Retrofit Cruise control to 2002 1.8 Zafira

[DarrylB]

Hi all,

Been reading the posts here and can see there's some real knowledge in this forums members!

I purchased my 1.8 petrol Zafira last year. At the time I really would have liked to have got one with cruise control, but there was nothing available locally.

I understand that to retrofit cruise control would require the multifunction switch with the cruise control buttons, the clutch switch and the two way brake pedal switch and the cruise control module. My information is based on two sources - the Vauxhall EPC and a Haynes manual bought from Halfords.

Problem 1: The four pin connector for the cruise buttons on the multifunction switch do not appear to be in my steering column housing.

Problem 2: The connector for the clutch switch doesn't appear to be present .

Now it is possible that I just couldn't see the clutch switch cable, but I suspect that since the other connector isn't present, the loom just doesn't contain the right bits for the cruise control.

Never mind, says I, I'll just find out where the wires are meant to go and route them separately.... Hence purchasing he Haynes manual for the circuit diagrams.

Now I can see where the wiring for the multifunction switch go to the cruise control unit in the haynes manual - this looks fairly simple (I may need to change the brake pedal switch to be the dual gang version required for the cruise control, but nothing too complex. The feed clutch switch supply is common with the brake switch supply - 12 volt off fuse 38, so that's easy enough.) but I'm not so sure about some of the connections for the cruise control module.

From the Haynes diagram, I can see the connections for the buttons (simple enough) with the extra brake switch and the reset button on the multifunction switch in series. The input from the brake lights is obvious enough and the input from the road speed signal (curteosy of the ABS control unit on mine). However, the diagram labels the green wire on PIN D as Ub, going to 'various locations - arrow Sb', but I can only see it going to the clutch switch (clutch down puts 12 volt on pin D) since diagram 11 shows arrow Ub from the clutch switch going to diagram 14 arrow Ub... The two diagrams are inconsistent!

Question is - If anyone has a 1.8 Zafira or Astra G with cruise control, could you possibly check if PIN D of the cruise control unit goes to the clutch switch? Or if anyone has a better service manual with a more reliable diagram, can you confirm it for me? My concern is that this connection is possibly meant to be connected to something else as well as the clutch switch.

One other point of interest - the only thing common to the ECU and the cruise control unit is the road speed signal - do you think this is a bi-directional line, not just an input? The motor in the Throttle Position Sensor appears to be the only way the ECU can alter the throttle, maybe the ECU does the hard work when the cruise control module puts the right signal into the road speed signal line?

If anyone of authority can point me in the right direction on this, I will be extremely grateful.

Have fun,
Darryl.

[Mark T]

This is where I found the Stalk connector on a Zafira without CC.

[DarrylB]

Thanks for the quick reply - I found that picture earlier when searching the forum. Mine definately doesn't have that plug. I even opened up the grey plastic surround that the loom goes into and looked in there... Seems there must be more than one version of this loom on the car. Annoying really, since I've got the Elegance, it's got everything else - ABS, TC, Air Con, Electric windows/sunroof...

I'm just looking on the EPC now to see if I can find a picture of this loom - very hard to find stuff on it though if you don't know where to look!

Edit - I've just looked on the EPC and there appear to be 47 varieties of the instrument panel wiring harness - and I'm not even sure that it's the one that goes to the multifunction switch!

[DarrylB]

OK. Further investagtion has revealed some info... Now I need some help.

My Zafira has the Z18XE engine. According to the EPC this engine doesn't use the cruise control unit. So I expect the control stalk, clutch pedal and brake switches all go direct to the ECU.

I bought a Haynes manual for the wiring diagram, unfortunately it only includes the ingition circuit for the X18XE1 and X16XEL engines. If any of you have access to the wiring diagram for the Z18XE engine, can you tell me where the wires from the stalk, clutch switch and brake switch go to on my engine?

Many thanks,
Darryl.

