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Ignition Lock Cylinder Replacement > < Rear Body Fuse Block Replacement - Estate 35

Astra J

Body Wiring Harness Replacement (Wagon 35 - Right Hand Drive)

Special Tools

•  BO-569-A   Plug Lifter
•  EL-47955   Multi Diagnostic Interface MDI

For equivalent regional tools, refer to Special Tools .

Removal Procedure


Note:  For a better description the following graphic shows the vehicle without attaching parts.



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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 tray. Refer to 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 tail 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. Raise and support 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. Lower 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 instrument panel compartment. Refer to Instrument Panel Compartment 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.

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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.

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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.

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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) .

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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 instrument panel compartment. Refer to Instrument Panel Compartment 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. Raise the vehicle.
14. Use 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. Lower the vehicle.
21. Use 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 vehicle out- and inside.

Ignition Lock Cylinder Replacement > < Rear Body Fuse Block Replacement - Estate 35