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Safety Regulations for Electrical/Electronic Systems


•  Never touch high-voltage-bearing components (e.g.: ignition system, xenon lamps) - can be fatal.
•  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.
•  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

•  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:
  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.
  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.
•  Never connect/disconnect control unit or miscellaneous electronic component wiring harness plugs with the ignition switched on to avoid damaging the control units.
•  Never pull on cable when disconnecting wiring harness plugs. Carefully release locking mechanism at wiring harness plug.
•  When cleaning and contact sprays are being used, the manufacturer's recommendations must be followed. Improper use can damage sensitive electrical and electronic components.
•  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.
•  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.
•  When programming the control unit memory system, ensure that no persons are present in the interior - risk of injury!
•  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.
•  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.).
•  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

•  Wiring harness repairs must be performed by certified, qualified personnel only. This is assured at all Opel/Vauxhall affiliated dealerships.
•  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.
•  When repairing non-approved systems or wiring harnesses:
  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.
  Airbag and pyrotechnic seat belt tensioner system
  Electronically controlled throttle valve
  Electric power steering system
  Electrical seat adjustment
  High-voltage-bearing cables (e.g. ignition system, xenon lamp).

Vehicle Battery

•  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.
•  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.
•  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.
•  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.
•  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.
•  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.


•  For testing purposes, use only a high-resistivity voltage tester.
•  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.
•  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.
•  The battery must be in good condition and adequately charged when performing diagnosis on electrical/electronic systems.
•  Only suitable test probes may be used for measuring so as to avoid damage to the contacts.

General Information > Specifications > Safety Regulations for Electrical/Electronic Systems