[Mark T]

Here's the Z18XE diagram from the 99> Vecra manual.
http://82.34.51.160/temp/Vectra%20Z18XE%20wiring.jpg

The stalk is on there, the Stop light switch(the 4 pin version) and Clutch switch wiring should be in your manual.

[DarrylB]

Perfect. Thanks Mark. However, since I don't have the Vectra manual, could you possibly post diagram 10 as well? On the other engines the clutch and brake switches go to the cruise control module (as do the switch) so my diagram is different from yours.

Thanks again.
p.s. if it's too much agro, I'll just go and buy the other manual!

[DarrylB]

I haven't had a chance to look at a Vectra manual yet, so could you possibly tell me if this guess of mine is correct?

The pin labelled a10 of the ECU that goes to diagram 10 (Cruise control) is wired in series through the clutch switch and brake switch to 12V to allow pressing of the clutch or brake to cancel cruise control.

Thanks again,
Darryl.

[DarrylB]

Ok. I found a vectra manual in Halfords and had a nose... The clutch switch appears to be the only relevant part on the Z18XE (since the EPC says mine doesn't need a special brake switch) and it simply connects 12V to pin a10 as I suspected.

So the experiment after work tonight is to wire 12V to pin a10 and make up a circuit with 3 switches to allow me to send 12V to each of other the three inputs on the ECU and see if I get cruise control. This way I won't have to shell out for a new multi purpose switch if the ECU doesn't support it!

I'll report back later...

[Jack-Off]

Ok if you cant find the plugs then you will have to run wires to the big multi plug that go's through the bulkhead behind the glovebox.
The pins shown should be empty so you will need to straiten out a paper clip and solder it to the end of your wire.

[Jack-Off]

Your ecu will support it but may have to be enabled via tech 2

[DarrylB]

Perfect. I'll try this after work. Thanks again.

[DarrylB]

Well... I wired it up and nothing happened!

Now I need to find someone with a Tech2 to find out if it's enabled in the ECU (to eliminate the possibility of my wiring being naff). My local Vauxhall dealer are not particularly helpful - when I asked if they could retrofit the cruise control, they told me that I needed a whole new engine wiring loom and that the job was too complex to do.

Ho hum.

Anyone near Milton Keynes with a tech 2? I think the going rate for switching on one flag in an ECU is a couple of pints!

Also, does anyone know where to get the smaller crimps for this large connector - sticking paper clips in it doesn't seem like the best method! I might still enquire about the cost of the dash loom with the connectors on it from vauxhall - I just don't fancy ripping out the whole dashboard...

Thanks again for the help.

[Jack-Off]

Paper clips have worked fine on all the one's ive done. to fit the correct pins you will nedd to take the plug apart.

[DarrylB]

I'll try to get the ECU set tomorrow. The (non vauxhall) garage I bought it from in Thame have a Tech 2 and their engineer seemed quite approachable. And there's always the Vauxhall dealer in Aylesbury who might be more keen to help.

Still, I've learnt a fair bit so far, so I'm not at all disapointed!

[Mark T]

Ian V6 on here has a Tech 2 (Orpington - Kent)

Currently on loan to me (Chelmsford, Essex)

[DarrylB]

Thanks for the offer, but I've booked it into Camden Vauxhall in Aylesbury for tommorrow morning for the princly sum of £46.

I wouldn't mind driving over to Chemsford though... Could get there and back and buy you a couple of drinks for less than that!

[DarrylB]

Before I go to Mr Vauxhall, can anyone tell me whether the tech 2 will be able to show the state of the control buttons/clutch switch? If it can, this would allow me to verify my wiring. Obviously, knowing about this before I go will help in case the engineer doesn't really know how to use it!

[Jack-Off]

Yes tech 2 shows live readings and will show you the inputs from the tip switch and clutch switch

[DarrylB]

Thanks to all your help, I now have fully functional cruise control!

