Wiring Systems - Introduction: Other Chevrolet SSR I

Truck Zoning

All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that corresponds to where they are located in the vehicle. The following table explains the numbering system.

Scheme 53

Truck Zoning

Electrical Symbols

Electrical Symbols OLD Symbol NEW Symbol - Description Supplemental Inflatable Restraint (SIR) or Supplemental Restraint System (SRS) Icon This icon is used to alert the technician that the system contains SIR/SRS components that require certain precautions before servicing. On-Board Diagnostic (OBD II) Icon This icon is used to alert the technician that the circuit is essential for proper OBD II emission controls circuit operation. Any circuit which, if it fails, causes the malfunction indicator lamp (MIL) to turn on, is identified as an OBD II circuit. Important Icon This icon is used to alert the technician that there is additional information that will aid in servicing a system. Voltage Indicator Boxes These boxes are used on schematics to indicate when voltage is present at a fuse. Partial Component When a component is represented in a dashed box, the component or its wiring is not shown in its entirety. Entire Component When a component is represented in a solid box the component or its wiring is shown in its entirety. Fuse Circuit Breaker Fusible Link Connector Attached to Component Pigtail Connector Bolt On or Screw On Eyelet Terminal Inline Harness Connector Splice Chassis Ground Case Ground Single Filament Light Bulbs Double Filament Light Bulb Light Emitting Diodes Capacitor Battery Variable Battery Resistor Variable Resistor Position Sensor I/O Resistors I/O Switches Diode Heating Element Motor Solenoid Coil Antenna Twisted Wires Shield Switches Single Pole/Throw Relay - Normally Open Single Pole/Throw Relay - Normally Closed

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

Scheme 75

Basic Knowledge Required

Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire.

Checking Aftermarket Accessories

Do not connect aftermarket accessories into the following circuits

1. SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol.
2. OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol.

Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems.

Possible causes of vehicle problems related to aftermarket accessories include

1. Power feeds connected to points other than the battery
2. Antenna location
3. Transceiver wiring located too close to vehicle electronic modules or wiring
4. Poor shielding or poor connectors on antenna feed line
5. Check for recent service bulletins detailing installation guidelines for aftermarket accessories.

Probing Electrical Connectors

Frontprobe

Disconnect the connector and probe the terminals from the mating side (front) of the connector.

Note. Do not insert test equipment probes (DVOM etc.) into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal will cause a poor connection, which will result in a system failure. Always use the J-35616 GM-Approved Terminal Test Kit or the J 42675 Flat-Wire Probe Adapter in order to front probe terminals. Do not use paper clips or other substitutes to probe terminals. When using the J-35616 GM-Approved Terminal Test Kit, ensure the terminal test adapter choice is the correct size for the connector terminal. Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity. Using a larger terminal test adapter will damage the terminal. Refer to the J-35616 GM-Approved Terminal Test Kit label on the inside of the J-35616 GM-Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size.

Refer to the following table as a guide in selecting the correct test adapter for frontprobing connectors

Probing Electrical Connectors

Backprobe

Do not disconnect the connector and probe the terminals from the harness side (back) of the connector.

Tools Required

J 36169-A Fused Jumper Wire. See Special Tools and Equipment .

The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. See Special Tools and Equipment . This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested.

Measuring Voltage

Note. Refer to Test Probe Notice in Cautions and Notices.

The following procedure measures the voltage at a selected point in a circuit.

1. Disconnect the electrical harness connector for the circuit being tested, if necessary.
2. Enable the circuit and/or system being tested. Use the following methods: Turn ON the ignition, with the engine OFF. Turn ON the engine. Turn ON the circuit and/or system with a scan tool in Output Controls. Turn ON the switch for the circuit and/or system being tested.
3. Select the V (AC) or V (DC) position on the DMM.
4. Connect the positive lead of the DMM to the point of the circuit to be tested.
5. Connect the negative lead of the DMM to a good ground.
6. The DMM displays the voltage measured at that point.

Measuring Voltage Drop

Note. Refer to Test Probe Notice in Cautions and Notices.

The following procedure determines the difference in voltage potential between 2 points.

Scheme 76

1. Set the rotary dial of the DMM to the V (DC) position.
2. Connect the positive lead of the DMM to 1 point of the circuit to be tested.
3. Connect the negative lead of the DMM to the other point of the circuit.
4. Operate the circuit.
5. The DMM displays the difference in voltage between the 2 points.

Measuring Frequency

Note. Refer to Test Probe Notice in Cautions and Notices.

The following procedure determines the frequency of a signal.

1. Apply power to the circuit.
2. Set the rotary dial of the DMM to the V (AC) position.
3. Connect the positive lead of the DMM to the circuit to be tested.
4. Connect the negative lead of the DMM to a good ground.
5. Press the Hz button on the DMM.
6. The DMM will display the frequency measured.

