Vauxhall Workshop Service and Repair Manuals

Step D - Repair  

D1 - Damage type 1 - repairing damaged cables  

D1.1 - Strip lead ends  

•  Number cables according to plug pattern, section 5, or mark according to the cable colours, to prevent the risk of confusion when subsequently rejoining the cables.
•  Separate the defective cable at a suitable point; vary the separation points in order to largely retain the cross-section of the wiring harness as a whole.
•  Determine the cross-section of the cable (see circuit diagram), select corresponding crimping pliers: red, yellow or blue.
•  Insert end of lead (1) to stop (2) in crimping pliers. Check position of cable in stripping position of crimping pliers (3).
	Do not hold cable at a slant to the crimping pliers, or individual conductors of the cable strand may be damaged. Strip cable.
	Do not twist lead ends.

D1.2 - Attach shrink-down plastic tubing  

•  Select shrink-down plastic tubing (4) according to cable cross-section and guide over the end of the lead.  

D1.3 - Crimping  

•  Select cable connectors (5) according to cable cross-section, insert into crimp cavity (6) from the unlabelled side (7) of the crimping pliers.

•  Press the crimping pliers together until cable connector is fixed in position (8).

•  Select cable with corresponding cross-section for repair, insert cable from the labelled side (9) of the crimping pliers to stop (10).

•  Press crimping pliers together to the action point (11). The crimping tool can only be released again once the action point (12) has been attained.

•  Crimp second lead end with the cable connector.

D1.4 - Shrink shrink-down plastic tubing  

•  Position shrink-down plastic tubing (1) centrally over cable connector.

•  Shrink shrink-down plastic tubing with hot air dryer (2) and reflector nozzle (3) until sealing compound (4) escapes at both sides.

D1.5 - Perform any additional crimpings  

•  Repeat operation steps D1.1 to D1.4 for repairs of additional cables.
	Offset the crimping points (5) in order to avoid significantly increasing the cross-section of the wiring harness.

D1.6 - Insulate wiring harness  

•  Insulate wiring harness with commercially available plastic or textile adhesive tape in the same manner as the original insulation of the wiring harness (6).

•  Insulate wiring harness in the other direction as well (7).

D2 - Damage type 2 - replacing plug casings  

D2.1 - Release secondary lock  

•  Slide back rubber grommet (1) and remove.  

•  Number cables according to plug pattern, section 5 (2), to prevent the risk of confusion when subsequently rejoining the cables.  

•  Release secondary lock (3) of spring-finger connectors with small screwdriver or specified detachment tool.  

D2.2 - Release primary lock  

•  Guide detachment tool (4) into lock groove of spring-finger connector to stop.  

•  Pull released spring-finger connector out of plug casing.  

•  To prevent confusion, we recommend that the cables be transferred from the old to the new plug casing one at a time.  

Important: Cables must be guided through new rubber grommets.  

D2.3 - Attach new plug casing  

•  Insert spring-finger connectors in plug casing in correct positions, check for firm seating.  

•  For water-tight wiring harness plugs, fit enclosed sealing plugs to unoccupied chambers.  

•  Apply secondary lock (5).  

•  Slide on new rubber grommet (6) using expander pliers (7).  

•  Insulate wiring harness as specified in D1.6.  

•  Fasten rubber grommet to wiring harness plug.  

D3 - Damage type 3 - replacing individual spring-finger connectors in wiring harness plugs  

D3.1 - Release secondary lock  

•  Slide back rubber grommet (1).  

•  Number affected cables according to plug pattern, section 5 (2), to prevent the risk of confusion when subsequently rejoining the cables.  

•  Release secondary lock (3) of spring-finger connectors with small screwdriver or specified detachment tool.  

D3.2 - Release primary lock  

•  Guide detachment tool (4) into lock groove of spring-finger connector to stop.  

•  Pull released spring-finger connector out of plug casing, separate at suitable point. We recommend that that cables be exchanged one at a time. Vary the separation points (5) in order to largely retain the cross-section of the wiring harness as a whole.  

D3.3 - Insert new spring-finger connector with lead ends  

•  Number lead ends according to plug pattern, section 5, so that panels etc. do not have to be removed for subsequent repairs.  

•  Insert new spring-finger connector in plug casing at correct position, check for firm seating.  

•  Crimp lead ends as specified in operation steps D1.1 to D1.3 and insulate or seal with shrink-down plastic tubing (6).  

Repeat operation steps D3.2 to D3.3 for replacement of any additional spring-finger connectors.  

D3.4 - Assemble wiring harness plug  

•  Apply secondary lock.  

•  Insulate wiring harness as specified in D1.6.  

•  Fasten rubber grommet to wiring harness plug.  

D4 - Damage type 4 - replacing plug casing and individual spring-finger connectors  

D4.1 - Release secondary lock  

•  Slide back rubber grommet (1) and remove.  

•  Number all cables according to plug pattern, section 5, to prevent the risk of confusion when subsequently rejoining the cables (2).  

•  Release secondary lock (3) of spring-finger connectors with small screwdriver or specified detachment tool.  

D4.2 - Release primary lock and remove plug casing  

•  Guide detachment tool (4) into lock groove of intact spring-finger connectors to stop.  

•  Pull released spring-finger connector out of plug casing.  

  Guide connectors one by one into new plug casing.  

Important: Lead ends must be guided through new rubber grommets.  

•  Separate defective spring-finger connectors with lead ends individually at suitable point. Vary the separation points (5) in order to largely retain the cross-section of the wiring harness as a whole.  

•  Guide new spring-finger connector with lead end into new plug casing.  

•  Insert into plug casing, check for firm seating.  

Important: Note rubber grommet.  

•  Crimp new lead end as specified in operation steps D1.1 to D1.4.  

•  Number new lead end near plug according to plug pattern.  

•  For water-tight wiring harness plugs, fit enclosed sealing plugs to unoccupied chambers.  

Repeat operation steps D3.2 to D3.3 for replacement of any additional spring-finger connectors.  

•  Slide on new rubber grommet (6) using expander pliers (7).  

D4.3 - Assembly wiring harness plug  

•  Apply secondary lock.  

•  Insulate wiring harness as specified in D1.6.  

•  Fasten rubber grommet to wiring harness plug.  

D5 - Damage type 5 - replacing complete wiring harness plugs  

D5.1 - Separate defective wiring harness plug  

•  Slide back rubber grommet (1) and remove.  

•  Detach one cable from wiring harness.  

•  Crimp new spring-finger connector with lead end as specified in operation steps D1.1 to D1.4.  

Important: New lead ends must be guided through new rubber grommets.  

•  Connect new spring-finger connector to new plug casing (2).  

•  Number new lead end near plug according to plug pattern.  

•  Repeat the above steps according to the number of remaining cables.  

D5.2 - Reattach wiring harness plug  

•  Slide on new rubber grommet (3) using expander pliers (4).  

•  For water-tight wiring harness plugs, fit enclosed sealing plugs to unoccupied chambers.  

•  Apply secondary lock (5).  

•  Insulate wiring harness as specified in D1.6.  

•  Fasten rubber grommet to wiring harness plug.