Vauxhall Workshop Service and Repair Manuals

Step D - Damage type 3, Replacement of individual spring contacts

D3.1 - Release secondary lock

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.

D3.2 - Release primary lock

Insert release tool (4) into locking groove of spring contact to the stop. Pull released spring contact out of plug casing, 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.

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.