Wire Repair: Notes

If any wire except pigtail (a wire or wires attached directly to device, not a connector) is damaged, wire should be repaired by splicing a new section of wire with same gauge size wire. Sealed splices and splice crimping tool from Saturn Terminal Repair Kit (SA 9138Z) must be used for these repairs. The following wiring repair procedure must be used to ensure integrity of sealed splice assemblies.

1) Remove tape if wiring harness is taped. Use care not to damage wire insulation. Always cut as little wire off as possible from damaged section of wire. Extra length of wire may be needed to change location of a splice.

2) Adjust splice locations to ensure each splice is at least 1.5" (40 mm) away from other splices, harness branches or connectors. When adding a length of wire to existing harness, ensure same gauge size wire is used.

1. Select proper sealed splice sleeve according to wire size from appropriate Saturn Terminal Repair Kit. See WIRE SIZE & COLOR  table. Using splice crimp tool supplied, position splice sleeve in proper color nest of splice crimp tool.
   WIRE SIZE & COLOR
   
   

   Wire Size (AWG)	22, 20, 18	16, 14	12, 10
   Wire Size	.35, .5, .8	1.0, 2.0	3.0, 6.0
   P/N 12089189	Salmon	-	-
   P/N 12089190		Blue	-
   P/N 12089191			Yellow

2. Place splice sleeve in nest so that crimp falls midway between end of barrel. Sleeve has stop in middle of barrel to prevent wire from going further. See Fig 1. Close crimp tool handles to hold splice sleeve firmly in proper nest.
   Fig 1: Installing Wire Repair Splice Sleeve

   Courtesy of GENERAL MOTORS CORP.
3. Insert wire into splice sleeve until it hits barrel stop and close crimp tool handles tightly until crimp tool handles open when released. Crimp tool handles will not open until proper amount of pressure is applied to splice sleeve. Repeat procedure for opposite end of splice. After installing splice sleeve, go to next step.
4. Using heat torch, apply heat where barrel is crimped. Gradually move heat across barrel to open end of splice sleeve, shrinking sleeve as heat is applied. Small amount of sealant will come out of end of splice sleeve when sufficient shrinking is achieved.