C 3500 Truck 2WD V8-454 7.4L VIN J SFI (1999)
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-B.
General Information
The Supplemental Inflatable Restraint (SIR) system requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR system wiring, and the wiring components (such as connectors and terminals).
IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR system terminals unless specifically indicated by the terminal
package.
TOOLS REQUIRED
J 38125-B Terminal Repair Kit
The tool kit J 38125-B contains the following items:
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Special sealed splices - in order to repair the SIR system wiring
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A wire stripping tool
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A special crimping tool
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A heat torch
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An instruction manual
The sealed splices have the following 2 critical features:
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A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.
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A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits.
The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items:
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A large sampling of common GM electrical terminals
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The correct tools in order to attach the terminals to the wires
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The correct tools in order to remove the terminals from the connectors
Sir Connector (Plastic Body and Terminal Metal Pin) Repair
Use the connector repair assembly packs in order to repair the damaged SIR wire harness connectors and the terminals. Do not use the connector repair
assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the
new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-B. You must
use the splice crimping tool in order to apply these splices.
The terminals in the SIR system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits.
These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs.
If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to
replace the SDM harness connector:
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The SDM harness connector pigtail assembly
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The SDM harness connector replacement kit
If the individual terminals are damaged on any other SIR connection, use the appropriate connector repair assembly pack in order to replace the entire
connection.
Replace the entire SIR wiring harness, if needed, in order to maintain SIR circuit integrity.
Sir Wire Pigtail Repair
IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to
the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering
wheel module coil is an example of a pigtail component.
Sir Wire Repair
TOOLS REQUIRED
J 38125-B Terminal Repair Kit
IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in
order to ensure circuit integrity.
