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Author Topic: Zafira Cooling Module  (Read 12385 times)

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TheBoy

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Zafira Cooling Module
« on: 16 July 2020, 16:54:14 »
Following yesterdays "incident", I thought I'd better plug in the Tech2 to check over the Battlesbus.  Aside from the Cooling Module, which is the reason for checking, the rest of the car had no unexpected DTCs, apart from one of the rear speakers, that I hadn't noticed.  Expected faults were glow plug circuit (it doesn't have a full compliment of glow plugs, and even less working ones), and CDC3 (most of it is missing, purely there to allow Aux in).

So back to Cooling Module, 4 DTCs:
21 Not Present Pushing Blower Motor, Malfunction
22 Not Present Pushing Blower Motor, Low Input
11 Not Present Sucking Blower Motor, Malfunction
12 Not Present Sucking Blower Motor, Low Input

Assume  Pushing motor is the fan in front of A/C condenser, and Sucking is the one behind the main fan?

I have checked in-cabin fuses related to cooling fans (F2, F39, F40) as described in glovebox manual, but they are all good.  So now will look at TIS to check schematics for other fuses...   ...but its being an arse, grrrr.
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TheBoy

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Re: Zafira Cooling Module
« Reply #1 on: 16 July 2020, 17:10:41 »
Main F4 fuse seems to (only) feed those 2 fans :)
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YZ250

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Re: Zafira Cooling Module
« Reply #2 on: 16 July 2020, 18:32:07 »
Fan resistor plug dirty / loose / faulty.  :-\   What are the symptoms  :-\ , fan not kicking in at all, fan running at high speed only?  :-\  Hopefully Dave The Builder can throw some light on it, as this is his area of expertise, whereas I'm just guessing.  :-\
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My fun car is a 2020 Bmw F32 430d M Sport with indicators.
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TheBoy

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Re: Zafira Cooling Module
« Reply #3 on: 16 July 2020, 18:38:05 »
Only symptom - ignoring yesterdays overheat, the reason for which is known about - is warning light on dash.

Presumably, the cooling fans won't come on, should the engine need additional cooling.


Main fuse 4 is OK, and 12V at it.  The 2 fuses in the relay box, one per fan, are also both OK.  Guess next step is to find this cooling module, and see what power is reaching it.
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YZ250

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Re: Zafira Cooling Module
« Reply #4 on: 16 July 2020, 18:47:42 »
What happened to the good old days of flicking on a cabin switch connected to the fans when things got a bit hot. After market Kenlowe springs to mind.  :)  Can you test the fans from Tech 2.  :-\ 
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My fun car is a 2020 Bmw F32 430d M Sport with indicators.
My cruiser is an Audi A6 Avant S Line Black Edition with indicators.

TheBoy

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Re: Zafira Cooling Module
« Reply #5 on: 16 July 2020, 18:52:08 »
Quote from: YZ250 on 16 July 2020, 18:47:42
What happened to the good old days of flicking on a cabin switch connected to the fans when things got a bit hot. After market Kenlowe springs to mind.  :)  Can you test the fans from Tech 2.  :-\
I tried it, it comes up with a message straight away about the module not support Power Stage 4, so *appears* to be applying quite a low voltage to the fans (according to itself), but fairly certain fans aren't running*


*struggling to get to front of car, because to get all the cars on the driveway, they are all parked a rizla from each other, and no room on the road this afternoon.
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Nick W

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Re: Zafira Cooling Module
« Reply #6 on: 16 July 2020, 19:24:55 »
Quote from: YZ250 on 16 July 2020, 18:47:42
What happened to the good old days of flicking on a cabin switch connected to the fans when things got a bit hot. After market Kenlowe springs to mind.  :)  Can you test the fans from Tech 2.  :-\


Because it's very easy to forget. I've never owned(I don't think I've ever seen) a standard car with anything other than a thermo-switch for electric fans. I have replaced manual switches for thermo ones on aftermarket installations, especially when the hopeless Kenlowe junk has failed.

