Vauxhall Workshop Service and Repair Manuals

Corsa-B

Astra-F

Vectra/Cavalier

Calibra

Omega-A/Carlton

Production

Vehicle Ident. No

Vehicle Ident. No.

Vehicle Ident. No.

Vehicle Ident. No.

Vehicle Ident. No.

from

to

from

to

from

to

from

to

from

to

Antwerp

-

-

P5 267269

R5 175398

P5 329080

R5 175397

-

-

-

-

Bochum

-

-

P2 735251

R2 665328

-

-

-

-

-

-

Eisenach

P6 000001

R6 067 301

-

-

-

-

-

-

-

-

Ellesmere Port

-

-

P8 199094

R8 175036

-

-

-

-

-

-

Finland

-

-

-

-

-

-

R9 002660

R9 007674

-

-

Luton

-

-

-

-

P7 632766

R7 573500

-

-

-

-

Ruesselsheim

-

-

-

-

P1 222378

R1 108423

R1 047808

R1 108429

P1 236137

P1 251264

Szentgotthard

-

-

PS 721117

RS 627047

-

-

-

-

-

-

Zaragoza

P4 137484

R4 252842

-

-

-

-

-

-

-

-

Recognition Features of Affected Components

Window Winder Motors

Affected electronic window winders designs are shown in illustration F 0357 (cf. also TI-C-10, N-187, 9/1993, "version 4").

Window Winder Motors, Front Doors

(1)   Connection for wiring harness plug

(2)   Electronic unit

(3)   Motor

Window Winder Motors, Rear Doors (with Cable)

(4)   Motor

(5)   Electronic unit

(6)   Connection for wiring harness plug

Defective Electronic Unit

Identification:      ·   black plug plate with white dash (illustration F 0357, bottom right) or

·   black plug plate without identification

Correct Electronic Unit

Identification:      ·   black plug plate with white, green or pink dot - any other coloured dots can be regarded as irrelevant for judging whether units are OK (illus. F 0357, bottom right) - or

·   white plug plate.

Defective Wiring Harness Plug

Identification:      ·   triangle logo (diagram 7, black arrow)/ green wiring harness seal (diagram 7, white arrow)

Correct Wiring Harness Plug:

Identification:      ·   printed with "AMP" (diagram 8, black arrow)

Test Step

Remedial Measure

1   Check window winder motors for which complaints were received

·   Replace defective electronic unit.

·   Note:        On Corsa-B, Astra-F 3‑door, Vectra/Cavalier (rear door), Calibra and Omega-A/Carlton (rear door), the window winders must be removed in order to replace the electronic unit. After replacing the electronic unit according to pp. 14f, reinstall window winder.

2   Check wiring harness plugs

·   If identified with triangle logo and green wiring harness seal, replace wiring harness.

·   If there is noticeable ingress of moisture and/or corrosion on the plug connection, replace the wiring harness and the motor.

3   Check wiring harness routing

·   Should the wiring harness be routed with the cable tension too high, release tension in the wiring harness by loosening cable ties.

·   To prevent wiring harness chafing on sheet metal parts, attach edge protectors.

4   After points 1 - 3

·   Disconnect wiring harness plug from motor electronic unit. Grease O-ring lightly from outside, connect plug and fill plug gap with grease (Grease Cat. No. 19 70 207/ Part No. 90 153 245) to protect it against moisture ingress.

5   Attach identification

·   Each door which has been subjected to points 1-4 must be marked with a black dot if the vehicle paint is white, or a white dot for all other vehicle paint colours, below the door stop bracket on the A or B pillar (illustration F 0492). Illustration F 0492 shows the door stop bracket on the left A pillar.

6  Astra-F only

·   In doors where there were no complaints about the window winders, grease plug connection as described in point 4.

Installation Positions of Affected Components

The following shows the installation positions of the affected window winder motors and wiring harnesses with affected plug connections.

The operations...

·   Door Inner Panelling/Loudspeakers, Remove and Install

·   Window Winder Motors, Remove and Install

·   Wiring Harness, Front/Rear Doors, Remove and Install

...are described in the relevant Service Instructions, "groups C, N, R", and are therefore not given here.

Note:

The water vapour barriers should in general be replaced, see also TI-C-35, C-85, 04/1994 "Water Vapour Barriers".

Corsa-B (3/5-door)

Front Doors

(1)   Window winder motor

(2)   Wiring harness

(3)   Wiring harness plug

·   The wiring harness must be routed free from tensile stress.

·   To replace the electronic unit, remove window winder motor.

Astra-F (3-door)

Front Doors

(1)   Window winder motor

(2)   Wiring harness

(3)   Wiring harness plug

Notes:

·   Route wiring harness tension-free by loosening cable tie (arrow, upper diagram).

