Electronic Window Winders Opel Corsa B

This TI replaces TI - C - 84, N - 207 dated 8 / 1994; TI - C - 84 is to be destroyed

Subject:

Electronic Window Winders

Attention: Compared with TI - C - 84, the following information is new:

· new breakpoints within the paragraph "affected vehicles" (see page 2).

· only Electronic Unit with white plug plate is correct (see page 3).

· on Corsa - B, Astra - F and Omega - B not only the defective door, but all doors with electronic window winders have to be checked.

Vehicles:

Corsa - B, Astra - F, Vectra / Cavalier, Calibra, Carlton, Omega - B with electronic window winders (see page 3).

Condition:

Window opens by itself or electronic window winder does not function

Causes:

· Wiring harness routing causing excessive mechanical tension, leading to water ingress to wiring harness plug connection to electronic motor unit.

· Water ingress to wiring harness plug connection to electronic motor unit due to faulty wiring harness plug.

· Moisture ingress to electronic motor unit.

Remedy:

In general, the test steps and remedial measures shown on page 4 and 5 are to be implemented free of charge for the customer if the Vehicle Ident. No. is included in the following table and if the vehicle Is not older than 3 years following the initial registration.

Affected vehicles:

Affected are ail vehicles with Vehicle Ident. No. included in the following list.

In case of failiure, remedy for vehicles not included as described in the Service Instructions (Electronic Unit must not be exchanged).

Corsa - B P4 137484 - R4 398808 / P6 000001 - S6 000012

Astra - F * P2 735251 - R2 745849 / P5 267269 - S5 001591 / P8 199094 - R8 213230 / PS 721117 - RS 736078

Vectra / Cavalier P1 222378 - S1 001944 / P5 329080 - S5 001381 / P7 632766 - R7 626719

Calibra R1 047808 - S1 001953 / R9 002660 - R9 007690

Carlton P1 236137 - P1 251264

Omega - B R1 000001 - S1 001955

* Vehicle Variants see pages 19 and 20

Recognition Features of Affected Components

Window Winder Motors

Affected electronic window winders desings are shown in illustration F 5405 (cf. also TI - C - 10, N - 187, 9 / 1993, "version 4")

Window Winder Motors, Front Doors

(1) Connection for wiring harness plug

(2) Electronic unit

(3) Motor

Window Winder Motors, Rear Doors (with cable)

(4) Motor

(5) Electronic unit

(6) Connection for wiring harness plug

Defective Electronic Unit

Identification:

· black plug plate (8)

· with or without colour dot identification.

Correct Electronic Unit

Identification:

· white plug plate (7)

Detective Wiring Harness Plug

Identification:

· triangle logo (9, arrow)

Correct Wiring Harness Plug

Identification:

Notes, Test Steps and Remedial Measures

Note:

·Electronic units from warrehouse stock, that are designated as defective, must not be used.

· Replace Electronic unit, if designated as defective (black plug plate).

Note: On Corsa - B, Astra - F (3door), Vectra / Cavalier (rear door), Calibra and Omega - A / Carlton (rear door), the window winders must be removed in order to replace the electronic unit. After replacing the electronic unit re - install window winder according to pp. 16 and 17.

· If identified with triangle logo, replace wiring harness.

· If there is noticeable ingress of moisture and / or corrosion on the plug connection, replace the wiring harness and the electronic unit.

· Should the wiring harness be routed with the cable tension too high, release tension in the wiring harness by loosening cable ties.

· To prevent wiring harness chaving on sheet metal parts, attach edge protectors.

· Disconnect wiring harness plug from motor electronic unit. Grease O - ring lightly from outside connect plug and fill plug gap with grease (Part - No.: 90 513 245) to protect it against moisture ingress.

· Reprogram Window winder (Close the window completely by holding down the relevant rocker switch. Once the window is dosed, the rocker switch must be held down for another 5 seconds).

Test Step 5 Attach colour identification

Each door which has been subjected to points 1 - 4 must be marked with a black dot if the vehicle paint is white, or a white dot for all other vehicle paint colours, below the door stop bracket on the A or B pillar (illustration F 0492).

Illustration F 0492 shows the door stop bracket on the left A pillar.

Installation Positions of Affected Components

The following shows the installation positions of the affected window winder motors and wiring harnesses with affected plug connections.

The operations...

· Door Inner Panelling / Loudspeakers; Remove and Install

· Window Winder Motors, Remove and Install

· Wiring Harness, Front / Rear Doors, Remove and Install

.. are described in the relevant Service Instructions, "group C, N, R", and are therefore not given here.

Note:

The water vapour barriers should in general be replaced, see also TI - C - 35, C - 85, 04 / 1994 "Water Vapour Barriers".

Corsa - B (3 / 5 - door)

Front Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Notes:

· The wiring harness must be routed free from tensile stress

Astra - F (3 - door)

Front Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Notes:

· Route wiring harness tension - free by loosening cable tie (arrow, upper diagram).

· If not present, attach edge protector to panel edge (arrow, lower diagram)

Astra - F (4 / 5 - door)

Front Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Notes:

· Route wiring harness tension - free by loosening cable tie (arrow, upper diagram).

