Gm Wiring Repair Strategy Information (13-00-89-008A)

GM WIRING REPAIR STRATEGY INFORMATION

TECHNICAL SERVICE BULLETIN

SERVICE INFORMATION

This bulletin is being published to provide a resource map to find information and parts to perform wiring repairs on GM Vehicles.

GLOBAL WIRING REPAIR

The global wiring repair strategy is:

• Major Harnesses (Body, Engine, Instrument Panel, Forward Lamp, etc.) are to be repaired whenever possible.
• Minor Harnesses (door, seat, steering column, etc.) are serviced as assemblies.

This direction was established to reduce the number of individual part numbers needed to service our vehicles, as even small harnesses can have many different part numbers for the individual connectors and terminals. When new terminals or connectors are released within the major harnesses they will be serviced through the release of Connectors, Terminated Leads, Pigtails, Etc. and made available through CCA Parts. If a terminal happens to be a legacy part already available in the Terminal Repair Kit, it will be called out in SI as well.

PARTS

There are two sources for wire harness repair parts. They are the J-38125 Terminal Repair Kit and your Parts Department.

The J-38125 Terminal Repair Kit is still a very valuable resource. Many of the terminals that are available in the kit still are in use on current model vehicles. The kit also contains many tools and instructions to service harness connectors and wiring.

Tip:  Replenishment tools and terminals for the J-38125 are available through Bosch at 1-800-GM-TOOLS (1-800-468-6657).

Tip:  U.S dealers can download an electronic copy of the J-38125 Terminal Repair Kit Instruction Manual by logging onto the GM Center of Learning web site at https://www.centerlearning.com  then under "Resources" and select STC Training Materials. The file is located in the Service Technical Books section and is called out as "J-38125-620H Terminal Repair Kit Instruction Manual (16.2MB). Canadian dealers can download the J-38125 Terminal Repair Kit Instruction Manual from GM GlobalConnect (located in Library/Service/Technician Resources).

Major Harnesses  - new parts are released as Terminated Leads, Connector Kits, and Connectors and are available through CCA Parts.

Tip:  Terminated Leads, Connectors, and Harness assemblies are only available through CCA Parts.

PARTS NUMBER INFORMATION

The source for the part number information and where to obtain parts is found in eSI Service Information in the Connector End View section. The Harness/Connector/Terminal Part Information is found just below the connector end view drawing.

Connector Part Information

• Harness Type: Engine
• OEM Connector: 345664483
• Service Connector: 19300571
• Description: 73 F 0.64, 2.8 Series, Sealed

Terminal Type ID	Terminated Lead	Diagnostic Test Probe	Terminal Removal Tool	Service Terminal	Tray	Core Crimp	Insulation Crimp
I	13588062	J-35616-65B (L-BU)	J-38125-215A	Not Available	Pending	Not Available	Not Available
II	13576392	J-35616-35 (VT)	J-38125-11A	7116-4152-02	20	2	5

This information shows two different part numbers; one is only available as a terminated lead and the other is available both as a terminated lead and in the terminal repair kit. Remember that Terminated Leads are only available through CCA Parts. The information in the column titled "Service Terminal" has part number for terminals that were released in the J-38125 Terminal Repair Kit, followed by the tray number and crimping information.

WIRE AND FUSE PARTS

It's important to use TXL wire to maintain factory specifications for wire harness integrity. TXL wire is available through the CCA parts catalog within the Chemical Catalog section.

NOTE - For the Electronic Parts Catalog (EPC) the TXL wire and fuses are located in the Chemicals - Fuses - Wire - book section. To locate this section, select Make (Chevrolet, Buick, etc.) then Year, then under Model select Chemicals - Fuses - Wire catalog. The TXL Wire will be called out under group 8.966 Wire, Primary wire. Fuses are located under group 8.965 Fuse.

For the Electronic Parts Catalog Next Generation the TXL wire and fuses are in the Q - CHEMICALS - FUSES - WIRES - BULBS section. To locate this section, select Make (Chevrolet, Buick, etc.) then Year, then under Model select Q - CHEMICALS - FUSES - WIRES - BULBS and then select 08 - Vehicles Maintenance. The TXL Wire will be called out under group 08.966 WIRE, Primary Wire. Fuses are located under group 08.965 FUSE, Fuse.

REPAIR PROCEDURES AND CONNECTOR REPAIR INFORMATION

Information covering wiring and terminal replacement procedures as well as disassembly instructions for various connectors is covered in SI. Navigate to this information by: select vehicle being serviced, select "Wiring Systems and Power Management" then select "Diagnostic Information and Procedures." This is an extensive resource that covers the many wiring type repairs including coax cable.

This area also calls out some of the required materials to correctly perform wiring repairs, such as splice sleeves. These are available through CCA Parts.

Wire Gauge mm2 (AWG)	DuraSeal Splice Sleeve/Part Number
0.5-0.8 (18-20)	Salmon (Yellow-Pink) / 19300089
1.0-2.0 (14-16)	Blue 19168447
3.0-5.0 (10-12)	Yellow 19300091

Heat Shrink Tubing is available through CCA Parts and is currently called out in the Standard Parts Catalog.

Part Resource Matrix 

Part Name	Part Number Resource	Order Through
Terminal	SI	Bosch Automotive Service Solutions
Crimp Tools	SI	Bosch Automotive Service Solutions
Terminated Leads	SI	CCA Parts
Connector w/Leads	SI	CCA Parts
Connector	SI	CCA Parts
Splice Sleeves	SI and CCA Parts Catalog	CCA Parts
Harness Assembly	CCA Parts Catalog	CCA Parts
Wire, Fuse and Heat Shrink	CCA Parts Catalog	CCA Parts

TECHLINK REFERENCE INFORMATION

An extensive and useful reference file has been placed in the Reference Guide section of the TechLink website. To locate it, look at the top of any month's home page (any language). Click on Reference Guide tab. Then scroll down to locate the Terminal Repair Kit Update Information.

Tip:  This file is in PowerPoint format and may take a while to open.

This extensive presentation (82 slides) shows every step in the history of the J-38125 Terminal Repair Kit. But more importantly, it shows how to organize all of the previous updates, resulting in the current J-38125-H. Remember, this needs to be done before you do the J-38125-770 update.