Express 1/2 Ton Van V8-5.7L VIN R (1999)
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 manual 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 it previously removed
9. Tape the diode to the harness or connector using electrical tape.
IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape.
HO2S Wiring Repairs
NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed.
If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to
repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is
obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of
the air reference and degrade oxygen sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
^
Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor
performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a
path for foreign materials to enter the sensor and cause performance problems.
^
Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the
lead wire.
^
Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as
the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance.
^
To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector.
The engine harness may be repaired using the J 38125-B.
General
The Supplemental Inflatable Restraint (SIR) system requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the
specific procedures and instructions when working with the SIR system wiring, and the wiring components (such as connectors and terminals).
IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR system terminals unless specifically indicated by the terminal
package.
TOOLS REQUIRED
J 38125-B Terminal Repair Kit
The tool kit J 38125-B contains the following items:
^
Special sealed splices - in order to repair the SIR system wiring
^
A wire stripping tool
^
A special crimping tool
^
A heat torch
^
An instruction manual
The sealed splices have the following 2 critical features:
^
A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.
^
A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits.
The J 38125-B also serves as a generic terminal repair kit. The kit contains the following items:
^
A large sampling of common GM electrical terminals
^
The correct tools in order to attach the terminals to the wires
^
The correct tools in order to remove the terminals from the connectors.
SIR Connector (Plastic Body and Terminal Metal Pin) Repair
Use the connector repair assembly packs in order to repair the damaged SIR wire harness connectors and the terminals. Do not use the connector repair
assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the
