Vauxhall Workshop Service and Repair Manuals

Relay Frame – Engine Compartment Main Fuse Carrier, Remove and Install

  Remove

3.	Remove relay frame engine compartment fan module

4.	Remove relay box Body Control Module •   Release relay box, Body Control Module

5.   Unclip relay frame for engine compartment main fuse carrier (2) and relay frame for engine compartment light module (3) (arrows)

7.   Pull out cover flap, relays and fuses. 8.   Remove cable ties (tape loops) on the back Note:   Note the installation positions of the relays and fuses. 9.   Compress head of housing retainers (1) and remove

10.   Release secondary retainer: 11.   Release both housing parts on both sides (1) 12.   Lever up both housing parts (2) and in both cases slide in direction (3) Note:   For a clearer illustration, the cables are not shown.

13.   The individual cables must be replaced in the new housing one by one if possible. If this is not possible, the cables must be marked correspondingly. Note:   With the new housings, the secondary retainer must be released. 14.   Before inserting into the new housing, the spring contacts must be checked. If necessary, the lock (1) must be corrected carefully.

15.   Release tools required: 1. MKM-923-2 2. MKM-923-4 3. MKM-923-5 4. 2 hex screwdriver 2 mm (not shown) or suitable tool

16.   Release locks of the Maxi-Power-Timer contacts (1) and Maxi-Power-Timer current conductors (2) with two 2 mm hex screwdrivers (3) and pull out. Note:   The two locks are on the sides on the contacts. Note:   Only one side is depicted in the lower part of the illustration.

17.   Release locking mechanism of the RT 6.3–contacts with Special Tool MKM-923-2 and pull out the contacts Note:   The locks (1) for these contacts are in the housing.

18.   Release locking mechanisms of the Fasten 9.5-contacts with Special Tool MKM-923-2 and pull out the contacts Note:   The locks (1) are on the contacts.

19.   Release locking mechanisms of the MP 2.8-contacts and the MP 2.8 current conductor with Special Tool MKM-923-4 and pull out the contacts and the current conductors. Note:   The locks are on the contacts.

20.   Move the secondary locking mechanism (9-pin drawer) with a suitable aid from the limit position to the preliminary position (approx. 1mm) 21.   The preliminary position is reached when the secondary locking mechanism is aligned with the housing wall of the lower part. In the illustration, the secondary locking mechanism is still in the locked position.

22.   Release the locking mechanisms of the Ducon 1.5-contacts (1) and Ducon 2.8 contacts (2) with Special Tool MKM-923-4 and pull out the contacts

  Install

23.   Insert the contacts that have not yet been inserted into the previously noted chamber of the new housing 24.   Lock the secondary locking mechanism( 5) (9–pin drawer) (push in to the stop) 25.   Compress head of the two housing retainers (1) and remove 26.   Release secondary locking mechanisms (2) and slide the upper parts into the limit position. Upper and lower parts are now flush 27.   Secure upper parts by inserting the housing retainers (3) 28.   Check correct seating of all the contacts 29.   Secure cables at 3 points (4) with tape loops

30.   Insert relays, fuses and cover flap 31.   Secure released wiring harnesses, connect disconnected wiring harness plugs, connect released earth connections

34.	Install relay carrier, engine compartment fan module