Hummer H2. Manual — part 1346

Fig. 7: Applying Solder To Back Of Clip Opening
Courtesy of GENERAL MOTORS CORP.

11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's

instructions for the solder equipment.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

Fig. 8: Applying Electrical Tape
Courtesy of GENERAL MOTORS CORP.

12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing

wires.

Fig. 9: Additional Splice Taping
Courtesy of GENERAL MOTORS CORP.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness

covering. Use a winding motion in order to cover the first piece of tape.

SPLICING COPPER WIRE USING SPLICE SLEEVES

Tools Required

J-38125 Terminal Repair Kit. See Special Tools and Equipment .

Splicing Copper Wire Using Splice Sleeves

Use duraseal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial. Use
duraseal splice sleeves where there is special requirements such as moisture sealing. Follow the instructions
below in order to splice copper wire using duraseal splice sleeves.

Splicing Copper Wire Using Splice Sleeves

1. Open the harness.

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If the harness is taped, remove the tape.

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To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.

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If the harness has a black plastic conduit, pull out the desired wire.

2. Cut the wire.

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Cut as little wire off the harness as possible.

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Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.

IMPORTANT: Use only duraseal splice sleeves, other splice sleeves may not protect the

splice from moisture or provide a good electrical connection.

Splice Sleeve Color

Crimp Tool Nest Color

Wire Gauge AWG/(Metric)

Salmon

12089189

Red

20,18 / (0.5, 0.8)

Blue

12089190

Blue

16, 14 / (1.0, 2.0)

Yellow

12089191

Yellow

12, 10 / (3.0, 5.0)

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

Fig. 10: Proper Crimping Of Solderless Connector
Courtesy of GENERAL MOTORS CORP.

3. Select the proper size and type of wire.

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The wire must be of equal or greater size than the original.

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The wires insulation must have the same or higher temperature rating (4).

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Use general purpose insulation for areas that are not subject to high temperatures.

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Use a cross-linked polyethylene insulated wire for areas where high temperatures are
expected.

IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not

replace cross-linked polyethylene with PVC.
Cross-linked polyethylene wire is not fuel resistant. Do not use
to replace wire where there is the possibility of fuel contact.

2004 Hummer H2

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2