Suzuki 2007 XL7, Service Manual

Page: 2272 / 3159

9A-164 Wiring Systems:
High Temperature Wiring Repairs
Special tool
J-38125 Terminal Repair Kit
High Temperature Wiring
Wiring that is exposed to high temperatures, 135
°
C
(275
°
F) or higher, for prolonged periods of time may use
materials i.e. wires, connectors, and shielding that has a
higher heat rating than typical wiring. When making a
repair in a high temperature area observe the following:
• Use high temperature bulk wire rated at 150
°
C
(302
°
F) continuous temperature to replace any
damaged wire.
• Replace any heat shielding that is removed.
• Cover any DuraSeal splice sleeves with SCT1 shrink
tubing (available in the J-38125 Terminal Repair kit).
• After making a wiring repair, ensure that the location
of the wiring is not moved closer to the heat source.
Identifying High Temperature Wiring
Wiring that is exposed to high temperature, 135
°
C
(275
°
F) or higher, for prolonged periods of time need
special considerations when making wiring repairs.
Areas that may be exposed to higher temperatures can
be identified by heat resistant materials that are being
used in those areas. These materials may include heat
reflective tape, moon tape, and high temperature shrink
tubing. Also conduit and other protective coverings may
be used. Because conduit or similar coverings are used
throughout the vehicle regardless of the temperature, it
may be necessary for the technician to determine if an
area is exposed to excessive heat before making a
wiring repair. Obvious areas of consideration would be
any area located near the exhaust manifolds, catalytic
converter, and exhaust pipes.
The J-38125 contains much of the material you will need
to perform repairs on areas exposed to high heat. The kit
contains the following items:
• DuraSeal splice sleeves to crimp and seal
connections
• High temperature SCT1 shrink tubing to protect the
splice sleeves
• A large sampling of common electrical terminals
• The correct crimp tool to attach the terminals to the
wires
• The correct tools to remove the terminals from the
connectors
The J-38125 does not contain wire that is suitable to
high temperature exposure. Use high temperature bulk
wire rated at 150
°
C (302
°
F) continuous temperature of
the same or larger gage size as the original wire when
repair damage wire. Also replace any reflective tape that
you remove during the repair.
High Temperature Wire Repair
NOTE
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.
If any wire except the pigtail is damaged, repair the wire
by splicing in a new section of wire rated at 150
°
C
(302
°
F) continuous temperature rating of the same gage
size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the DuraSeal
splice sleeves and splice crimping tool from the J-38125
and then encapsulate the splice sleeve using the high
temperature SCT1 shrink tubing. Use the following
wiring repair procedures in order to ensure the integrity
of the sealed splice.
NOTE
You must perform the following procedures
in the order listed. Repeat the procedure if
any wire strands are damaged. You must
obtain a clean strip keeping all of the wire
strands intact.
1. Open the harness by removing any tape.
2. Use a sewing seam ripper, available from sewing
supply stores, in order to cut open the harness in
order to avoid wire insulation damage.
3. 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.
Splice Sleeve
Color
Crimp Tool Nest
Color
Wire Gage 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)
Green
88988379
Red (1) 0.22-0.35/(22-24)