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dave the builder

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Re: Zafira Cooling Module
« Reply #7 on: 16 July 2020, 20:39:09 »
Only just back sorry
coolant control module is under the N/s wing(on a astra G ,assume the Zaf is the same) ,red/burgundy slide ZIF type connector (due to the location the plug pins could get water ingress .
the fans have 3 wire speed resistor heat sensors item 5 clicky ,1 on the front push fan, 1 or 2 on the back fan(depending on spec )  , common for these to fail
I have spare CCU, loom,fans ,sensors if you can't find a replacement for what is dead
don't have the Zaf A  here or the manual  :(

i'd check the speed resistors for function, wiring plugs ,power the fans to make sure they work to start if you checked fuses (including a big fuse in engine bay caddy )



 
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TheBoy

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Re: Zafira Cooling Module
« Reply #8 on: 16 July 2020, 20:50:27 »
Thanks.

The wiring diagram doesn't seem to show any resistors.

Looks like the bumper has to come off on the Zaf to get to the module, which probably means I'm gonna have to jack it, which will be fun at the moment.  Looking at the wiring diagram, it either got to be both fans have failed, or the module has failed.  Guess when I get to module, its easier to track the fault.
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TheBoy

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Re: Zafira Cooling Module
« Reply #9 on: 16 July 2020, 20:56:01 »
Take that back - there is a resistor fan side of the fan connector on each, and a separate resistor on A/C equipped cars as well :y
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dave the builder

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Re: Zafira Cooling Module
« Reply #10 on: 16 July 2020, 21:08:24 »
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dave the builder

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Re: Zafira Cooling Module
« Reply #11 on: 16 July 2020, 21:13:21 »
I suspect the gubbins in the red circle is the culprit (may be 2 or 3 fitted )
you can bypass and power the fan direct to test
tomorrow i can meter out ones i have here and give a resistance reading ,may be available info on the interweb

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iansoutham

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Re: Zafira Cooling Module
« Reply #12 on: 17 July 2020, 12:14:34 »
Quote from: TheBoy on 16 July 2020, 20:50:27
Thanks.

The wiring diagram doesn't seem to show any resistors.

Looks like the bumper has to come off on the Zaf to get to the module, which probably means I'm gonna have to jack it, which will be fun at the moment.  Looking at the wiring diagram, it either got to be both fans have failed, or the module has failed.  Guess when I get to module, its easier to track the fault.

If it is the module, there are 4 types, petrol or diesel and with or without aircon
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dave the builder

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Re: Zafira Cooling Module
« Reply #13 on: 17 July 2020, 14:50:03 »
the resistor for front push is marked 0.30 ohms
the resistor for rear pull is marked 0.24 ohms
they are soldered to the fan (and sold as a complete unit including fan motor ),
there's a gazzilion different part numbers for fans  ::)
and several part numbers for the mounting shroud (but they just un-bolt from the shroud with torx bolts)
I've got both push and pull fans with resistors here (DE11 Swadlincote ,70 miles from the blast zone Brackley) Free to you if you need either  :y
the CCU and loom I have will be from a 1.6  :(

I could post out a fan motor but you live in Brackley ,it would never arrive  ;D
Quote from: iansoutham on 17 July 2020, 12:14:34

If it is the module, there are 4 types, petrol or diesel and with or without aircon

dam , the one I have is petrol with AC ,so probably no good for Jamie

Corsa ones clicky are available separately £11 delivered and i can't see the internals being much different  :-\ 
obviously they won't deliver to Brackley either  ;D



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TheBoy

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Re: Zafira Cooling Module
« Reply #14 on: 17 July 2020, 17:42:06 »
Cheers for readings :y


Cant start the stripdown until TBE can be dumped somewhere to make space, so that needs fixing first, before I start ripping the front off the Battlebus.  Only TBE is waiting for a part from egay ordered on Tuesday lunchtime and estimated for Thurs/Today, but according to the tracking number is yet to be posted  >:(
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