Vauxhall Corsa D Service and Repair Manuals | Workshop Guide

Step D - Damage type 4, Replacement of plug casings and individual spring contacts

D4.1 - Release secondary lock

Push back rubber grommet (1) and remove. Number all 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.

D4.2 - Release primary lock and remove plug casing

• Insert release tool (4) into locking groove of intact spring contacts to the stop.
• Pull released spring contact out of plug casing.Insert contacts into new plug casing one at a time.

Note:  Lead ends must be guided through new rubber grommet.

• Sever defective spring contacts with lead ends individually at suitable locations, varying separation locations (5) to essentially retain the same cross-section for the entire wiring harness.
• Insert new spring contact with lead end into the new plug casing.
• Insert into plug casing, check seating is secure.

Note:  Pay attention to rubber grommet.

• Crimp new lead end in accordance with steps D1.1 to D1.4 .
• Number new lead end close to plug according to plug diagram.
• For water-tight wiring harness plugs, provide chambers that are not occupied with sealing plugs.

Repeat steps D4.2 to D4.3 for replacing additional spring contacts.

• Slide on new rubber grommet (6) using three-pronged pliers (7).

D4.3 - Assemble wiring harness plug

Attach secondary lock. Insulate wiring harness according to D1.6. Secure rubber grommet on wiring harness plug.