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AFL Retrofit wiring 5-Door ONLY.
#1
[Image: vx.o.c.jpeg]

AFL Retrofit wiring 5-Door ONLY.

Another VXOC First.


****VERY IMPORTANT GM WILL NO LONGER SUPPORT THIS RETROFIT AND THEY WILL NOT SUPPLY A VCI****

This only covers 5-door J's.

This is not a case of swapping wires around on the headlamp plug, there are 2 reasons for this.
1. The wire gauge is different.
2. only a few wires go to the fuse board the rest go inside the car.

So the first thing you need to do is buy some wire and terminals.

I shall give you a list of wire you can choose what ever colours you want but I'll tell you mine and where I got it from in-case you want to follow this a bit better.

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20M White /Red 0.5
20M Brown / White 0.5
20M Grey / Black 0.5
10M Purple / Red 0.5
10M Green / Brown 0.5
10M Green / Purple 0.5
10M White 0.5
10M Blue 0.5
15M Black 0.5

From You are not allowed to view links. Register or Login to view.
15M Purple / Yellow 1.5
10M Yellow 1.5
3M Blue / Red 1.5
10M Black / White 1.5
15M Black 1.5

From You are not allowed to view links. Register or Login to view.
12M Blue / Brown 1.0
12M Slate / Blue 1.0

From You are not allowed to view links. Register or Login to view.
10M White / Blue 0.5

Please note I ordered more wire than was needed in case of any mistakes happened.

Terminals were very hard to track down I got them from mouser in the end but was not cheap.

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I ordered 35 of each

You also need to buy the following as I couldn't track the pins outs or the plugs.

2x 93181753 for the levelling sensors.

1x 13314092 for the AFL module connector x2.

You could use the connectors you have for the headlamp but I'd advise you go to a scrap yard and get some from a J or H or you can them new 88988927
The Terminals for these are listed above from Mouser

While you are at the scrap yard you might as well look in the H (Radio area) for the plug needed K28 X1 or you can buy it new 93187174.
The Terminals for this are here You are not allowed to view links. Register or Login to view.

I shall list all the parts that need new wiring below, This will have a picture of the connector and then a table underneath with the wires (I will only list the wires needed).

Headlamp connectors

[Image: E13L.jpg]

PIN Wire Circuit Function
1 1.5 Black 1150 Ground (T4F or T95)
2 Not Used Not Used Not Used
3 1.5 Yellow 712 Left Headlamp Low Beam Supply Voltage (T4F or T95)
4 1.0 Grey / D-Blue 7538 Left Front DRL Supply Voltage (T4F or T95)
5 Not Used Not Used Not Used
6 1.5 Brown / Yellow 189 Headlamp Levelling Motor Supply Voltage (T4F or T95)
7 0.5 D-Green / Brown 7529 Linear Interconnect Network Bus 7 (T4F or T95)
8 1.5 Black 1050 Ground (T4F or T95)
9 1.5 Yellow / Grey 57 Left Cornering Lamp Supply Voltage (T95)
10 1.5 Black 1150 Ground (T4F or T95)

[Image: E13R.jpg]

PIN Wire Circuit Function
1 1.5 Black 1050 Ground (T4F or T95)
2 Not Used Not Used Not Used
3 1.5 Yellow 312 Right Headlamp Low Beam Supply Voltage (T4F or T95)
4 1.0 D-Blue / Brown 7539 Right Front DRL Supply Voltage (T4F or T95)
5 Not Used Not Used Not Used
6 1.5 Brown / Yellow 189 Headlamp Levelling Motor Supply Voltage (T4F or T95)
7 0.5 D-Green / Violet 7528 Linear Interconnect Network Bus 6 (T4F or T95)
8 1.5 Black 1050 Ground (T4F or T95)
9 1.5 Yellow / White 55 Left Cornering Lamp Supply Voltage (T95)
10 1.5 Black 1050 Ground (T4F or T95)


