vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Step D - Damage type 3, Replacement of individual spring contacts > < Step D - Damage type 1, Repair of damaged cables

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Step D - Damage type 2, Replacement of plug casings

D2.1 - Release secondary lock

  • Push back rubber grommet (1) and remove.
  • Number cables 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.

D2.2 - Release primary lock

  • Insert release tool (4) into locking groove of spring contact to the stop.
  • Pull released spring contact out of plug casing.
  • To prevent confusion, it is advisable to move the cables one at a time from the old plug casing to the new plug casing.

Note:  Cables must be guided through new rubber grommet.


D2.3 - Attach new plug casing

  • Insert spring contacts into plug casing at correct position, check seating is secure.
  • For water-tight wiring harness plugs, provide chambers that are not occupied with sealing plugs supplied.
  • Attach secondary lock (5).
  • Slide on new rubber grommet (6) using three-pronged pliers (7).
  • Insulate wiring harness in accordance with D1.6 .
  • Secure rubber grommet on wiring harness plug.

Step D - Damage type 3, Replacement of individual spring contacts > < Step D - Damage type 1, Repair of damaged cables