·   If not present, attach edge protector to panel edge (arrow, lower diagram).

·   To replace the electronic unit, remove window winder motor.

Astra-F (4/5-door)

Front Doors

(1)   Window winder motor

(2)   Wiring harness

(3)   Wiring harness plug

Notes:

·   Route wiring harness tension-free by loosening cable tie (arrow, upper diagram).

·   If not present, attach edge protector to panel edge (arrow, lower diagram).

·   The electronic unit can be replaced with window winder installed.

Vectra / Cavalier

Front Doors

(1)   Window winder motor

(2)   Wiring harness

(3)   Wiring harness plug

Notes:

·   If not present, attach edge protector to panel edge (arrow, lower diagram).

·   The electronic unit can be replaced with window winder installed.

Vectra / Cavalier

Rear Doors

(1)   Window winder motor

(2)   Wiring harness

(3)   Wiring harness plug

Note:

·   To replace the electronic unit, remove window winder motor.

Calibra

Front Doors

(1)   Window winder motor

(2)   Wiring harness

(3)   Wiring harness plug

Note:

·   To replace the electronic unit, remove window winder motor.

Omega-A / Carlton

Front Doors

(1)   Window winder motor

(2)   Wiring harness

(3)   Wiring harness plug

Notes:

·   The electronic unit can be replaced with window winder installed.

·   Close window halfway.

Omega-A / Carlton

Rear Doors

(1)   Window winder motor

(2)   Wiring harness

(3)   Wiring harness plug

Note:

·   To replace the electronic unit, remove window winder motor.

Designation of Electronic Units:

Electronic units are assigned to the window winder motors according to the stamp on the plug (upper diagram).

The manufacturer no. in the parts table (pp. 16ff) consists of the first six digits of the upper row of digits (arrow, upper diagram).

Replacing the Electronic Unit

Important:   The window winder motor must only be removed for:

front door:  Corsa-B, Astra-F (3‑door), Calibra

rear door:    Vectra/Cavalier, Omega-A/Carlton

Front door:

1.  Unscrew two Torx screws (1) using a Torx screwdriver.

2.  Carefully remove electronic unit (2).

3.  If necessary, remove seal remnants at installation location of electronic unit.

4.  Install new electronic unit:

·   Correct Part No. according to tables, pp. 16ff.

·   Grasping the plug with two fingers (illustration), carefully remove from package and insert in guide (3) without tilting.

·   Do not touch or soil the electronics.

5.  Screw in both Torx screws using a Torx screwdriver. Hand‑tighten Torx screws, do not over-tighten.

Rear Door:

1.  Remove control cable guide clip (1) by driving through the two pins (2).

2.  Unscrew two Torx screws (3) using a Torx screwdriver.

3.  Remove electronic unit (4) up to stop along direction A, then tilt along direction B, until it can be removed.

4.  If necessary, remove seal remnants at installation location of electronic unit.

5.  Install new electronic unit:

·   Correct Part No. according to tables, pp. 16ff.

·   Do not touch or soil the electronics.

·   Grasping the plug with two fingers (illustration), carefully remove from package and insert back in guide in reverse order of point 3.

·   Introduce electronic unit in guide (5) without tilting.

6.  Screw in both Torx screws using a Torx screwdriver.

Hand‑tighten Torx screws, do not over-tighten.

7.  Re-fasten the control cable gide clip by pressing in both pins.

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 387 367

(Driver's side)

12 95 953

(Driver's side)

90 511 873

(left door)

90 94 704

(left door)

105708

(left door)

90 387 373

(Co-driver's side)

12 95 954

(Co-driver's side)

90 511 874

(right door)

90 94 705

(right door)

105709

(right door)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 481 606

(Driver's side)

12 96 193

(Driver's side)

90 511 875

(left door)

90 94 706

(left door)

111159

(left door)

90 481 609

(Co-driver's side)

12 96 192

(Co-driver's side)

90 511 876

(right door)

90 94 707

(right door)

111160

(right door)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 450 083

(Driver's side)

12 96 163

(Driver's side)

90 511 869

(left door)

90 94 700

(left door)

103740

(left door)

90 450 197

(Co-driver's side)

12 96 162

(Co-driver's side)

90 511 870

(right door)

90 94 701

(right door)

103741

(right door)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 450 985

(Driver's side)

12 96 420

(Driver's side)

90 511 869

(left door)

90 94 700

(left door)

103740

(left door)

90 451 273

(Co-driver's side)

12 96 439

(Co-driver's side)

90 511 870

(right door)

90 94 701

(right door)

103741

(right door)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 450 086

(Driver's side)

