Corvette V8-6.2L (2008)
High Temperature Wiring Repairs
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and
shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following:
Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire.
Replace any heat shielding that is removed.
Cover any DuraSeal splice sleeves with SCT1 shrink tubing (available in the J-38125 Terminal Repair kit).
After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source.
Identifying High Temperature Wiring
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:
DuraSeal splice sleeves to crimp and seal connections
High temperature SCT1 shrink tubing to protect the splice sleeves
A large sampling of common electrical terminals
The correct crimp tool to attach the terminals to the wires
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
High Temperature Wire Repair
Important: Refer to Wiring Repairs (See: Testing and Inspection/Component Tests and General Diagnostics) 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
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.
1. Open the harness by removing any tape.