· If not present, attach edge protector to panel edge (arrow, lower diagram)

Vectra / Cavalier

Front Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Notes:

· If not present, attack edge protector to panel edge (arrow, lower diagram)

Rear Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Note:

Front Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Note:

Front Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Notes:

· The electronic unit can be replaced with the window winder installed..

Rear Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Note:

Omega - B

Front Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring harness plug

Notes:

· The electronic unit can be replaced with the window winder installed.

Omega - B

Rear Doors

(1) Window winder motor

(2) Wiring harness

(3) Wiring - harness plug

Note:

· The electronic unit can be replaced with the window winder installed.

Identification of Electronic Units:

Electronic units are assigned to the window winder motors according to the stamp on the plug (upper diagram).

The manufacturer No. in the parts tables (see pages 18 to 24) consists of the first six digits of the upper row of digits.

Replacing the Electronic Unit:

Important: The window winder motor must only be removed for:

Front door:

Corsa - B, Astra - F (3door),

Calibra Rear door:

Vectra / Cavalier, Omega - A / Carlton

Front door:

1. Unscrew two Torx screws (1) using a Torx screwdriver.

2. Carefully remove electronic unit (2).

3. If necessary, remove seal remnants at installation location of electronic unit. 4. Install new electronic unit:

· Correct Part - No. according to tables on pages 18 to 24.

· Grasping the plug with two fingers (illustration), carefully remove from package and insert in guide (3) without tilting.

· Do not touch or soil the electronics.

5. Screw in both Torx screws using a Torx screwdriver.

Rear door:

1. Remove control cable guide clip (1) by driving through the two pins (2).

2. Unscrew two Torx screws (3) using a Torx screw driver.

3. Remove electronic unit (4) up to stop along direction A, then tilt along direction B, until it can be removed.

4. If necessary, remove seal remnants at installation location of electronic unit.

5. Install new electronic unit:

· Correct Part No. according to tables on pages 18 to 24..

· Do not touch or soil the electronics

· Grasping the plug with two fingers (illustration), carefully remove from package and insert back in guide (5) in reverse order of point 3.

· Introduce electronic unit in guide (5) without tilting.

6. Screw in both Torx screws using a Torx screwdriver.

Hand - tighten Torx screws, do not over - tighten.

Parts:

Only if required: Screws, self cutting; electronic unit at motor, window winder

Part No.: 90 511906

Vehicle Type: Corsa - B, 2 door

90387367

90387373

Vehicle Type: Corsa - B, 4 door

90 481 606

90 481 609

Vehicle Type: Astra - F, 2 door

Chassis No.: P 2500001 - P 2732523 / P 3000001 - P 3027239 / P 4000001 - / P 5000001 - P 5266210 / P 6000001 - P 6015261 / P 8100001 - P 8204569

90 450 083

90 451 273

Vehicle Type: Astra - F, 2 door

Chassis No.: P 2732524 - / P 3027240 - / P 5266211 - / P 6015262 - / P 8204570 -

90 450 985

90 451 273

Vehicle Type: Astra - F, 4 door

Chassis No.: P 2500001 - P 2733421 / P 8000001 - P 3027239 / P 4000001 - / P 5000001 - P 5266210 / P 6000001 - P 6015261 / P 8100001 - P 8202669

90 450 086

90 450 203

Vehicle Type: Astra - F, 4 door

Chassis No.: P 2733422 - / P 3027240 - / P 5266211 - / P 6015262 - / P 8202670 -

90 450 087

90 451 277

Vehicle Type: Vectra / Cavalier, 4 - and 5 door

90 461 478

90 357 903

90 357 907

90 357 907

Vehicle Type: Calibra, 3 door

90 357 912

90 357 917

Vehicle Type: Carlton, 4 - and 5 door

90 377 833

90 458 459

90 379 934

90 379 934

Vehicle Type: Omega - B, 4 - and 5 door

90 540 298

90 540 297

Vehicle Type: Omega - B, 4 - and 5 door

driver

co - driver

Time Allowence - Corsa - B, Astra - F and Omega - B

TC: 92

0.9

Astra - F

TC: 92

+: door trims R + R, replace water vapour barriers, check and grease wiring harnesses and electronic units, reprogram window winder, mark doors

0.3

0.5

Astra - F

Omega - B, FD

0.1

0.3

0.1

Astra - F (3 door)

Astra - F (5 door)

Omega - B, FD

0.7

0.4

0.6

Astra - F (3door)

Astra - F (5door)

Omega - B, FD

FD = Front Door

RD = Rear Door

Time Allowence - Cavalier, Calibra and Carlton

TC: 92

0.6

0.6

0.7

Cavalier, FD

Cavalier, RD

Carlton, FD

TC: 92

0.4

0.7

0, 5

Cavalier, FD

Cavalier, RD

Carlton, FD

TC: 92

+: door trims, R + R, replace water vapour barriers, check and grease wiring harnesses and electronic units, reprogram window winder, mark door

0.7

1.0

0.7

Cavalier, FD

Cavalier, RD

Carlton, FD

Carlton, RD

0.6

0.6

0.7

Cavalier, FD

Cavalier, RD

Carlton, FD

0.4

0.7

0.5

Cavalier, FD

Cavalier, RD

Carlton, FD

0.7

1.0

0.7

Cavalier, FD

Cavalier, RD

Carlton, FD

FD = Front Door

RD = Rear Door N. B These allowances do not include the 0.2 hours set up time