Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2011AVEO LT, 4D SEDAN, AUTOMATICREPAIR AND DIAGNOSISELECTRICALBODY ELECTRICALWIRING SYSTEMS AND POWER MANAGEMENT - DIAGNOSTIC INFORMATION AND PROCEDURESDIAGNOSTIC INFORMATION AND PROCEDURESREPAIRING CONNECTOR TERMINALS (TERMINAL REPAIR)NOTES
2011 Chevrolet Aveo LT, 4D Sedan, Automatic
Repairing Connector Terminals (Terminal Repair): Notes
2011 Chevrolet Aveo LT, 4D Sedan, AutomaticSECTION Notes
Special Tools
- J-38125: Terminal Repair Kit
- J-38125-6: Crimp Tool
- J-38125-7: Crimp Tool
- J-38125-8: Crimp Tool
- J-38125-64: Crimp Tool
- J-38125-101: Crimp Tool
- J-38125-641: Crimp Tool
- J-38125-642: Crimp Tool
- J-38125-643: Crimp Tool
For equivalent regional tools, refer to Special Tools .
Use the following repair procedures to repair each type of terminal:
- For push to seat terminals, refer to Delphi Connectors (Weather Pack) or Delphi Connectors (Push To Seat) or Delphi Connectors (Pull To Seat) or Delphi Connectors (Micro-Pack 100W) or Delphi Connectors (Micro .64) or Delphi Connectors (12-Way) or Delphi Connectors (Steering Gear) .
- For pull to seat terminals, refer to Delphi Connectors (Weather Pack) or Delphi Connectors (Push To Seat) or Delphi Connectors (Pull To Seat) or Delphi Connectors (Micro-Pack 100W) or Delphi Connectors (Micro .64) or Delphi Connectors (12-Way) or Delphi Connectors (Steering Gear) .
NOTE:
The first step for all terminal repairs is to find the connector end view in SI.
Cable Seal Terminals
- Cut off the terminal between the core and the insulation crimp to minimize any wire loss.
- Remove the old seal.
- Apply the correct cable seal, per the wire gauge size, from the kit. Slide the seal back along the wire to enable removal of the insulation.
- To minimize wire loss, remove only the insulation required.
- Using the connector end view, determine the correct crimp tool and crimp jaw.
- Align the seal with the end of the cable insulation.
- Position the stripped wire and seal in the terminal.
- Hand Crimp the core wings first.
- Hand Crimp the insulation wings around the seal and the cable.
- Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes.
Unsealed Terminals
- Cut off the terminal between the core and the insulation crimp to minimize any wire loss.
- To minimize wire loss, remove only the insulation required.
- Position the stripped wire in the terminal.
- Hand Crimp the core wings first.
- Hand Crimp the insulation wings around the cable.
- Solder all of the hand crimp terminals except the Micro-Pack 100 and 0.64 sizes.
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.