For anyone else that might be thinking of trying it, here's what I did:

I looked for the 4 pin connector by the steering column and didn't find it or the connector for the clutch switch.

Not realising there was any difference in the cruise controls for different engines, I purchased a Haynes Astra/Zafira manual (without knowing which engine I had at this point).

This (and the EPC) showed that there was a cruise control module in the engine compartment that was wired to the tip buttons on the stalk and the clutch and brake switches. I got suspicious at this point, since other people had succeeded in adding cruise control by just adding the correct stalk - I couldn't beleive that Vauxhall would put the cruise control module in cars without cruise control. Then I found that the module was only on certain engines, so I found out which engine was in mine - the Z18XE.

Another check on the EPC showed that mine indeed did not have the cruise control module or a special brake switch - so I tried to find the wiring diagram for the Z18XE engine - thanks goes to Mark T for posting the page from the Haynes manual.

This shows that the stalk butons go straight to the ECU - next step was how to get them there - I was just about to set off find the ECU and use my trusty Multimeter to trace back into the wiring loom and find the place to add my connections when Jack Off came to the rescue with his diagram!

Instead of using straightened out paper clips, I tried three different sized tinned copper wires (from Maplin) and made my own switch with three 49p push to make switches and one push to break. I then connected these to the pins in Jack Off's diagram and tried it... no joy.

At this point, either the ECU wasn't configured or my wiring/switches were wrong - a trip to a friendly Vauxhall dealer and a fixed price diagnostic session was booked. Their remit was simply to activate the cruise control - but I also asked that I could check my wiring using their tech 2 while it was on the car.

Thursday morning, the Vauxhall engineer warned me that he might not be able to activate cruise control (he thought the ECU might only be programmable once), but I asked him to give it a try anyway. After about 15 minutes he came back to me and told me that he'd activated it and invited me to the car to test the wiring - since at this point I had no idea whether Jack Off's diagram was correct or if my connections were naff... The tech 2 showed that my clutch switch and my tip switch 'l' button's both worked, but the 'O' and 'R' buttons did not.

So I came home, studied the haynes manual a little more carefully and spotted that the 'O' button is push to break - i.e. 12V is always on the O input to the ECU except when it's pressed (or the switch isn't there). Quick rewire and re-seat the other pins in the connector and it worked!

Another trip to my local vauxhall dealer and I had the proper clutch switch - pain in the neck to fit, but 20 minutes later, all wired up. No stalk in MK, Aylesbury, Buckingham, Bedford or Watford - but I found one in Luton... So off I trot down the M1 under cruise control with my 49p buttons to get the stalk.

About £30 for the stalk, £10 for the clutch switch and £46 for the diagnosis at the Vauxhall dealer and I've now got cruise control on my 1.8 Zafira.

Thanks again to everyone who helped... My trip up the M40/M6 to Glasgow today will be a little easier!

Have fun,
Darryl

[mvecd]

Hi

I have the same engine as you, except mines dual fuel.
I also have looked into retro fitting CC.
I got a diagram and noticed you wire to the ECU, thats where I chickened out!
But now I see you've done it, I want another go.
Could you email me presice instructions, including how you wired up the 3 maplin switches and which pins on the ECU to use etc?
I would really appriciate your help on this.

thanks

Mark

[DarrylB]

I've had a few PM's asking for more information on how I did this. All the information you need is in this thread if you have any basic electronics knowledge - it's the info that I used.

However, Here's what I know and how I did it. I'll try to answer the questions in the process.

1. Don't try to do this if you don't understand simple electronics - i.e. wires and switches. Sorry if you think this is rude, but I don't expect anyone on this forum to do all the work for you unless you pay them to do the whole job for you!

2. If you don't have the Z18XE engine you need to find out if yours has the easy cruise control option. The 1.6 engines, for instance, appear to have a separate cruise control module, and I have no idea where to fit it. To find out if you can use my method, firsty find out which engine you've got. Apparently it's stamped on the crank case somewhere, but mine had a great big sticker with Z18XE in large friendly black text.

