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.
Attachment 407
The bottom of the grille latches into the bumper with eight lugs, which you may need to press with a screwdriver to release them.
Attachment 408
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:
Attachment 409
Upper right:
Attachment 410
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.
Attachment 411
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.
Attachment 412
- and here are the parts which need fitting.
Attachment 413
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.
Attachment 414
The 17mm cutter made a hole that was too small, however the hole made by the 19mm cutter was perfect.
Attachment 415
I test-fitted the grommet into the hole to be sure.
Attachment 416
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.
Attachment 417
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.
Attachment 419
Once the fluid had drained, the hole could be drilled with the 19mm cutter.
Attachment 420
Here's the finished hole.
Attachment 422
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.
Attachment 423
I smeared a little washing-up liquid around the sensor and then pushed it fully home.
Attachment 424
As the wiring loom was not ready, I taped up the connector to prevent muck getting into it.
Attachment 425
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