vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Engine Electrical|Description and Operation > < Generator Replacement - 1.3L Diesel LSF

Astra J

Engine Control Module Wiring Harness Replacement (LSF without Start/Stop System)

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
3. Remove the battery tray. Refer to Battery Tray Replacement .
4. Remove the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement .

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5. Remove the electronic steering pump ground cable nut (1).
6. Remove the 2 electronic steering pump ground cables (2).

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7. Remove the windshield washer solvent container filler tube (1).

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8. Unclip the 3 wiring harness plugs (3).
9. Disconnect the wiring harness plug from the front compartment fuse block.

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10. Remove the 3 ground nuts (1).

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11. Disconnect the 2 wiring harness plugs (1, 2).
12. Disconnect the positive crankcase ventilation pipe connector wiring harness plug.
13. Disconnect the oxygen sensor plug from the engine control module wiring harness.

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14. Disconnect the air conditioning compressor wiring harness plug (3).
15. Disconnect the exhaust temperature sensor wiring harness plug (5).
16. Unclip the retainer clip (4) from the exhaust temperature sensor wiring harness bracket.
17. Disconnect the turbocharger wastegate sensor wiring harness plug (2).
18. Unclip the retainer clip (6) from the oil filter housing.
19. Disconnect the turbocharger wastegate actuator vacuum control solenoid valve wiring harness plug (1).
20. Unclip the retainer clip from the turbocharger wastegate actuator vacuum control solenoid valve bracket.

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21. Disconnect the camshaft sensor wiring harness plug (1) from the camshaft sensor (3).
22. Unclip the 3 retainer clips from:
  •  Engine lift bracket (5)
  •  Engine sight shield stud bracket (4)
  •  Oil filler tube (2)

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23. Disconnect the 4 fuel injector wiring harness plugs (8).
24. Disconnect the fuel rail sensor wiring harness plug (1).
25. Disconnect the manifold absolute pressure sensor wiring harness plug (2).
26. Disconnect the oxygen sensor wiring harness plug (3).
27. Disconnect the exhaust pressure sensor wiring harness plug (4).
28. Disconnect the throttle body wiring harness plug (5).
29. Remove the 2 wiring harness bracket bolts (6).
30. Unclip the engine control module wiring harness from the radiator inlet hose bracket.
31. Disconnect the glow plug wiring harness connector (7).
32. Disconnect the engine coolant temperature sensor wiring harness plug from the thermostat housing.
33. Disconnect the oil temperature sensor wiring harness plug from the oil temperature sensor.
34. Disconnect the crankshaft position sensor wiring harness plug from the crankshaft position sensor.
35. Disconnect the fuel injection fuel pump wiring harness plug from the fuel injection fuel pump.
36. Disconnect the backup lamp switch wiring harness plug from the backup lamp switch.
37. Unclip the wiring harness retainer clips.
38. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
39. If equipped remove the engine shield. Refer to Engine Shield Replacement .
40. If equipped remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .

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41. Remove the upper turbocharger wastegate actuator pipe (1).
42. Remove the lower turbocharger wastegate actuator pipe (4).
43. Remove the 2 exhaust gas recirculation valve vacuum tank bolts (2).
44. Remove the exhaust gas recirculation valve vacuum tank (3) from the exhaust gas recirculation valve vacuum tank bracket (5).

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45. Unclip the turbocharger wastegate actuator pipe from the turbocharger wastegate actuator pipe clip.
46. Remove the 2 exhaust gas recirculation valve vacuum tank bracket bolts (2).
47. Remove the exhaust gas recirculation valve vacuum tank bracket (1).

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48. Remove the starter positive cable nut (3).
49. Disconnect the generator wiring harness plug (2).
50. Disconnect the exhaust gas recirculation valve wiring harness plug (1).
51. Disconnect the exhaust gas recirculation cooler wiring harness plug (4).
52. Unclip the wiring harness from oil level indicator tube.
53. Unclip the wiring harness from the exhaust gas recirculation cooler.
54. Lower the vehicle.
55. Remove the engine control module wiring harness from the vehicle.