Levelling sensors

[Image: B51F.jpg]

Pin Wire Circuit Function
1 0.5 Black / Grey 7526 Front Axle Level Sensor Low Reference (T4F or T95)
2 0.5 Brown / White 7525 Front Axle Level Sensor Signal (T4F or T95)
3 0.5 White / Red 7524 Front Axle Level Sensor 5 Volt Reference (T4F or T95)

[Image: B51R.jpg]

Pin Wire Circuit Function
1 0.5 Black / Brown 2185 Automatic Level Control Position Sensor Low Reference (T4F or T95)
2 0.5 Brown 2184 Automatic Level Control Position Sensor Signal (T4F or T95)
3 0.5 White / Red 2165 Automatic Level Control Position Sensor 5 Volt Reference (T4F or T95)

Headlamp Levelling Control

[Image: K28X1.jpg]

Pin Wire Circuit Function
1 0.5 Black 1150 Ground (T4F or T95)
2 0.5 White / Red 2165 Automatic Level Control Position Sensor 5 Volt Reference (T4F or T95)
3 0.5 Black / Brown 2185 Automatic Level Control Position Sensor Low Reference (T4F or T95)
4 0.5 White 2501 High Speed GMLAN Serial Data (-) (1) (T4F or T95)
5 0.5 D-Blue 2500 High Speed GMLAN Serial Data (+) (1) (T4F or T95)
6 0.5 Brown 2184 Automatic Level Control Position Sensor Signal (T4F or T95)
7 0.5 White / D-Blue 5986 Serial Data Communication Enable (T4F or T95)
8 Not Used Not Used Not Used
9 Not Used Not Used Not Used
10 0.5 Red / Violet 1242 Battery Positive Voltage (T4F or T95)
11 0.5 White / Red 7524 Front Axle Level Sensor 5 Volt Reference (T4F or T95)
12 0.5 Black / Grey 7526 Front Axle Level Sensor Low Reference (T4F or T95)
13 Not Used Not Used Not Used
14 Not Used Not Used Not Used
15 0.5 Brown / White 7525 Front Axle Level Sensor Signal (T4F or T95)
16 Not Used Not Used Not Used
17 0.5 D-Green / Violet 7528 Linear Interconnect Network Bus 6 (T4F or T95)
18 0.5 D-Green / Brown 7529 Linear Interconnect Network Bus 7 (T4F or T95)

[Image: K28X2.jpg]

Pin Wire Circuit Function
1 1.5 Violet / Yellow 539 Run/Crank Ignition 1 Voltage (T4F or T95)
2 1.5 Violet / Yellow 539 Run/Crank Ignition 1 Voltage (T4F or T95)
3 Not Used Not Used Not Used
4 Not Used Not Used Not Used
5 1.5 Yellow / White 58 Right Cornering Lamp Supply Voltage (T95)
6 1.5 Yellow / Grey 57 Left Cornering Lamp Supply Voltage (T95)


BCM (Body Control Module)

[Image: K9X1.jpg]

Pin Wire Circuit Function
24 0.5 White 2501 High Speed GMLAN Serial Data (-) (1)
25 0.5 D-Blue 2500 High Speed GMLAN Serial Data (+) (1)


[Image: K9X4.jpg]

Pin Wire Circuit Function
1 1.0 D-Blue / Brown 7539 Right Front DRL Supply Voltage (T4F or T95)
2 1.0 Grey / D-Blue 7538 Left Front DRL Supply Voltage (T4F or T95)
23 0.5 White / D-Blue 5986 Serial Data Communication Enable


[Image: K9X5.jpg]

Pin Wire Circuit Function
10 0.35 Brown / Yellow 1970 Headlamp Low Beam Relay Control (T4F or T95)


Engine Fuse board

[Image: X50AX1.jpg]

