astra g Headlight Self Leveling investigation

evocarlos

Stupid Bollocks
Staff
ok i started this in my project thread but found it to be a bit over whelming so here it is just the Self Leveling system thread :)

pics
sender and bracket
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000032.jpg


sender plug above fuel tank
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000042.jpg


bracket fitted to rear beam
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000045.jpg


sender + bracket fitted and plugged in
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000047.jpg


loom from outside to inside under back seat
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000055.jpg


it runs down the passenger side of the car to the front foot well
where there is 2 plugs
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000066.jpg


the wires in the rear loom go to the blue plug and stop there
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000077.jpg


other pics for reference
ai556.photobucket.com_albums_ss6_evocarlos1_th_WP_000080.jpgai556.photobucket.com_albums_ss6_evocarlos1_th_WP_000079.jpg

all important wiring diagram
ai556.photobucket.com_albums_ss6_evocarlos1_ASTRAG_ALWR_2_1.jpg


its quite simple if you dont have the wiring already installed its just a case of making a 7 wire loom with a plug to fit the sender
then
  • Pin 1 Ground (terminal 31) ----------------------------------- light switch Pin 12 - (brown)
  • pin 2 Supply voltage (terminal 15) -------------------------- light switch pin 4 - (black)
  • pin 3 Warning lamp ---------------------------------------------instrument cluster pin 15 (Brown / blue)
  • pin 4 Tachometer signal -------------------------------------- instrument cluster pin 27 to (blue /red)
  • pin 5 Diagnosis -------------------------------------------------- Immobilizer control unit PIN (6 brown / white)
  • pin 6 Light signal (pin 56) ------------------------------------ light switch pin 13 (yellow)
  • Pin 7 Output to the actuators ------------------------------ light switch pin 8 - (! cut from switch then connect to sender) (brown / yellow)
  • Pin 8 -------------------------------------------------- ------- Not used
ai556.photobucket.com_albums_ss6_evocarlos1_th_speedoplug_1.jpgai556.photobucket.com_albums_ss6_evocarlos1_th_imb.jpgai556.photobucket.com_albums_ss6_evocarlos1_th_headlightswitchplug.jpgai556.photobucket.com_albums_ss6_evocarlos1_th_lichtschaltersteckerpj1_1.jpg
 
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evocarlos

Stupid Bollocks
Staff
spare pin from a speedo plug came from a scrap yard
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000119.jpg


just remember to remove the red runner or the wire wont go all the way in
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000120.jpg


applied 12v to the wire to test for an LED seams there was one there already :)
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000121.jpg


heres the 7 wires that need extending to make the system work
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000123.jpg
 

Dave One

Regular Member
Great work Carl,

I'm hoping to do this soon too, but I need to re-manufacture the leveler bracket on my lower spec'd G :(.
 

evocarlos

Stupid Bollocks
Staff
Great work Carl,

I'm hoping to do this soon too, but I need to re-manufacture the leveler bracket on my lower spec'd G :(.
thanks :)
do you have the brake ballast adjuster ?

Excellent mods there.

What do the yellow wires in your last pic connect up to on the drivers side?
thanks
well i only had yellow and black wires about the place that i had left over from making the power leads on my pc so use up what i had of them
all wires go over to the drivers side
2 for speedo
1 for steering collum
4 for headlight switch
see next post :)
 

evocarlos

Stupid Bollocks
Staff
speedo wires
blue/red = tachometer signal
brown/blue = warning lamp (this was the added pin to the speedo)
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000129.jpg


this image is bad but just to show the loom placement
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000131.jpg


tachometer cable in and solderd
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000133.jpg


headlight switch
yellow to yellow = Light signal
black to brown = Ground
yellow to brown/yellow = Output to the actuators
black to black = Supply voltage
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000135.jpg


loom tided with conduit and fixed in place
just one wire left the connecting to the imobilizer for tech2 connection
i used 2 zip ties to hold the sprung loaded shroud in place while im working
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000136.jpg


ignore the scotch blocks there for the automatic wipers :)


next step
finish wiring and test
 

Dave One

Regular Member
do you have the brake ballast adjuster ?

