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HOMESERVICE MANUALSCHEVROLET2012CHEVY EXPRESS G2500, VAN PASSENGER, 4.8L ENG VIN AREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1003 (WIRING SYSTEMS AND POWER MANAGEMENT - SERVICE, TROUBLESHOOTING & DIAGNOSIS)DELPHI CONNECTORS (MICRO-PACK 100W)TERMINAL REPAIR PROCEDURE
2012 Chevrolet Chevy Express G2500, Van Passenger, 4.8L Eng VIN A

Terminal Repair Procedure

2012 Chevrolet Chevy Express G2500, Van Passenger, 4.8L Eng VIN ASECTION Terminal Repair Procedure
WARNING: This page is about a different car, the 2008 GMC Sierra, 2008 GMC Cab & Chassis Sierra, 2008 Chevrolet Silverado, and 2008 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

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. IMPORTANT: After cutting the damaged terminal from the wire, determine if the remaining wire is long enough to reach the connector without putting a strain on the wire. If the wire is not long enough, splice a small length of the same gage wire to the existing wire, then crimp the new terminal on the added wire.
  2. Strip 5 mm (3/16 in) of insulation from the wire.
    3. Fig 1: Identifying Crimping Tool Spring Loaded Locator
    GM862167Courtesy of GENERAL MOTORS CORP.
  3. Depress the spring loaded locator of the J 38125-101 (W jaw) crimping tool until the terminal holder is completely visible.
    4. Fig 2: Locating Terminal In Crimping Tool
    GM862185Courtesy of GENERAL MOTORS CORP.
  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.
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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.