Find a Haynes manual (I went to Halfords and looked at it on the shelf - saved myself 15 quid). Check your engine is in it. I found mine in the vectra manual in the end. If the diagram contains a cruise control unit, this method will not work.

3. Remove the top half of steering column cover (you need to turn the steering wheel 90 degrees to see the screws). If the plug is there (see Mark T's picture) go and buy the new mutli function switch.

4. If the plug isn't there you'll need to run the cables to the ECU. This doesn't mean that you need to locate the ECU - I still have no idea where it is - you just need to run a 12V ignition switched wire (just use a multimeter to fine one - I took it from my in car entertainment) to the correct wire of the switch and three more wires from the switch to the relevant pins of the multi-way plug behind the glove box (see diagram when I get round to posting it).

I used tinned copper wire from Maplin, rather than straightened out paper clips. I'm sure they would work fine, but I feel more confortable putting tinned copper wire into a car I paid 9 grand for...

Of course, if you have got the cruise control wiring loom, all you've got to do is plug in the connector.

5. Check you've got a clutch switch. Remove the trim from the driver's side footwell and remove the air-vent pipe. With a bit of contortion and a torch you can look up and see the brake switch and the rectangular hole where the clutch switch goes. If yours is missing, go and buy one and run a 12v ignition switched wire (again just use a multimeter to fine one) to one side of it and run a wire from the other side to the relevant pin of the multi-way connector behind the glove box.

Again, if you've got the cruise control wiring loom, all you've got to do is plug in the connector.

6. Try it. According to the owner's manual it will only work from about 20 mph. If it doesn't work, you'll need to find out why. Pop down to your freindly vauxhall dealer and e prepared to pay £40 for them to plug in a tech2.
Get the techy guy to go to the cruise screen and press your clutch, and the three buttons on the stalk in turn while looking at the entries on the screen to see if they change. If all your switches are OK then you'll need to get the Vauxhall guy to enable cruise control. If he tries to tell you that it can only be set in the factory, don't be rude to him and tell him he's talking nonsense (even though he is) - he'll just charge you £40 and you still won't have cruise control!

7. Cruise home.

Well, that's what I did anyway. It stopped working for a day last week - maybe a wire came free, but it's fine again now. Note that all the switches that enable the cruise control feature are wired in so that they put 12v on the relevant pin of that multi-way controller. This is a safety feature - if the wiring to the clutch switch comes disconnected, for example, the cruise control is de-activated.

Jack-off's diagram has come back. If it disappears again let me know and I'll re-post it.

Good luck,
Darryl.

[DarrylB]

Could you email me presice instructions, including how you wired up the 3 maplin switches and which pins on the ECU to use etc?
I would really appriciate your help on this.
Mark

You don't need the switches from Maplin - I just used this to check my theory before shelling out on the stalk and clutch switches - to simulate them. If you understand basic electronics you can do the same - use the diagram in the Haynes manual. Note you'll need push to make for the clutch and reset switches. Otherwise you'll have to hold them down for it to work! Also the poor thing revs its guts out if you don't press the clutch button when changing gear!

I recommend just using the proper kit - I've done the experiment on your behalf!

As for the ECU pins, I'll re-post Jack-Off's diagram when I get the chance.

[mvecd]

thanks.
did you take a feed for your clutch switch from the brake switch?

Is there a cheaper option of tech 2? will only dealers have it?
for that price do they only enable CC or do they check the whole system?

many thanks for your help

mark

[Mark T]

Ian V6 has a Tech2 (on loan to me at the moment), if you are local.

[mvecd]

thanks for the offer, but I'm near Grimsby (up north)
local VX dealer will do it for £20 so prob ask them

Are the control stalks from the vectra/omega the same as the zaf?

thanks again

Mark