Unfortunately, I do :(.

I have sourced the auto-leveler and the even rarer headlight switch with the manual adjuster blanked out. Went out to survey what needed doing to realise the brake balancing valve is in the way :(. Teach me to not have ABS...

Thanks for sharing your hard work, it is appreciated by many :).
Dave
 

evocarlos

Stupid Bollocks
Staff
Unfortunately, I do :(.

I have sourced the auto-leveler and the even rarer headlight switch with the manual adjuster blanked out. Went out to survey what needed doing to realise the brake balancing valve is in the way :(. Teach me to not have ABS...

Thanks for sharing your hard work, it is appreciated by many :).
Dave
give me the head light switch NOW lol :)
i have a sender plug for you do you need one ? its just the plug with about 20cm of wire would need extending for use
so i take it you will have to make a bracket to support the sender then drill and screw the beam bracket ?
 

Dave One

Regular Member
give me the head light switch NOW lol :)

I know what you mean, they hardly ever come up!

i have a sender plug for you do you need one ? its just the plug with about 20cm of wire would need extending for use

Thanks for the offer mate but I have almost exactly the same on the Leveler (from the breakers)

so i take it you will have to make a bracket to support the sender then drill and screw the beam bracket ?

Yep. God knows how but I'll find a way!
 

Dave One

Regular Member
I take it the dash light doesn't clear after they have motored to position? :( (IIRC that light is the 'out of range' isn't it?)
 

evocarlos

Stupid Bollocks
Staff
the dash light is to say the sender is new
but will also come on in a out of range situation
op-com readings
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000139.jpg


255 positions its at 124 so plenty left and not out of range
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000140.jpg
 

Dave One

Regular Member
Very interested in the outcome mate :).

I'll update tomorrow but just put auto headlights into mine today...... Headlight leveling when the weather picks up as its gonna be a nightmare engineering a bracket (anyone want to do it for me? ,lol).
 

evocarlos

Stupid Bollocks
Staff
no joy with op-com software the new ver just would not accept the driver and kept giving plug in usb error so we give up looks like it might be a tech2 jobby
 

astra22bertoneauto

Senior Member
no joy with op-com software the new ver just would not accept the driver and kept giving plug in usb error so we give up looks like it might be a tech2 jobby

If you use a newer version (or different) then i believe you have to update the firmware in the opcom unit too otherwise you get problems. As mine is the china clone version i darent change it.

Is there not some special features or programming options if you enter your ecu security code?

Nice work btw(y)
 

evocarlos

Stupid Bollocks
Staff
If you use a newer version (or different) then i believe you have to update the firmware in the opcom unit too otherwise you get problems. As mine is the china clone version i darent change it.
Is there not some special features or programming options if you enter your ecu security code?
Nice work btw(y)
thanks :) it gets better :)
with op-com his plugin was 1.45 but 2010 software not sure about the firware bit yet i have op-com in the post and will keep playing to see if it can be used
the special features and programming were grayed out

ok well had a chat with a guy at my local vx
and told him for the price of the sender im coming down and your programming it :)
went down after work
got a tec from out the back and i explained what i had done and how it was fitted etc,etc
he then went a fetched the laptop and plugged it in
he had no idea what to do with it but i told him
2004 - astra g - body - headlight alignment\
he went in to programming then i told him 004 then only had 1 error in the log and not 2
he went back a step and clicked calibrate the sender level
4 sec later the dash light went out and it was all working

no error codes :)
ai556.photobucket.com_albums_ss6_evocarlos1_WP_000152.jpg


me and dad had a play when i got back :)
video
ai556.photobucket.com_albums_ss6_evocarlos1_th_WP_20130304_172506Z.jpg
 
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evocarlos

Stupid Bollocks
Staff
forgot to add upon programming body type needs to be set also
001 Saloon
002 Hatchback
Wagon 003
004 Coupe
005 Convertible
 
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