Pin Wire Circuit Function
15 1.5 Brown / Yellow 189 Headlamp Levelling Motor Supply Voltage (T4F or T95)
50 1.5 Yellow 312 Right Headlamp Low Beam Supply Voltage (T4F or T95)
51 1.5 Yellow 712 Left Headlamp Low Beam Supply Voltage (T4F or T95)


[Image: X50AX2.jpg]

Pin Wire Circuit Function
2 2.5 Violet / Grey 539 Run/Crank Ignition 1 Voltage (T4F or T95)
42 0.35 Brown / Yellow 1970 Headlamp Low Beam Relay Control (T4F or T95)
64 1.5 Red / Yellow 3040 Battery Positive Voltage (T4F or T95)
68 1.5 Red / Yellow 3040 Battery Positive Voltage (T4F or T95)
76 0.5 Red / Violet 1242 Battery Positive Voltage (T4F or T95)


My Wiring info to simplify all the above.

Start Point Function Wire Size / Colour Circuit End Point My Wire Size / Colour Note's
K28 H.C.C.M X1 pin 2 Automatic Level Control Position Sensor 5 Volt 0.5 White / Red 2165 BR51R - Rear Pin 3 0.5 White / Red
K28 H.C.C.M X1 pin 6 Automatic Level Control Position Sensor Signal 0.5 Brown 2184 BR51R - Rear Pin 2 0.5 Brown / White
K28 H.C.C.M X1 pin 3 Automatic Level Control Position Sensor Low Ref 0.5 Black / Brown 2185 BR51R - Rear Pin 1 0.5 Grey / Black
K28 H.C.C.M X1 pin 11 Front Axle Level Sensor 5 Volt Ref 0.5 White / Red 7524 BR51F - Front Pin 3 AS ABOVE
K28 H.C.C.M X1 pin 15 Front Axle Level Sensor Signal 0.5 Brown / White 7525 BR51F - Front Pin 2 AS ABOVE
K28 H.C.C.M X1 pin 12 Front Axle Level Sensor Low Ref 0.5 Black / Grey 7526 BR51F - Front Pin 1 AS ABOVE
X50A Fuse Block X1 pin 15 Headlamp Levelling Motor Supply Voltage 1.5 Brown / Yellow 189 E13R - Right & E13L - Left Pin 6 on both 1.5 Purple / Yellow Splits in headlight harness after Fuse Board
X50A Fuse Block X1 pin 50 Right Headlamp Low Beam Supply Voltage 1.5 Yellow 312 E13R-Right Pin 3 1.5 Yellow
X50A Fuse Block X1 pin 51 Left Headlamp Low Beam Supply Voltage 1.5 Yellow 712 E13L-Left Pin 3 1.5 Yellow
X50A Fuse Block X2 pin 2 Run / Crank Ignition 1 Voltage 2.5 Violet / Grey 539 K28 H.L.C.M x2 Pins 1 & 2 2.5 Red / Yellow Splits in Harness in car goes to K28 X2 pins 1 & 2
X50A Fuse Block X2 pin 76 Battery Positive Voltage 0.5 Red / Violet 1242 K28 H.L.C.M x1 Pin 10 0.5 Purple / Red
X50A Fuse Block X2 pin 42 Headlamp Low Beam Relay Control 0.35 Brown / Yellow 1970 K9 B.C.M x5 Pin 10 N/A see notes -> Just swap BCM X5 pin 21 in BCM X5 pin 10
X50A Fuse Block X2 pin 64 Battery Positive Voltage 1.5 Red / Yellow 3040 Loops Back To Pin 68 1.5 Blue / Red
X50A Fuse Block X2 pin68 Battery Positive Voltage 1.5 Red / Yellow 3040 Loops Back To Pin 64 1.5 Blue / Red
K28 H.C.C.M X1 pin 18 Linear Interconnect Network Bus 7 0.5 D-Green / Brown 7529 E13L-Left Pin 7 0.5 Green / Brown
K28 H.C.C.M X1 pin 17 Linear Interconnect Network Bus 6 0.5 D-Green / Violet 7528 E13R-Right Pin 7 0.5 Green / Purple
K28 H.C.C.M X2 pin 5 Right Cornering Lamp Supply Voltage 1.5 Yellow / White 58 E13R-Right Pin 9 1.5 Black / White
K28 H.C.C.M X2 pin 6 Left Cornering Lamp Supply Voltage 1.5 Yellow / Grey 57 E13L-Left Pin 9 1.5 Black / White
K9 B.C.M x4 pin 1 Right Front DRL Supply Voltage 1.0 D-Blue / Brown 7539 E13R-Right Pin 4 1.0 Blue / Brown
K9 B.C.M x4 pin 2 Left Front DRL Supply Voltage 1.0 Grey / D-Blue 7538 E13L-Left Pin 4 1.0 Blue / Slate
K9 B.C.M x4 pin 23 Serial Data Communication Enable 0.5 White / D-Blue 5986 K28 H.L.C.M x1 Pin 7 0.5 White / Blue
K28 H.C.C.M X1 pin 4 High Speed GMLAN Serial Data (-) (1) 0.5 White 2501 B.C.M x1 Pin 24 0.5 White
K28 H.C.C.M X1 pin 5 High Speed GMLAN Serial Data (+) (1) 0.5 D-Blue 2500 B.C.M x1 Pin 25 0.5 Blue
G102 Ground 1.5 Black 1050 E13R-Right Pins 1, 8, 10 1.5 Black Use a ground point in the engine bay by the Headlight
G101 Ground 1.5 Black 1150 E13L-Left Pins 1, 8, 10 1.5 Black Use a ground point in the engine bay by the Headlight
G101 Ground 0.5 Black 1150 K28 H.L.C.M Pin 1 0.5 Black Use a ground point in the engine bay by the Headlight


