SIR Wire Repair

Special wiring repair procedures have been developed for use on the Supplemental Inflatable Restraint (SIR) system due to the sensitive nature of the circuitry. You must follow these specific procedures and instructions when working with the SIR system wiring, and the wiring components (such as connectors and terminals).

Tools Required
J 38125-A Terminal Repair Kit.
If damage occurs to any wire except the pigtail, you should repair the wire by splicing in a new section of wire of the same gauge size (0.5, 0.8, 1.0 mm etc.). You must use the sealed splices and splice crimping tool from J 38125-A Terminal Repair Kit. You must use the following wiring repair procedures to ensure the integrity of the sealed splice application.
1. Open the harness.
^ Remove any tape from the harness. To avoid wire insulation damage, use a sewing seam ripper (available from sewing supply stores) to cut open the harness.
^ You may use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial.
^ You may only use the sleeves to form a one-to-one splice.
2. Cut the wire.
^ Cut as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire in order to change the location of a splice.
^ You may have to adjust splice locations in order to ensure that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.

Notice: 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.

3. Strip the insulation.
^ If you must add a length of wire to the existing harness, make sure to use the same size as the original wire.
^ To find the correct wire size, find the wire on the schematic. Then convert the metric size to the equivalent AWG size. You may also use an AWG wire gauge.
^ If unsure about the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. Strip approximately 7.5 mm (0.313 in) of insulation from each wire you intend to splice. Avoid nicking or cutting any of the strands. Avoid cutting any of the strands. Check the stripped wire for nicks or cut strands. If damage occurred to the wire, repeat this procedure after removing the damaged section.
4. Select and position the splice sleeve.
4.1. Select the proper sealed splice sleeve according to wire size. See the following table for color coding of the splice sleeves and the crimp tool nests.

Important: Refer to Wiring Repairs in Wiring Systems 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.

4.2. Position the splice sleeve in the proper color nest of the Splice Crimp Tool from J 38125-A Terminal Repair Kit.
4.3. Place the splice sleeve in the nest so that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop in the middle of the barrel to prevent the wire from going further.
4.4. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest.





5. Insert the wire into the splice sleeve until it hits the barrel stop.





6. Close the handles of the crimp tool tightly until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice.





7. Shrink the insulation around the splice. Using the heat torch apply heat to the crimped area of the barrel, gradually move the heat barrel to the open end of the tubing. Shrink the tubing completely as you move the heat along the insulation. When you achieve sufficient shrinkage, a small amount of sealant will come out of the end of the tubing.