X20dtl Motor Manual

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  • Service Repair Manual: Year: 1998-2000: Engine code: X20DTL: Engine size: 1995ccm: Power: 60kw: Idle speed: 820-920rpm: Compression: 25.0-28.0bar: Thermostat opens: 92℃ Cylinder head tightening torque 1: 25Nm: Cylinder head tightening torque 2: 65° Cylinder head tightening torque 3: 65° Cylinder head tightening torque 4: 65° Cylinder head.
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Subject:

Wiring harness repair - front wiring harness

Vehicles:

Astra-G, LHD, X 20 DTL with fossil heater

Condition:

The front wiring harness is connected with the heater wiringharness level with the engine cooling module control unit using crimps. Thissupplies the heater control unit with the 'IGNITION ON' signal(Terminal 15A).

This crimped connection must be re-manufactured whenreplacing the front wiring harness.

This Technical Information Bulletin describes this wiringharness repair as additional work for the operation 'Wiring Harness -Front, Replace'.

Additional work for 'Wiring Harness - Front, Replace'

1. Open grooved pipe level with engine cooling module.

2. Cut black cable (0.5 mm2) between wiring harness plug X2, terminal 84 and the control unit for the A19 engine cooling module, terminal 15, approx. 15 cm away from A19 unit plug and strip cable ends.

3. Slide heat shrink tube (printed with RBK-1, packaging marked red) over one cable end (1).

4. Insert the cable ends of the detached connnection together with stripped ends of the heater wiring harness (black 0.5 mm2) in one side of the cable connector (embossed with '1', packaging marked red) (2) and crimp using Crimping Pliers MKM-923-31 (red) as specified in 'Wiring Harness Repair' brochure.

5. Crimp remaining cable ends (1) analogously.

6. Slide heat shrink tubing centrally over cable connector and shrink with hot air drier and reflector nozzle until sealing compound emerges on both sides.

7. In addition, insulate repaired cable with commercially available plastic or textile tape, insert in grooved pipe and seal grooved pipe.


Parts:

Designation

Part no.

Catalogue no.

Heat shrink tubing (print RBK-1, packaging marked red)

90 543 866

12 86 664

Heat shrink tubing (print RBK-1, packaging marked red)

90 543 876

12 86 667

Adhesive tape

90 241 170

22 37 980

Time Allowances:

N 4515 99

Wiring Harness - Front, Replace'

3.7 hrs

TC: 88

+: Front panelling, both headlamps, battery, R + R battery, Reprogram Volatile Memories, Headlamp, Adjust

In addition:

001

Wiring repair kit for 3 cable ends

.3 hrs

X 20 DTL

The specified time allowances do not include the timeallowance for the vehicle set-up of .2 hrs.

For reimbursement of the vehicle set-up time of .2 hrs inwarranty claims, enter the authorisation code ”T” and increase the mainoperation time allowance by .2 hrs.

The authorisation code may be used once per work order. Itmay only be used more than once if the workplace and workteam are changed atthe same time