With a DMM

1. Set the rotary dial of the DMM to the ohms position.
2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit.
3. Disconnect the load.
4. Press the MIN MAX button on the DMM.
5. Connect one lead of the DMM to one end of the circuit to be tested.
6. Connect the other lead of the DMM to the other end of the circuit.
7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity.

1. Remove the power feed (i.e. fuse, control module) from the suspect circuit.
2. Disconnect the load.
3. Set the rotary dial of the DMM to the ohms position.
4. Connect 1 lead of the DMM to 1 end of the circuit to be tested.
5. Connect the other lead of the DMM to a good ground.
6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit.

Fuse Powering Several Loads

1. Review the system schematic and locate the fuse that is open.
2. Open the first connector or switch leading from the fuse to each load.
3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). When the DMM displays voltage the short is in the wiring leading to the first connector or switch. If the DMM does not display voltage refer to the next step.
4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted.

Round Wire Connectors

Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J-38125 or the J 38125-4 Instruction Manual for terminal identification. See Special Tools and Equipment .

Follow the procedure below in order to test terminal contact.

1. Separate the connector halves.
2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.
3. Using an equivalent male terminal from the J-38125 , test that the retention force is significantly different between a good terminal and a suspect terminal. See «Special Tools and Equipment»(ref-187796-S23025476162005090100000) . Replace the female terminal in question.

Flat Wire (Dock and Lock) Connectors

There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side.

Follow the procedure below in order to test terminal contact.

1. Remove the component in question.
2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well.
3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.
4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. See «Special Tools and Equipment»(ref-187796-S23025476162005090100000) .

Inducing Intermittent Fault Conditions

In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including

1. Wiggling the harness
2. Disconnecting a connector and reconnecting
3. Stressing the mechanical connection of a connector
4. Pulling on the harness or wire in order to identify a separation/break inside the insulation
5. Relocating a harness or wires

All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure . You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents .

Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well.

There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions.

Salt Water Spray

Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture.

Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as discussed previously.

High Temperature Conditions

Tools Required

J 25070 Heat Gun

If the complaint tends to be heat related, you can simulate the condition using the J 25070 .

Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition.

The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however.

Low Temperature Conditions

Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect.

If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs.

Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern.

Circuit Protection - Circuit Breakers

A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used.

Circuit Protection - Fusible Links

Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size.

Repairing a Fusible Link

Refer to Splicing Copper Wire Using Splice Clips .

Repairing Damaged Wire Insulation

If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire.

Wire Size Conversion

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.

Splicing Twisted or Shielded Cable

Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose® speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable.

1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape.
2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made.
3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm (2.5 in) is recommended.
4. Re-assemble the cable. Rewrap the conductors with the mylar tape. Use caution not to wrap the drain wire in the tape (1). Follow the splicing instructions for copper wire and splice the drain wire. 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.

SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair

Use the connector repair assembly packs in order to repair the damaged SIR/SRS 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 duraseal splice sleeves. Use the duraseal splice sleeves in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J-38125 . See Special Tools and Equipment . You must use the splice crimping tool in order to apply these splices.

The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs.

If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use one of the following 2 components in order to replace the SDM harness connector

1. The SDM harness connector pigtail assembly
2. The SDM harness connector replacement kit

If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain SIR/SRS circuit integrity.

SIR/SRS Wire Pigtail Repair

A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component.

SIR/SRS Wire Repair

If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire 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 . See Special Tools and Equipment . Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves.

SIR/SRS Wiring Repairs

1. Open the harness by removing any tape: Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial. Do not use the crimp and duraseal splice sleeve to form a splice with more than 2 wires coming together.
2. 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.
3. Strip the insulation: When adding a length of wire to the existing harness, use the same size wire as the original wire. Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. Use an AWG wire gage. 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. Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.
4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool nests.
5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. See «Special Tools and Equipment»(ref-187796-S23025476162005090100000) . In order to position the duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning of this repair procedure.
6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice sleeve in the proper nest.
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 duraseal 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: The tubing will shrink completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Connector Position Assurance (CPA)

The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS 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/SRS 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.

Connector Repairs

The Connector Repairs section contains the following types of connector repair information. Using these elements together will make connector repair faster and easier

1. «Connector Position Assurance Locks»(ref-187796-S25639627462005090100000)
2. «Terminal Position Assurance Locks»(ref-187796-S24634732442005090100000)
3. «Push to Seat Connectors»(ref-187796-S34612333922005090100000)
4. «Pull to Seat Connectors»(ref-187796-S17173996282005090100000)
5. «Weather Pack Connectors»(ref-187796-S07891007782005090100000)
6. «Repairing Connector Terminals»(ref-187796-S42817668512005090100000)

Connector Position Assurance Locks

The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all 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 mating terminals, of the connector.

