Step D - Damage type 3, Replacement of individual
spring contacts
D3.1 - Release secondary lock
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- Push back rubber grommet (1).
- Number cables concerned according to plug diagram (see section
5) (2) so that it will not be possible to confuse the cables when
connecting them later.
- Release secondary lock (3) of spring contacts with small
screwdriver or designated release tool.
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D3.2 - Release primary lock
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- Insert release tool (4) into locking groove of spring contact
to the stop.
- Pull released spring contact out of plug casing, detach at
suitable location. It is advisable to replace the cables one at a
time. In so doing, vary the separation locations (5) to essentially
retain the same cross-section for the entire wiring harness.
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D3.3 - Insert new spring contact with lead
ends
- Number lead end according to plug diagram (see section 5) so
that panelling etc. does not have to be removed for subsequent
repairs.
- Insert new spring contact into plug casing at correct position,
check seating is secure.
- Crimp lead end in accordance with steps D1.1 to D1.3 and insulate
and/or seal with shrink-down plastic tubing (6).
Repeat steps D3.2 to D3.3 for replacing additional spring
contacts.
D3.4 - Assemble wiring harness plug
- Attach secondary lock.
- Insulate wiring harness according to D1.6 .
- Secure rubber grommet on wiring harness plug.
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