Hummer H2. Manual — part 1348

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Duraseal splice sleeves-In order to repair the SIR/SRS system wiring

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A wire stripping tool

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A special crimping tool

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A heat torch

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An instruction manual

The duraseal splice sleeves have the following 2 critical features:

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A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing
adhesive inside.

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A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy
circuits.

The J-38125 also serves as a generic terminal repair kit. See Special Tools and Equipment . The kit contains
the following items:

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A large sampling of common electrical terminals

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The correct tools in order to attach the terminals to the wires

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The correct tools in order to remove the terminals from the connectors

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 . You must use the splice crimping tool in order to apply these splices. See Special
Tools and Equipment .

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:

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The SDM harness connector pigtail assembly

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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

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

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 gauge
size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the duraseal splice sleeves and splice crimping tool from the J-38125 .
Use the following wiring repair procedures in order to ensure the integrity of the duraseal splice sleeves. See
Special Tools and Equipment .

SIR/SRS Wiring Repairs

1. Open the harness by removing any tape:

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Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in
order to avoid wire insulation damage.

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Use the duraseal splice sleeves on all types of insulation except tefzel and coaxial.

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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:

IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire

pigtails.

IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the

circuit you are repairing. You must obtain this information in order to ensure
circuit integrity.

Splice Sleeve Color

Crimp Tool Nest Color

Wire Gauge mm

2

/ (AWG)

Salmon (Yellow-Pink)

12089189

Red (1)

0.035-0.8/(18-20)

Blue

12089190

Blue (2)

1-2/(14-16)

Yellow

12089191

Yellow (3)

3-5/(10-12)

IMPORTANT: You must perform the following procedures in the listed order. Repeat the

procedure if any wire strands are damaged. You must obtain a clean strip
with all of the wire strands intact.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

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When adding a length of wire to the existing harness, use the same size wire as the original wire.

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Perform one of the following items in order to find the correct wire size:

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Find the wire on the schematic and convert the metric size to the equivalent AWG size.

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Use an AWG wire gauge.

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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.

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Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.

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Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.

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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.

Fig. 15: Identifying Splice Crimp Tool Nests
Courtesy of GENERAL MOTORS CORP.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. 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. See Special Tools and Equipment .

Fig. 16: Identifying Durasteel Splice Sleeve
Courtesy of GENERAL MOTORS CORP.

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.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2