i-290 4WD L4-2.9L (2007)
Re-assemble the cable.
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Rewrap the conductors with the mylar tape.
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Use caution not to wrap the drain wire in the tape (1).
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Follow the splicing instructions for copper wire and splice the drain wire.
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Wrap the drain wire around the conductors and tape with mylar tape.
5. Tape over the entire cable. Use a winding motion when you apply the tape.
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 data 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. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape.
Tape the diode to the harness or connector using electrical tape.
Flat Wire Repairs
FLAT WIRE REPAIRS
NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness
must be replaced.
SIR/SRS Wiring Repairs
SIR/SRS WIRING REPAIRS
TOOLS REQUIRED
J-38125 Terminal Repair Kit
The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special wiring repair procedures due to the
sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS, and the wiring components, such as
connectors and terminals.
IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals. Use either an SIR/SRS pigtail or a