Installation Procedure

1. Position the engine control module wiring harness to the vehicle.
2. Raise the vehicle.

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3. Install the starter positive cable nut (3) and tighten.
4. Clip in the wiring harness to the exhaust gas recirculation cooler.
5. Clip in the wiring harness to the oil level indicator tube.
6. Connect the exhaust gas recirculation cooler wiring harness plug (4).
7. Connect the exhaust gas recirculation valve wiring harness plug (1).
8. Connect the generator wiring harness plug (2).

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9. Install the exhaust gas recirculation valve vacuum tank bracket (1).

Caution: Refer to Fastener Caution .
10. Install the 2 exhaust gas recirculation valve vacuum tank bracket bolts (2) and tighten to 22 N·m (16 lb ft) .

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11. Install the exhaust gas recirculation valve vacuum tank (3) to the exhaust gas recirculation valve vacuum tank bracket (5).
12. Install the 2 exhaust gas recirculation valve vacuum tank bolts (2) and tighten to 8 N·m (71 lb in) .
13. If equipped install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement .
14. If equipped install the engine shield. Refer to Engine Shield Replacement .
15. Lower the vehicle.
16. Clip the wiring harness retainer clips.
17. Connect the backup lamp switch wiring harness plug to the backup lamp switch.
18. Connect the fuel injection fuel pump wiring harness plug to the fuel injection fuel pump.
19. Connect the crankshaft position sensor wiring harness plug to the crankshaft position sensor.
20. Connect the oil temperature sensor wiring harness plug to the oil temperature sensor.
21. Connect the engine coolant temperature sensor wiring harness plug to the thermostat housing.

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22. Connect the glow plug wiring harness connector (7).
23. Clip in the engine control module wiring harness to the radiator inlet hose bracket.
24. Install the 2 wiring harness bracket bolts (6) and tighten to 9 N·m (80 lb in) .
25. Connect the throttle body wiring harness plug (5).
26. Connect the exhaust pressure sensor wiring harness plug (4).
27. Connect the oxygen sensor wiring harness plug (3).
28. Connect the manifold absolute pressure sensor wiring harness plug (2).
29. Connect the fuel rail sensor wiring harness plug (1).
30. Connect the 4 fuel injector wiring harness plugs (8).

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31. Connect the camshaft sensor wiring harness plug (1) to the camshaft sensor (3).
32. Clip in the 3 retainer clips to:
  •  Engine lift bracket (5)
  •  Engine sight shield stud bracket (4)
  •  Oil filler tube (2)
33. Clip in the retainer clip to the turbocharger wastegate actuator vacuum control solenoid valve bracket.

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34. Connect the turbocharger wastegate actuator vacuum control solenoid valve wiring harness plug (1).
35. Clip in the retainer clip (6) to the oil filter housing.
36. Connect the turbocharger wastegate sensor wiring harness plug (2).
37. Clip in the retainer clip (4) to the exhaust temperature sensor wiring harness bracket.
38. Connect the exhaust temperature sensor wiring harness plug (5).
39. Connect the air conditioning compressor wiring harness plug (3).
40. Clip in the oxygen sensor plug to the exhaust pressure sensor bracket and engine control module wiring harness.
41. Connect the positive crankcase ventilation pipe connector wiring harness plug.
42. Connect the positive crankcase ventilation pipe connector (3) to the positive crankcase ventilation oil separator.

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43. Connect the 2 wiring harness plugs (1, 2).

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44. Install the 3 wiring harness (2).
45. Install the 3 ground nuts (1) and tighten to 9 N·m (80 lb in) .

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46. Clip in the 3 wiring harness plugs (3).
47. Connect the wiring harness plug to the front compartment fuse block.
48. Install the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement .

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49. Install the windshield washer solvent container filler tube (1).

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50. Install the 2 electronic steering pump ground cables (2).
51. Install the electronic steering pump ground cable nut (1) and tighten to 9 N·m (80 lb in) .
52. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
53. Install the battery tray. Refer to Battery Tray Replacement .
54. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .

Engine Electrical|Description and Operation > < Generator Replacement - 1.3L Diesel LSF