Safety Regulations for Electrical/Electronic Systems
General
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Never touch
high-voltage-bearing components (e.g.: ignition system, xenon
lamps) - can be fatal. |
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Before disconnecting the
ground cable from the battery in Opel / Vauxhall vehicles, disarm
the power sounder. Disconnect the ground cable from the battery
within 15 seconds of switching off the ignition. |
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If an alarm is unintentionally
triggered via the power sounder, switch on the ignition (battery
connected) in order to override the alarm. |
General Repair Information
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When performing work where
there is a danger of an electrical short circuit, disconnect the
earth cable from the battery. The following procedure must be
observed to avoid injury to persons and damage to sensitive
electrical components: |
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The battery
terminals must be covered so that accidental contact does not occur
because the battery cable has gradually moved backwards. This also
prevents accidental contact during assembly, e.g. with bright metal
components or tools. |
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If individual
connection cables forming part of the battery connection have to be
dismantled, always remove the earth clip on the battery terminal
first so that all the power circuits on the vehicle are free from
voltage. Non-adherence to this ruling can lead to electronic
components being damaged. Reconnection takes place in reverse
order, the earth clip is the last to be connected to the
battery. |
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Never connect/disconnect
control unit or miscellaneous electronic component wiring harness
plugs with the ignition switched on to avoid damaging the control
units. |
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Never pull on cable when
disconnecting wiring harness plugs. Carefully release locking
mechanism at wiring harness plug. |
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When cleaning and contact
sprays are being used, the manufacturer's recommendations must be
followed. Improper use can damage sensitive electrical and
electronic components. |
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When returning a unit
containing a CD unit (e.g. navigation control unit, CD changer),
remove all CD's to avoid damage to the laser head or CD.
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Disconnect the battery from
the on-board power supply before charging or rapid charging. Never
start the vehicle using a rapid charger. Overvoltage in the
electrical system can damage control units. |
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When programming the control
unit memory system, ensure that no persons are present in the
interior - risk of injury! |
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After completing repair
operations, ensure that wiring harness connections and battery
connections are correctly seated and that ground connections have
been made correctly. Defective electrical connections cause
functional problems and destroy control units. |
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Wiring harnesses and wiring
troughs which are released or removed during repair work must be
refastened in their original positions using genuine Aftersales
parts (cable ties, clips, wiring trough brackets, etc.).
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Disconnecting the ground cable
from the battery automatically erases the contents of certain
electronic system memories (e.g. electric window winder, time and
date). After reconnecting the ground cable to the battery, these
volatile memories must be reprogrammed and audio equipment
decoded. |
Wiring Harness Repair
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Wiring harness repairs must be
performed by certified, qualified personnel only. This is assured
at all Opel/Vauxhall affiliated dealerships. |
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Cables or wiring harness plugs
may only be repaired using the methods described in the service
literature and using the special tools and spares specified.
Deviations may be made from this rule in individual cases, e.g. in
the course of roadside assistance. |
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When repairing non-approved
systems or wiring harnesses: |
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Shielded
cables/coaxial cables e.g. for the ABS, ESP, radio, telephone,
engine, alarm system. An exception to this rule are CAN-bus cables,
which can be repaired in accordance with KTA-1950/2, section
D6. |
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Airbag and
pyrotechnic seat belt tensioner system |
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Electronically
controlled throttle valve |
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Electric power
steering system |
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Electrical seat
adjustment |
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High-voltage-bearing cables (e.g. ignition system, xenon
lamp). |
Vehicle Battery
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Fluid-filled vehicle batteries
must only be stored and charged in well-ventilated areas. Gaseous
hydrogen released when the battery is charged is lighter than air
and combines with air to form an explosive mixture. Avoid the
formation of sparks, smoking and naked flames. |
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If, on batteries fitted with a
"magic eye", this is colourless or light yellow, the acid level is
too low and overheating may occur during recharging - danger of
explosion. Only charge undamaged batteries. |
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Disconnect the negative
battery terminal before charging or rapid charging. Never start the
vehicle using a rapid charger. Overvoltage (>16 Volts) in the
electrical system can damage control units. |
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The recommended battery acid
temperature during charging is between 10 °C (50
°F) and 30 °C (86 °F) .
Reduce the charging current if the temperature exceeds 50
°C (122 °F) and terminate charging if it exceeds
55 °C (131 °F) . The battery cannot be
charged at temperatures below 0 °C (32 °F)
. The temperature of the battery acid can be estimated from the
temperature of the battery casing. |
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Electrolyte (sulphuric acid)
escaping from vehicle batteries can lead to serious acid burns -
danger of injury. Escaping electrolyte must be diluted and flushed
away using large volumes of water, soaked up with sawdust or with
an absorbent cloth. |
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Due to the quiescent current
of control units (e.g. vehicle anti-theft system, radio units), the
battery may become discharged during long standing periods (e.g.
stored vehicles) - disconnect battery and recharge if
necessary. |
Diagnosis
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For testing purposes, use only
a high-resistivity voltage tester. |
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The pyrotechnic system (e.g.
airbag) may only be tested using the diagnostic tester. In order to
prevent unintentional deployment, never use a test lamp or
multimeter to perform measurements on the pyrotechnic units -
danger of injury. |
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The test operations during
which wiring harness plug contacts or control units are connected
to ground or the battery voltage (+12 V) must be performed with
extreme care and concentration. A wrong contact can destroy
internal circuits in the relevant control units. |
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The battery must be in good
condition and adequately charged when performing diagnosis on
electrical/electronic systems. |
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Only suitable test probes may
be used for measuring so as to avoid damage to the contacts.
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