Savana 3500 V8-4.8L (2009)
Splicing Copper Wire Using Splice Sleeves
Special Tools
J-38125 Terminal Repair Kit
Note: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection.
Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use DuraSeal splice sleeves where there are
special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves.
Note: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a
clean strip with all of the wire strands intact.
1. Open the harness by removing any tape:
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Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.
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Use the DuraSeal splice sleeves on all types of insulation except tefzel and coaxial.
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Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together.
2. 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.
3. 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 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.
4. 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.
