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.

SYS.OK|MANUAL.DB● LIVE

HOMESERVICE MANUALSCHEVROLET2019EXPRESS 2500 BASE, VAN CARGO EXTENDED, 6.0L ENG VIN GREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 12 (WIRING SYSTEMS AND POWER MANAGEMENT - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSREPAIRING CONNECTOR TERMINALS (TERMINAL REPAIR)NOTES

2019 Chevrolet Express 2500 Base, Van Cargo Extended, 6.0L Eng VIN G

Repairing Connector Terminals (Terminal Repair): Notes

2019 Chevrolet Express 2500 Base, Van Cargo Extended, 6.0L Eng VIN GSECTION Notes

WARNING: This page is about a different car, the 2018 GMC Savana 3500, 2018 GMC Savana 2500, 2018 Chevrolet Express 3500, and 2018 Chevrolet Express 2500. However, it is still accessible from the selected car via links, so may be relevant.

Special Tools

J-38125-580 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) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro .64) Delphi Connectors (12-Way) Delphi Connectors (Steering Gear) .
For pull to seat terminals, refer to Delphi Connectors (Weather Pack) Delphi Connectors (Push To Seat) Delphi Connectors (Pull To Seat) Delphi Connectors (Micro-Pack 100W) Delphi Connectors (Micro .64) Delphi Connectors (12-Way) 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.

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.

RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready Tools Free Quote Check Quote Shield Pro

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.