C 1500 Truck V6-43L Power and Ground Distribution - Diagrams Instructions
3. Select the proper size and type of wire.
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The wire must be of equal or greater size than the original.
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The wire's insulation must have the same or higher temperature rating (4).
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Use general purpose insulation for areas that are not subject to high temperatures.
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Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected.
IMPORTANT:
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Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC.
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Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact.
4. Strip the insulation.
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Select the correct size opening in the wire stripper or work down from the largest size.
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Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).
5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table.
6. Place the nest tool in the J 38125-C crimp tool.
7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice.
8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest.
9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent
the wire from passing through the splice (3).
10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of
pressure is applied to the splice sleeve.
11. Shrink the insulation around the splice.
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Using the heat torch apply heat to the crimped area of the barrel.
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Gradually move the heat barrel to the open end of the tubing.
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The tubing will shrink completely as the heat is moved along the insulation.
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A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.
Splicing Inline Harness Diodes
SPLICING INLINE HARNESS DIODES
Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the
following procedure.
1. Open the harness.
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If the harness is taped, remove the tape.
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To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.
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If the harness has a black plastic conduit, pull out the diode.
2. If the diode is taped to the harness, remove all of the tape.
3. Check and record the current flow direction and orientation of diode.
4. Remove the inoperative diode from the harness with a suitable soldering tool.
IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering
tool.
5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the
new diode.
6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring
schematic to obtain the correct diode installation position.
7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the
diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment.
8. Reinstall terminal(s) into the connector body if previously removed.
9. Tape the diode to the harness or connector using electrical tape.