Now I will list all Pins that need to be removed (This is for the Halogen system).

If you haven't already get yourself a nice set of Terminal Release Tools, This is the kit I have after trying a few of the cheaper tools that were too short too small or just too big.
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Engine Fuse Board

[Image: X50AX1.jpg]

Pin Wire Circuit Function
11 1.5 White 311 Right Headlamp High Beam Supply Voltage (T4A)
15 1.0 Violet / D-Green 439 Run/Crank Ignition 1 Voltage (TR6
16 1.0 Violet / D-Green 439 Run/Crank Ignition 1 Voltage (TR6
18 1.0 D-Blue / Brown 7539 Right Front DRL Supply Voltage (T3N with T4A)
19 1.0 Yellow 312 Right Headlamp Low Beam Supply Voltage
47 1.5 White 711 Left Headlamp High Beam Supply Voltage (T4A)
52 1.0 Yellow 712 Left Headlamp Low Beam Supply Voltage
54 1.0 Grey / D-Blue 7538 Left Front DRL Supply Voltage (T3N with T4A)


[Image: X50AX2.jpg]

Pin Wire Circuit Function
18 0.35 Brown / Violet 1969 Headlamp High Beam Relay Control (T4A)
37 0.35 Grey / D-Blue 545 DRL Relay Control (T3N with T4A)
64 1.0 Yellow 712 Left Headlamp Low Beam Supply Voltage (T4A)
66 1.0 Yellow 312 Right Headlamp Low Beam Supply Voltage (T4A)

B.C.M (Body Control Module)

[Image: K9X4.jpg]

Pin Wire Circuit Function
1 1.0 Yellow 312 Right Headlamp Low Beam Supply Voltage (without T4F or T95)
2 1.0 Yellow 712 Left Headlamp Low Beam Supply Voltage (without T4F or T95)


[Image: K9X5.jpg]

Pin Wire Circuit Function
15 0.35 Grey / D-Blue 545 DRL Relay Control (T3N with T4A)
18 0.35 Brown / Violet 1969 Headlamp High Beam Relay Control (T4A)
21 0.35 White / Brown 544 DRL Relay Control (T3N with T4A)

Once you have made all the wiring changes your new AFL lights will only only work you've you requested a VCI it's not as simple as just request it for the AFL Also AFL is not a recognized retrofit and therefore it's not quite so straight forward.

