Colorado 4WD L5-3.5L VIN 6 (2005)
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Start in the middle and gradually move the heat barrel to the open ends 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.
Heated Oxygen Sensor (HO2S) Wiring Repairs
HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS
TOOLS REQUIRED
J 38125 Terminal Repair Kit
NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to
repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is
obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of
the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
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Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor
performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a
path for foreign materials to enter the sensor and cause performance problems.
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Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the
lead wire.
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Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as
the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance.
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To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector.
The engine harness may be repaired using the J 38125.
High Temperature Wiring Repairs
HIGH TEMPERATURE WIRING REPAIRS
TOOLS REQUIRED
J 38125 Terminal Repair Kit
HIGH TEMPERATURE WIRING
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and
shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following:
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Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire.
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Replace any heat shielding that is removed.
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Cover any duraseal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit).
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After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source.
IDENTIFYING HIGH TEMPERATURE WIRING
Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring
repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These
materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used.
Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine
if an area is exposed to excessive heat before making a wiring repair. Obvious areas of consideration would be any area located near the exhaust
manifolds, catalytic converter, and exhaust pipes.
