel.



The bottom of the grille latches into the bumper with eight lugs, which you may need to press with a screwdriver to release them.



Working under the wheel arch, undo the four torx screws (two on each side) securing the wheel arch liner to the bumper. There's not much room so you may want to turn the steering around or even remove the front wheels.

Lower right:



Upper right:



Pull out the centre pins and extract the six expanding rivets securing the underside of the bumper to the mounting strip on the front subframe. The pins are a bit of a pain to remove. A fork-shaped tool may assist.

Pull out the centre pins and extract the two expanding rivets - one on each side of the radiator grille aperture. The picture shows the pins already removed and sitting on the bumper.



Undo the two 8mm upper retaining screws (one on each side), adjacent to the headlights.

Disconnect the cable from the front temperature sensor, then you should be able to remove the bumper. Another pair of hands would be useful when doing this. The sides of the bumper will need to be disengaged from the body by pulling them outwards and upwards.

The washer bottle looks like this.



- and here are the parts which need fitting.



In order to fit the washer sensor, a hole needs to be made in the washer bottle. The grommet is a push-fit into the bottle, then the sensor is pushed into the grommet until it is fully home. I measured the diameter of the grommet and it was somewhere between 19mm and 20mm. I would suggest that you measure yours in case there is any difference. I used a hole cutter to make the hole, however hole cutters can sometimes cut larger holes than the stated size, so I would recommend drilling some test holes before doing the real thing. I found an old plastic oil can to practice on. I tried a 17mm cutter and a 19mm cutter.



The 17mm cutter made a hole that was too small, however the hole made by the 19mm cutter was perfect.



I test-fitted the grommet into the hole to be sure.



The hole actually measured 19.5mm (using a vernier), so it was slightly larger than the stated size, but the fit was spot on.

Now it was time to make the hole in the actual washer bottle. I put the grommet in the correct location and marked the location with a pencil, after which I marked the centre.



Before using the hole cutter, I drilled a 5mm pilot hole, which also allowed the washer fluid to drain out. I caught this in a washing up bowl.



Once the fluid had drained, the hole could be drilled with the 19mm cutter.



Here's the finished hole.



Once this was done, I put the washing up bowl in place and poured water into the filler in the top, in order to flush out any plastic swarf that may have got into the bottle. There was a little swarf which came out.

Then I fitted the grommet and got the sensor ready.



I smeared a little washing-up liquid around the sensor and then pushed it fully home.



As the wiring loom was not ready, I taped up the connector to prevent muck getting into it.

[cross-keys]

The replacement coolant header tank looks identical to the original, the difference is that the new one has a floating 'ring' inside which floats on the coolant and actuates the sensor, presumably via a magnet. Note that you can NOT modify the original tank by drilling a hole in it, as this will achieve nothing.

The new tank looks like this:



and the sensor like this:



You may be able to make out the ring when the tank is backlit. Also, the new tank rattles when shaken, unlike the original (without ring).



The sensor fits into the tank like this:



The first job was to empty the coolant out of the header tank. I siphoned this into a clean washing-up bowl, so that it could be re-used.



Once the siphoning was done, I found a couple of M6 allen bolts and a wine bottle cork in order to plug the three hoses which connect to the tank. I then removed the battery. There was a lot of crud which had collected under the battery, and there were two drain holes that were blocked up. The holes seemed to be on the small side, so I enlarged them with a 5mm drill.





The header tank slides onto a metal bracket and a plastic clip slides onto the end to prevent the tank sliding off.



The clip needs to be removed first ...



and then the tank can be slid off.



Comparison of old and new tanks:



Once the sensor has been clicked into position, the new tank can be fitted.



The sensor can be seen in this picture. You can also see one of the allen bolts blocking up one of the two small hoses.



Now the three hoses can be reconnected. I'm not a big fan of the standard springy rings that are fitted as standard, so I fitted new jubilee clips all round.



The coolant can now be replaced and topped up to the correct level.

As the wiring loom was not ready, I taped up the connector to prevent muck getting into it.

[pecky]

Cracking guide mate, very informative. That pretty much follows the same way as the Astra, only the washer bottle looks a little different.

[baltutis]

Try upgrade my Zafira'06.
Fitted coolant level sensor and found wiring for this sensor.
Now want fit washer level sensor. Unfortunately no wiring for this sensor.
Where connect washer sensor?
Thanks
P.S.
can't enable Check control on display, untill connect washer sensor, otherwise computer always show error message.

Found on TIS, that sensor must be connected to XE1 pin number 16.
How remove fuse box to connect wires?

[pecky]

That is why I created this http://diagnostics.org.uk/shop/index...products_id=21

This plugs onto the washer bottle sensor and has the pin and earth for the UEC. It comes with full pictures and instructions.

To remove the fuse box, undo the 3 Torx screws where all the fuses and relays are, then remove the cover at the top ans remove the 10mm nut.

Once you have undone these, you can pull the top of the fuse box up and remove. Some pictures are on this page http://www.diagnostics.org.uk/2010/0...-headlights-2/

[bunch21]

Thanks everyone involved in this sweet mod. I was lucky I had the wiring fitted on mine so only needed a few bits really. Well smart when the warning comes up

Does the GID do the bulb checking as well now check control is on?

[baltutis]

Thanks everyone involved in this sweet mod. I was lucky I had the wiring fitted on mine so only needed a few bits really. Well smart when the warning comes up

Does the GID do the bulb checking as well now check control is on?

If you want receive information about bad bulbs you must enable Check control in GID (I enabled in BID).
If you want receive information about coolant level and washer bottle level - must enable Check control in UEC, but some UEC not support Check control even you fit all sensors and wires.
In my car is fited UEC with ident GR - and I can't enable check control, because Tech2 can't program this function in my car.
In UEC with other idents Tech2 can activate Check control.