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.

Terminal Repair

1. Slip the cable seal away from the terminal.
2. Cut the wire as close to the terminal as possible.
3. Slip a new cable seal onto the wire.
4. Strip 5 mm (3/16 in) of insulation from the wire.
5. Crimp a new terminal to the wire.
6. Solder the crimp with rosin core solder.
7. Slide the cable seal toward the terminal.
8. Crimp the cable seal and the insulation.
9. If the connector is outside of the passenger compartment, apply grease to the connector.

Reinstalling Terminal

1. In order to reuse a terminal or lead assembly. Refer to «Wiring Repairs»(ref-187796-S26318282122005090100000) .
2. Ensure that the cable seal is kept on the terminal side of the splice.
3. Insert the lead from the back until it catches.
4. Install the TPA, CPA and/or the secondary locks.

1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Crimp a new terminal to the wire.
4. Solder the crimp with rosin core solder.

J-38125 Terminal Repair Kit. See Special Tools and Equipment .

Repair Procedure

The Micro-Pack 100W connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-101 (W jaw) crimping tool was developed to crimp Micro-Pack 100W terminals. The J 38125-101 (W jaw) crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. After the terminal is removed from the connector perform the following procedure in order to repair Micro-Pack 100 terminals.

1. Cut the wire as close to the terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible.
4. Insert the terminal into the crimp tool until the core wings are flush with the anvil on the crimp tool. Be sure that the wings are pointed toward the crimp tool former and release the spring locator. The locator will hold the terminal in place. Inspect the alignment of the terminal wings with the crimp tool former. If the terminal wings are wider than the crimp tool former, remove the terminal and bend the terminal wings in slightly.
5. Place stripped wire into terminal.
6. Crimp the new terminal to the wire. If a jam occurs, press the emergency release to open applicator.

J-38125 Terminal Repair Kit. See Special Tools and Equipment .

Follow the steps below in order to repair Micro 64 connector terminals.

The Micro 64 connectors have small terminals that are difficult to handle and hold when crimping. In order to aid the technician when crimping these terminals, a new crimping tool was developed. The J 38125-64 (M jaw) was developed to crimp Micro 64 terminals. The J 38125-64 crimping tool has a terminal holding block that will hold the terminal in place while the terminal is being crimped. The J 38125-64 crimping tool is also designed to crimp both the wire and the insulation at the same time.

After the terminal is removed from the connector perform the following procedure in order to repair Micro 64 terminals.

1. Cut the wire as close to the damaged terminal as possible.
2. Strip 5 mm (3/16 in) of insulation from the wire.
3. Depress the spring loaded locator of the crimping tool until the terminal holder is completely visible.
4. Insert terminal into the appropriate terminal holder until it hits bottom and stops. The correct terminal holder is determined by the wire size. Also ensure that the terminals wings are pointing towards the former on the tool and the release locator.
5. Insert the stripped cable into the terminal. Insulation should be visible on both sides of the terminal insulation wings.
6. Compress the handles until the ratchet automatically releases.
7. Place the terminal into the appropriate cavity and assemble the connector.

Weather Pack Connectors

The following is the proper procedure for the repair of Weather Pack® Connectors.

1. Separate the connector halves (1).
2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1).
3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position.
4. Insert the Weather Pack® terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1).
5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector.
6. Inspect the terminal and connector for damage. Repair as necessary. Refer to «Repairing Connector Terminals»(ref-187796-S42817668512005090100000) .
7. Reform the lock tang (2) and reset terminal in connector body.
8. Close secondary locks and join connector halves.
9. Verify that circuit is complete and working satisfactorily.
10. Perform system check.

Repairing Connector Terminals

Tools Required

J-38125 Terminal Repair Kit. See Special Tools and Equipment .

Use the following repair procedures in order to repair the following

1. Push to Seat terminals
2. Pull to Seat terminals

Some terminals do not require all of the steps shown. Skip the steps that do not apply for your terminal repair. The J-38125 contains further information. See Special Tools and Equipment .

1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For cable seal terminals, remove the seal.
2. Apply the correct cable seal per gage size of the wire, if used. Slide the seal back along the wire in order to enable insulation removal.
3. Remove the insulation.
4. For sealed terminals only, align the seal with the end of the cable insulation.
5. Position the strip in the terminal. For sealed terminals, position the strip and seal in the terminal.
6. Hand crimp the core wings.
7. Hand crimp the insulation wings. For sealed terminals, hand crimp the insulation wings around the seal and the cable.
8. Solder all of the hand crimp terminals excepting Micro-Pack 100.64 size. Soldering Micro-Pack 100 World terminals may damage the terminal.

J 43244 Relay Puller Pliers. See Special Tools and Equipment .