Opel Frontera UE. Manual - part 1558

6E–447

6VD1 3.2L ENGINE DRIVEABILITY AND EMISSIONS

Be certain of the type of connector/terminal before
making any connector or terminal repair.  Weather-Pack
and Com-Pack III terminals look similar, but are serviced
differently.

PCM Connectors and Terminals

Removal Procedure

1. Remove the connector terminal retainer.
2. Push the wire connected to the affected terminal

through the connector face so that the terminal is
exposed.

3. Service the terminal as necessary.

Installation Procedure

1. Bend the tab on the connector to allow the terminal to

be pulled into position within the connector.

2. Pull carefully on the wire to install the connector

terminal retainer.

Wire Harness Repair: Twisted

Shielded Cable

Removal Procedure

1. Remove the outer jacket.
2. Unwrap the aluminum/mylar tape.  Do not remove the

mylar.

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3. Untwist the conductors.
4. Strip the insulation as necessary.

048

Installation Procedure

1. Splice the wires using splice clips and rosin core

solder.

2. Wrap each splice to insulate.
3. Wrap the splice with mylar and with the drain

(uninsulated) wire.

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6VD1 3.2L ENGINE DRIVEABILITY AND EMISSIONS

4. Tape over the whole bundle to secure.

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Twisted Leads

Removal Procedure

1. Locate the damaged wire.
2. Remove the insulation as required.

051

Installation Procedure

1. Use splice clips and rosin core solder in order to splice

the two wires together.

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2. Cover the splice with tape in order to insulate it from

the other wires.

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6VD1 3.2L ENGINE DRIVEABILITY AND EMISSIONS

3. Twist the wires as they were before starting this

procedure.

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4. Tape the wires with electrical tape.  Hold in place.

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Weather-Pack Connector

Tools Required

5-8840-6632-0 Weather-Pack II Terminal Remover

Removal Procedure

A Weather-Pack connector can be identified by a rubber
seal at the rear of the connector.  This engine room
connector protects against moisture and dirt, which could
from oxidation and deposits on the terminals.  This
protection is important, because of the low voltage and
the low amperage found in the electronic systems.

1. Open the secondary lock hinge on the connector.

070

2. Use tool 5-8840-6632-0 or the equivalent to remove

the pin and the sleeve terminals.  Push on
5-8840-6632-0 to release.

NOTE: Do the use an ordinary pick or the terminal may
be bent or deformed.  Unlike standard blade terminals,
these terminals cannot be straightened after they have
been improperly bent.

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6VD1 3.2L ENGINE DRIVEABILITY AND EMISSIONS

3. Cut the wire immediately behind the cable seal.

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Installation Procedure

Make certain the connectors are properly seated and all
of the sealing rings are in place when you reconnect the
leads.  The secondary lock hinge provides a backup
locking feature for the connector.  The secondary lock
hinge is used for added reliability.  This flap should retain
the terminals even if the small terminal lock tangs are not
positioned properly.
Do not replace the Weather-Pack connections with
standard connections.  Read the instructions provided
with the Weather-Pack connector and terminal packages.

1. Replace the terminal.
2. Slip the new seal onto the wire.
3. Strip 5 mm (0.2”) of insulation from the wire.
4. Crimp the terminal over the wire and the seal.

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5. Push the terminal and the connector to engage the

locking tangs.

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6. Close the secondary locking hinge.

Com-Pack III

General Information

The Com-Pack III terminal looks similar to some
Weather-Pack terminals.  This terminal is not sealed and
is used where resistance to the environment is not
required.  Use the standard method when repairing a
terminal.  Do not use the Weather-Pack terminal tool J
28742-A or equivalent.  These will damage the terminals.

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