All this information was gathered by myself and shown to work after successfully obtaining the VCI codes on 27th October 2014.

As with all electrical how-to's
we except no responsibility for any issues
that could arise all are carried out at your own risk.
If the how-to is followed correctly you should have no issues.


PLEASE ASK ALL QUESTION IN THIS THREAD AS PM'S WILL BE IGNORED
(LET OTHERS KNOW THE ANSWER/S TO ANY QUESTION/S TOO)


****VERY IMPORTANT GM WILL NO LONGER SUPPORT THIS RETROFIT AND THEY WILL NOT SUPPLY A VCI****

[Image: vx.o.c.jpeg]
[Image: Rusty-2_zpsuzrvgsp6.GIF]
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
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#2
Top work mate👍👍
[SIGPIC][/SIGPIC]
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#3
you did a fantastic job there rusty and well done on being the first to get this working Doublethumbs
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#4
I'd love afl but that's way above my skillset
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#5
Hi Rusty, I just find this How To ! I'm the guy on youtube Smile
Reply
#6
luffy Wrote:Hi Rusty, I just find this How To ! I'm the guy on youtube Smile

Hi sorry not getting back yesterday.

What do you need help with?
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#7
no problem Smile ! To begin, I want to check if I can retrofit to AFL on my Astra, I read that I have to check something on the fuse box ? If I have the good fuse ?
Reply
#8
Yes you do need to check the pin's in the bottom of the board.

Right for those that want to check the fuse board.


Please note these are pictures of a donor board.


[Image: 1.JPG]


Fuse's and relays
12 Adaptive forward lighting module
23 Headlamp washer system
24 Right low beam (Xenon)
25 Left low beam (Xenon)
33 Adaptive forward lighting
K05 KR2 HeadlampWasher Fluid Pump Relay
K06 KR49 Headlamp Low Beam Relay


You can check where all these are in the fuse's thread You are not allowed to view links. Register or Login to view. 2nd post


If you have them it would be safe to say you have all pins underneath but it will pay to double check this.


So Disconnect the Negative terminal of the battery, then undo the 3 10mm bolts (they wont come out) you will feel a slight click when they are undone.
DO NOT REMOVE ANY FUSES OR RELAYS YOU DON'T NEED TO


[Image: 2.JPG]


Next get a trim tool and if you look on each side of the board you will see 2 clips just use the the tool and praise them outwards and lift one Conner of the board at a time (Not too far just enough so they are un-clipped)


[Image: 3.JPG]


Then carefully lift the board up may need a wiggle and then turn it over and just make sure the bottom of the board has all pins in (in this picture you can see some are missing).


[Image: 4.JPG]


Refit the board Make sure you do not over tighten the blots but make sure they are done up nice and tight If your car wont start afterwards you've not tightened them up enough.

I will get all the pin info later today.
[Image: Rusty-2_zpsuzrvgsp6.GIF]
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Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
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#9
Ok thank,

This is my fuse box :

[ATTACH=CONFIG]531[/ATTACH]

In RED : 24 and 25, I have nothing here
In GREEN : 23
In BLUE : 12
In WHITE : 33

And for k05 and k06, I think I have it but I'm not sure, can you confirme ?


