K 2500 Truck 4WD V8-6.0L VIN U (1999)
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7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.
8. Tightly close the handles of the crimp tool until the crimper handles open when released.
The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end
of the splice.
9. Using the heat torch, apply heat to the crimped area of the barrel.
10. Gradually move the heat barrel to the open end of the tubing:
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The tubing will shrink completely as the heat is moved along the insulation.
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A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.
SIR System Wire Splice Repair
Apply a new splice (not sealed) from the J 38125-B if damage occurs to any of the original equipment splices (3 wires or more) in the SIR wiring
harness. Carefully follow the instructions included in the kit for proper splice clip application.
Connector Position Assurance (CPA)
The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA
ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating
terminals.
Terminal Position Assurance (TPA)
The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely
seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement.
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.
Connector Position Assurance Locks
The Connector Position Assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA
ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating
terminals.
Terminal Position Assurance Locks
The Terminal Position Assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely
seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement.
Push to Seat Connectors
Terminal Removal
Follow the steps below in order to repair push to seat connectors.
Connector Repairs: Push-To-Seat Connector
1. Remove the Terminal Position Assurance (TPA) device, the Connector Position Assurance (CPA) device, and/or the secondary lock.
2. Separate the connector halves (1).