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Vauxhall Workshop Service and Repair Manuals

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Engine Control Module Wiring Harness Replacement - 1.6 LDE, LXV, 1.8L 2H0 > < Starter Replacement - LBS with Start/Stop System

Astra J

Engine Control Module Wiring Harness Replacement (1.6L LLU)

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement .
4. If equipped, remove the headlamp washer nozzle hose. Refer to Headlamp Washer Nozzle Hose Replacement .

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5. If equipped, disconnect the engine oil level sensor wiring harness plug (7).
6. Disconnect the generator wiring harness plug (5).
7. Remove the starter positive cable nut (8) and remove the starter positive cable.
8. Unclip the heated oxygen sensor connection from the bracket (9) and disconnect the heated oxygen sensor wiring harness plug (3).
9. Disconnect the knock sensor wiring harness plug (4).
10. Unclip the 2 wiring harness clips (2, 6) from the wiring harness brackets.
11. Disconnect the crankshaft position sensor wiring harness plug (1) and hang the wiring harness aside.
12. Lower the vehicle.

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13. Disconnect the barometric pressure sensor wiring harness plug (2).
14. Disconnect the charge air bypass regulator solenoid valve wiring harness plug (3) and unclip the 2 wiring harness clips (1, 4).

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15. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .
16. Unclip the wiring harness clip (4) from the bracket and disconnect the engine coolant temperature sensor wiring harness plug (2).
17. Disconnect the coolant thermostat wiring harness plug (5) and disconnect the camshaft position sensor wiring harness plug (6).
18. Unclip the 2 wiring harness clips (7) from the bracket and disconnect the heated oxygen sensor wiring harness plug (8).
19. Unclip the wiring harness clip (1).
20. Remove the wiring harness ground bolt (3) and remove the wiring harness ground cable (9).

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21. Disconnect the 2 engine control module wiring harness plugs (3) from the engine control module (4).
22. Unclip the 3 wiring harness plugs (1, 2).
23. Remove the engine control module bracket along with the engine control module in top direction.
24. Remove the battery tray. Refer to Battery Tray Replacement .
25. Remove the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement .

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26. Remove the wiring harness ground cable nut (2) and remove the wiring harness ground cable (3).
27. Remove the wiring harness plug (1) in top direction.
28. Disconnect the wiring harness connection adapter plug (4).

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29. Unclip the transmission wiring harness clip (1) and disconnect the transmission wiring harness plug (2).

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30. Disconnect the air conditioning compressor wiring harness plug (5).
31. Disconnect the turbocharger wastegate regulator solenoid valve wiring harness plug (2).
32. Unclip the wiring harness clip (3) from the radiator outlet hose (4).
33. Unclip the wiring harness clip (1).

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34. Disconnect the mass air flow sensor wiring harness plug (5) and unclip the wiring harness clip (2) in top direction from the air cleaner housing (1).
35. Disconnect the positive crankcase ventilation pipe connector (4) and unclip the 2 wiring harness clips (3).

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36. Disconnect the evaporative emission purge solenoid valve wiring harness plug (5) and disconnect the manifold absolute pressure sensor wiring harness plug (7).
37. Unclip the 3 engine wiring harness clips (4, 6).
38. Unclip the 2 engine wiring harness conduits (2) in top direction.
39. Disconnect the ignition coil wiring harness plug (1) and disconnect the 4 injector wiring harness plugs (3).
40. Remove the engine control module wiring harness from the vehicle.

Installation Procedure


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1. Position the engine control module wiring harness to the vehicle.
2. Connect the ignition coil wiring harness plug (1) and connect the 4 injector wiring harness plugs (3).
3. Clip in the 2 engine wiring harness conduits (2) to the camshaft cover.
4. Clip in the 3 engine wiring harness clips (4, 6).
5. Connect the evaporative emission purge solenoid valve wiring harness plug (5) and connect the manifold absolute pressure sensor wiring harness plug (7).

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6. Connect the positive crankcase ventilation pipe connector (4) and clip in the 2 wiring harness clips (3).
7. Connect the mass air flow sensor wiring harness plug (5) and clip in the wiring harness clip (2) to the air cleaner housing (1).

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8. Position the wiring harness.
9. Clip in the wiring harness clip (1).
10. Clip in the wiring harness clip (3) to the radiator outlet hose (4).
11. Connect the turbocharger wastegate regulator solenoid valve wiring harness plug (2).
12. Connect the air conditioning compressor wiring harness plug (5).

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13. Clip in the transmission wiring harness clip (1) and connect the transmission wiring harness plug (2).

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14. Connect the wiring harness connection adapter plug (4).
15. Install the wiring harness plug (1) to the front compartment fuse block.
16. Install the wiring harness ground cable (3).

Caution: Refer to Fastener Caution .
17. Install the wiring harness ground cable nut (2) and tighten to 9 N·m (80 lb in) .
18. Install the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement .
19. Install the battery tray. Refer to Battery Tray Replacement .

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20. Install the engine control module bracket along with the engine control module (4) to the battery tray.
21. Clip in the 3 wiring harness plugs (1, 2).
22. Connect the 2 engine control module wiring harness plugs (3) to the engine control module.

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23. Install the wiring harness ground cable (9) and the wiring harness ground bolt (3) and tighten to 8 N·m (71 lb in) .
24. Clip in the wiring harness clip (1).
25. Connect the heated oxygen sensor wiring harness plug (8) and clip in the 2 wiring harness clips (7) to the bracket.
26. Connect the coolant thermostat wiring harness plug (5) and connect the camshaft position sensor wiring harness plug (6).
27. Connect the engine coolant temperature sensor wiring harness plug (2) and clip in the wiring harness clip (4) to the bracket.
28. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .

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29. Clip in the 2 wiring harness clips (1, 4) and connect the charge air bypass regulator solenoid valve wiring harness plug (3).
30. Connect the barometric pressure sensor wiring harness plug (2).
31. Raise the vehicle.

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32. Position the wiring harness.
33. Connect the crankshaft position sensor wiring harness plug (1).
34. Clip in the 2 wiring harness clips (2, 6) to the wiring harness brackets.
35. Connect the knock sensor wiring harness plug (4).
36. Connect the heated oxygen sensor wiring harness plug (3) and clip in the heated oxygen sensor connection to the bracket (9).
37. Install the starter positive cable and the starter positive cable nut (8) and tighten to 12.5 N·m (111 lb in) .
38. Connect the generator wiring harness plug (5).
39. If equipped, connect the engine oil level sensor wiring harness plug (7).
40. If equipped, install the headlamp washer nozzle hose. Refer to Headlamp Washer Nozzle Hose Replacement .
41. Install the charge air cooler outlet air hose. Refer to Charge Air Cooler Outlet Air Hose Replacement .
42. Lower the vehicle.
43. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Engine Control Module Wiring Harness Replacement - 1.6 LDE, LXV, 1.8L 2H0 > < Starter Replacement - LBS with Start/Stop System