12 96 161

(Driver's side)

90 511 871

(left door)

90 94 702

(left door)

103744

(left door)

90 450 203

(Co-driver's side)

12 96 160

(Co-driver's side)

90 511 872

(right door)

90 94 703

(right door)

103745

(right door)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 450 987

(Driver's side)

12 96 421

(Driver's side)

90 511 871

(left door)

90 94 702

(left door)

103744

(left door)

90 451 277

(Co-driver's side)

12 96 440

(Co-driver's side)

90 511 872

(right door)

90 94 703

(right door)

103745

(right door)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 461 478

(Driver's side)

12 95 726

(Driver's side)

90 511 858

(left door)

90 94 690

(left door)

191415

(left door)

90 451 903

(Co-driver's side)

12 95 730

(Co-driver's side)

90 511 859

(right door)

90 94 691

(right door)

191416

(right door)

90 357 907

(rear door, left)

12 95 362

(rear door, left)

90 511 860

(rear door, left)

90 94 692

(rear door, left)

193279

(rear door, left)

90 357 907

(rear door, right)

12 95 362

(rear door, right)

90 511 861

(rear door, right)

90 94 693

(rear door, right)

193278

(rear door, right)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 461 479

(Driver's side)

12 95 727

(Driver's side)

90 511 858

(left door)

90 94 690

(left door)

191415

(left door)

90 357 904

(Co-driver's side)

12 95 729

(Co-driver's side)

90 511 859

(right door)

90 94 691

(right door)

191416

(right door)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 357 912

(Driver's side)

12 95 725

(Driver's side)

90 511 867

(left door)

90 94 698

(left door)

193280

(left door)

90 357 917

(Co-driver's side)

12 95 728

(Co-driver's side)

90 511 868

(right door)

90 94 699

(right door)

193281

(right door)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 377 833

(Driver's side)

12 95 084

(Driver's side)

90 511 863

(left door)

90 94 694

(left door)

113163

(left door)

90 458 459

(Co-driver's side)

12 95 723

(Co-driver's side)

90 511 864

(right door)

90 94 695

(right door)

113164

(right door)

90 379 934

(rear door, left)

12 95 441

(rear door, left)

90 511 865

(rear door, left)

90 94 696

(rear door, left)

113168

(rear door, left)

90 379 934

(rear door, right)

12 95 441

(rear door, right)

90 511 866

(rear door, right)

90 94 697

(rear door, right)

113167

(rear door, right)

Wiring harness

Electronic unit

Part Number

Catalogue Number

Part Number

Catalogue Number

Manufacturer's Number

90 377 828

(Driver's side)

12 95 082

(Driver's side)

90 511 863

(left door)

90 94 694

(left door)

113163

(left door)

90 458 458

(Co-driver's side)

12 95 722

(Co-driver's side)

90 511 864

(right door)

90 94 695

(right door)

113164

(right door)

Operation No

Corsa-B

Astra-F

Calibra

Vectra/

Cavalier

Omega-A/

Carlton

Condition

Remedy

(includes checking cable, plug and electronic unit, and greasing plug)

One door, repair

Plug, grease, 2nd door

FD

RD

FD

RD

Plug

Corro - sion

Elec- tronic unit

Trouble Code TC

3-dr.

5-dr.

3-dr. and 5-dr.

n.o.k.

No

n.o.k.

T 0339 00

92

Cable and Electronic Unit - Replace

1.2

1.2

.8

.3

1.2

.7

1.0

.7

1.1

n.o.k.

Yes

n.o.k.

T 0339 01

92

Cable and Electronic Unit - Replace

1.2

1.2

.8

.3

1.2

.7

1.0

.7

1.1

n.o.k.

No

o.k.

T 0339 02

92

Cable - Replace

.7

.7

.7

.3

.7

.6

.6

.7

.7

n.o.k.

Yes

o.k.

T 0339 03

92

Cable and Electronic Unit - Replace

1.2

1.2

.8

.3

1.2

.7

1.0

.7

1.1

o.k.

No

n.o.k.

T 0339 04

92

Electronic Unit - Replace

.8

.8

.4

.3

.8

.4

.7

.5

.8

o.k.

Yes

n.o.k.

T 0339 05

92

Cable and Electronic Unit - Replace

1.2

1.2

.8

.3

1.2

.7

1.0

.7

1.1

o.k.

Yes

o.k.

T 0339 06

92

Cable and Electronic Unit - Replace

1.2

1.2

.8

.3

1.2

.7

1.0

.7

1.1

Operation No.

Trouble Code

Operation

Time Allowance

W 1000 00

TC 99

Vehicle from Parked Location and Back

.2