Savana 2500 V6-4.3L VIN X (2005)
HIGH TEMPERATURE WIRE REPAIR
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.
If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire rated at 150°C (302°F) continuous temperature rating of
the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 and then encapsulate
the splice sleeve using the high temperature SCT1 shrink tubing. Use the following wiring repair procedures in order to ensure the integrity of the
sealed splice.
1. Open the harness by removing any tape.
IMPORTANT: You must perform the following procedures in the order listed. Repeat the procedure if any wire strands are damaged. You must
obtain a clean strip keeping all of the wire strands intact.
2. Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.
3. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.Adjust splice
locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.
4. Strip the insulation:
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When adding a length of wire to the existing harness, use the same size wire as the original wire.
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Perform one of the following items in order to find the correct wire size:
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Find the wire on the schematic and convert the metric size to the equivalent american wire gage (AWG) size.
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Use an AWG wire gage.
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If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the
insulation.
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Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.
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Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
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If the wire is damaged, repeat this procedure after removing the damaged section.
5. Slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with
the splice procedure.
6. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color
coding of the duraseal splice sleeves and the crimp tool nests.
7. Use the Splice Crimp Tool from the J-38125 in order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool.
