XL-7 2WD V6-3.6L (2007)
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.
The J-38125 contains much of the material you will need to perform repairs on areas exposed to high heat. The kit contains the following items:
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DuraSeal splice sleeves to crimp and seal connections
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High temperature SCT1 shrink tubing to protect the splice sleeves
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A large sampling of common electrical terminals
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The correct crimp tool to attach the terminals to the wires
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The correct tools to remove the terminals from the connectors
The J-38125 does not contain wire that is suitable to high temperature exposure. Use high temperature bulk wire rated at 150 °C (302 °F) continuous
temperature of the same or larger gage size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the
repair.
High Temperature Wire Repair
NOTE: 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. See: Diagrams/Diagnostic Aids/Wiring Repairs
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.
NOTE: 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.
1. Open the harness by removing any tape.
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.
