Astra J
Body Wiring Harness Replacement (Wagon 35 - Left Hand Drive)Special Tools
For equivalent regional tools, refer to Special Tools . Removal Procedure
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Note: For a better description the following graphic shows the vehicle without attaching parts.
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Note: Arrange a place to embed the removed parts.
1. | Install the MDI, turn on the ignition and read out the trouble codes. |
Delete them and read out the trouble codes again. If there are any trouble codes notice them. |
2. | Open the hood and remove the battery and the battery tray. Refer to Battery Replacement and Battery Tray Replacement . |
3. | Remove the front floor panel carpet. Refer to Front Floor Panel Carpet Replacement . |
4. | Remove the luggage shade. Refer to Luggage Shade Replacement . |
5. | Remove the radio rear compartment speaker. Refer to Radio Rear Compartment Speaker Replacement . |
6. | Remove the rear seat. Refer to Rear Seat Replacement . |
7. | Remove the left and right body lock pillar upper trim panel. Refer to Body Lock Pillar Upper Trim Panel Replacement . |
8. | Remove both rear lamps. Refer to Tail Lamp Replacement . |
9. | Remove the radio speaker amplifier. Refer to Radio Speaker Amplifier Replacement . |
10. | Pass parts in the work area. |
11. | Make pictures for correct orientation. |
12. | Remove the left and right center pillar lower trim panel. Refer to Center Pillar Lower Garnish Molding Replacement . |
13. | Remove the headlining trim panel. Refer to Headlining Trim Panel Replacement . |
14. | Pass parts in the work area. |
15. | Make pictures for correct orientation. |
16. | Lift up the vehicle. Refer to Lifting and Jacking the Vehicle . |
17. | Remove all rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement . |
18. | Disconnect body wiring harness from electrical park brake. |
19. | Remove body wiring harness from fuel tank filler door lock actuator. |
20. | Remove the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement . |
21. | Disconnect body wiring harness from steering gear. |
22. | Pass parts in the work area. |
23. | Make pictures for correct orientation. |
24. | Lift down the vehicle. Refer to Lifting and Jacking the Vehicle . |
25. | Remove the fuse block. Refer to Fuse Block Replacement . |
26. | Remove the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement . |
27. | Pass parts in the work area. |
28. | Make pictures for correct orientation. |
29. | Remove the brake, accelerator, and clutch pedal. Refer to Brake, Accelerator, and Clutch Pedal Replacement . |
30. | Remove the left and right instrument panel upper outer trim panel. Refer to Instrument Panel Upper Outer Trim Panel Replacement . |
31. | Remove the body wiring harness from roof and a-pillars. |
32. | Remove the body wiring harness (1) from roof to interior by means off the hole from instrument panel upper outer trim panel on left and right side. |
33. | Release the X1 (1) plug connector from the a-pillar. Use BO-569-A plug lifter . |
34. | Release all fixations. |
35. | Take care about destroyed cable straps and harness guidance regarding noises and rattle. |
36. | Remove the body wiring harness guidance in the bulkhead and draw-out the body wiring harness from the engine compartment through the passenger compartment. |
37. | Remove the old body wiring harness and lay it on the floor. |
38. | Unpack the new body wiring harness and compare the old with the new harness concerning quantity of fixing points, cable straps, guides, part numbers and pin assignments. |
Installation Procedure
1. | After comparing the new with the old harness lay the new body wiring harness into the passenger compartment and carry the new harness trough the bulkhead into the engine compartment. |
Note: Take care for the leak tightness. |
2. | Then install the wiring harness guidance in the bulkhead. |
3. | Now check that there is no rotation and fix the new body wiring harness. |
Note: Take care for the correct counterpart and the pin assignment. Use the pictures for orientation. |
4. | Connect all electrical connectors. |
Caution: Refer to Fastener Caution . |
5. | Tighten all mass cables to the weld studs with 9 N·m (80 lb in) . |
6. | Install the body wiring harness (1) from interior to roof by means off the hole from instrument panel upper outer trim panel on left and right side. |
7. | Install the body wiring harness to roof and a-pillars. |
8. | Install the left and right instrument panel upper outer trim panel. Refer to Instrument Panel Upper Outer Trim Panel Replacement . |
9. | Install the brake, accelerator, and clutch pedal. Refer to Brake, Accelerator, and Clutch Pedal Replacement . |
10. | Show pictures for correct orientation. |
11. | Install the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement . |
12. | Install the fuse block. Refer to Fuse Block Replacement . |
13. | Lift up the vehicle. Refer to Lifting and Jacking the Vehicle . |
14. | Show pictures for correct orientation. |
15. | Connect body wiring harness to steering gear. |
16. | Install the windshield washer solvent container. Refer to Windshield Washer Solvent Container Replacement . |
17. | Install body wiring harness to fuel tank filler door lock actuator. |
18. | Connect body wiring harness from electrical park brake. |
19. | Install all rear wheelhouse panel liner. Refer to Rear Wheelhouse Panel Liner Replacement . |
20. | Lift down the vehicle. Refer to Lifting and Jacking the Vehicle . |
21. | Show pictures for correct orientation. |
22. | Install the headlining trim panel. Refer to Headlining Trim Panel Replacement . |
23. | Install the left and right center pillar lower trim panel. Refer to Center Pillar Lower Garnish Molding Replacement . |
24. | Install the radio speaker amplifier. Refer to Radio Speaker Amplifier Replacement . |
25. | Install both rear lamps. Refer to Tail Lamp Replacement . |
26. | Install the left and right body lock pillar upper trim panel. Refer to Body Lock Pillar Upper Trim Panel Replacement . |
27. | Install the rear seat. Refer to Rear Seat Replacement . |
28. | Install the radio rear compartment speaker. Refer to Radio Rear Compartment Speaker Replacement . |
29. | Install the luggage shade. Refer to Luggage Shade Replacement . |
30. | Install the front floor panel carpet. Refer to Front Floor Panel Carpet Replacement . |
31. | Install the battery tray. Refer to Battery Tray Replacement . |
32. | Install the MDI, turn on the ignition and read out the trouble codes. |
If there are any stored DTCs delete them and read out the trouble codes again. |
33. | Aim the headlamps. Refer to Headlamp Aiming . |
34. | Program the volatile memory and then check all electrical functions and make a test run. |
35. | Clean the car outside and inside. |