Opel Frontera UE. Manual - part 1644

8D–6

WIRING SYSTEM

Parts Handling
Be careful when handling electrical parts. They should not
be dropped or thrown, because short circuiting or other
damage may result.

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Cable Harness

1. When installing the parts, be careful not to pinch or

wedge the wiring harness.

2. All electrical connections must be kept clean and

tight.

D08RW139

3. Use a grommet or guard tube to protect the wiring

harness from contacting a sharp edge or surface.

D08RW139

4. Position the wiring harness with enough clearance

from the other parts and guard the wiring harness with
a vinyl tube (2) and clips (1) to avoid direct contact.

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SECTION

8D–7

WIRING SYSTEM

5. The wiring harness between engine and chassis

should be long enough to prevent chafing or damage
due to various vibrations.

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Splicing Wire

1. If the harness is taped, remove the tape. To avoid wire

insulation damage, use a sewing “seam ripper”
(available from sewing supply stores) to cut open the
harness.
If the harness has a black plastic conduit, simply pull
out the desired wire.

2. Begin by cutting as little wire off the harness as

possible. You may need the extra length of wire later if
you decide to cut more wire off to change the location
of a splice. You may have to adjust splice locations to
make certain that each splice is at least 1–1/2” (40
mm) away from other splices, harness branches, or
connectors.

3. When replacing a wire, use a wire of the same size as

the original wire.
Check the stripped wire for nicks or cut stands. If the
wire is damaged, repeat the procedure on a new
section of wire. The two stripped wire ends should be
equal in length.

4. Select the proper clip to secure the splice.

To determine the proper clip size for the wire being
spliced, follow the directions included with your clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.)
Overlap the two stripped wire ends and hold them
between your thumb and forefinger as shown in the
figure.

The center the spline clip (1) under the stripped wires
and hold it in place.

D08RW143

Open the crimping tool to its full width and rest one
handle on a firm flat surface.

Center the back of the splice clip on the proper anvil
and close the crimping tool to the point where the
back of the splice clip touches the wings of the clip.

Make sure that the clip and wires are still in the correct
position. Then, apply steady pressure until the
crimping tool closes as shown in the figure.

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SECTION

8D–8

WIRING SYSTEM

Before crimping the ends of the clip (1), be sure that:

The wires extend beyond the clip in each direction.

No strands of wire are cut loose, and

No insulation is caught under the clip.

Crimp the splice again, once on each end.
Does not let the crimping tool (2) extend beyond the edge
of the clip or you may damage or nick the wires as shown
in the figure.

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5. Apply 60/40 resin core solder to the opening in the

back of the clip as shown in the figure.
Follow the manufacturer’s instructions for the solder
equipment you are using.

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6. Center and roll the splicing tape.

The tape should cover the entire splice.
Roll on enough tape to duplicate the thickness of the
insulation on the existing wires.
Does not flag the tape. Flagged tape may not provide
enough insulation, and the flagged ends will tangle
with the other wires in the harness as shown in the
figure.

D08RW147

If the wire does not belong in a conduit or other
harness covering, tape the wire again. use a winding
motion to cover the first piece of tape as shown in the
figure.

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SECTION