Attached Files Thumbnail(s)
   
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#10
The fuses that are missing are also missing the pins inside the board from what I can see can you check to see they are there.
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#11
For fuse 24 and 25 I have no pins inside

For fuse 12 I have 1 pins on the right

For fuse 23 I have the 2 pins

For fuse 33 I have 1 pins on the left
Reply
#12
It that case it would mean a new fuse board and they are not cheap.
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#13
Ok, I can't add pins in my fuse board myself ?
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#14
You could try I guess you would need a donor board to get the pins from, I know they have bus-bar which handles one side of fuse, also I don't know if the inside circuit board will have all the tracks etc.
[Image: Rusty-2_zpsuzrvgsp6.GIF]
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Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
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#15
Ok, I think the best thing is to change the fuse box, but I'll try to find a donor board. So you think I have good chance to retrofit AFL on my astra if I change the fuse board ?
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#16
awesome mate, would love this on my car but its alot of work.

well done mate and great guide
[Image: Lewis_zpswvvuzf0s.jpg]
Reply
#17
luffy Wrote:Ok, I think the best thing is to change the fuse box, but I'll try to find a donor board. So you think I have good chance to retrofit AFL on my astra if I change the fuse board ?

If you can a board that matches yours + the AFL part then you should have no problems not all (I can't guarantee GM will give the VCI codes tho), as with all retrofits all it's all trail and error.
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#18
How many chance i have to have a VCI code you think ? tomorrow I'ill go to opel to ask for VCI code. Today I found the right headlamp for 200 euros so I think I'll buy it. While looking for a fuse box what else should I check ?
Reply
#19
You need both lights ballasts bulbs AFL module.

You need everything fitted before you can request a VCI Code as it uploads all the modules from the car if you they don't see an AFL module they won't give you any codes.
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#20
Yes the headlamp has light ballasts bulbs AFL module.

Ok, I just go ask if it is possible to have a VCI code when I'll have retrofit to AFL. And Now, I look for the sensor ? Or I have to check another pins ?
Reply
#21
Yes you need the front and rear sensors also the plate.

the dealers won't know if you can get one untill it's tried also as it's not a listed retrofit a dealer may have problems, what you really need to do is find someone who has an MDI and has acess to request VCI codes etc.
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#22
How come when I'm looking at the post everything has [TD] on it?


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#23
(5:th-Jan-2016, 19:04:56)Nemo Wrote: You are not allowed to view links. Register or Login to view.How come when I'm looking at the post everything has [TD] on it?


Sent from my iPhone using Tapatalk

Are you viewing it on tapatalk?

If so for some reason it doesn't display the table that you would see in a web browser hence the [TD]


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[Image: Rusty-2_zpsuzrvgsp6.GIF]
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Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
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#24
I am indeed, that'll explain it aha


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#25
PLEASE TAKE NOTE THAT GM WILL NO LONGER SUPPORT AFL RETROFIT AS ITS THE COMPANIES NEW POILCY!


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Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
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#26
Video 
After long time i finally found some time to test afl , i made some custom loom to test headlights and it successfully worked . I made a short ride to test it and know i need the wiring the most boring part thanx rusty for your help .
A short video ,

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#27
And finally afl retrofited

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#28
hello rasty 2009 I bought original headlights for afl, and I would like to install them but I don't want to install all the cables for AFL just to have them as headlights with up and down adjustment .... is it possible?
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#29
(7:th-May-2020, 22:31:03)sergiu26 Wrote: You are not allowed to view links. Register or Login to view.hello rasty 2009 I bought original headlights for afl, and I would like to install them but I don't want to install all the cables for AFL just to have them as headlights with up and down adjustment .... is it possible?

Should be possible, I did make a patch lead up but never got a chance to test it as the person sold their car.
[Image: Rusty-2_zpsuzrvgsp6.GIF]
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
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I can do programming and retrofits using genuine GM MDI and Dealer software.
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#30
(18:th-May-2020, 14:17:02)Rusty2009 Wrote: You are not allowed to view links. Register or Login to view.
(7:th-May-2020, 22:31:03)sergiu26 Wrote: You are not allowed to view links. Register or Login to view.hello rasty 2009 I bought original headlights for afl, and I would like to install them but I don't want to install all the cables for AFL just to have them as headlights with up and down adjustment .... is it possible?

Should be possible, I did make a patch lead up but never got a chance to test it as the person sold their car.

I'd like to know the same thing really. My fuse box is like this 

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