SIR Wire Repair
If any wire except the pigtail is damaged, the wire should be repaired by splicing in a new section of wire of the same gauge size (0.5, 0.8, 1.0, etc.). The sealed splices and splice crimping tool from Saturn repair kit SA 9138Z must be used for these repairs. The following wiring repair procedures must be used to ensure the integrity of the sealed splice application.1. OPEN THE HARNESS
If the harness is taped, remove the tape. To avoid wire insulation damage use a sewing "seam ripper" (available from sewing supply stores) to cut open the harness. The crimp and sealed splice sleeves may be used only to form a one-to-one splice.
2. CUT THE WIRE
Begin by cutting as little wire off the harness as possible. You may need the extra length of wire later if you decide to cut more wire to change the location of a splice. You may have to adjust splice locations to make certain that each splice is at least 40 mm (1.5 in.) away from other splices, harness branches, or connectors.
3. STRIP THE INSULATION
NOTICE: The following procedures must be followed in the order listed. If wire strands are damaged, the procedure must be repeated until a clean strip with all wire strands intact is obtained.
If it is necessary to add a length of wire to the existing harness, be certain to use the same size as the original wire.
To find the correct wire size either find the wire on the schematic and convert the metric size to the equivalent AWG size or use an AWG wire gage.
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 10 mm (5/16 in.) of insulation from each wire to be spliced. Be careful to avoid nicking or cutting any of the strands. Check the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.
4. SELECT AND POSITION THE SPLICE SLEEVE
Description:
*Packard Electric Part Number (can be ordered by calling 1-800-PACKARD)
**OTC Part Number (can be ordered through the Special Tool catalog)
Select the proper sealed splice sleeve according to wire size. The splice sleeves and tool nests are color coded (refer to chart).
Using the splice crimp tool position the splice sleeve in the proper color nest of the hand crimp tool. 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. Close the hand crimper handles slightly to hold the splice sleeve firmly in the proper nest.
5. INSERT WIRES INTO SPLICE SLEEVE AND CRIMP
Insert the wire into the splice sleeve until it hits the barrel stop and close the handles of the splice crimp tool tightly until the crimper handles open when released.
The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. Repeat steps 4 and 5 for opposite end of the splice.
6. SHRINK THE INSULATION AROUND THE SPLICE
CAUTION: DO NOT USE A MATCH OR AN OPEN FLAME TO APPLY HEAT TO SPLICE.
Using the Ultratorch(R), apply heat where the barrel is crimped.
Gradually move the heat barrel to the open end of the tubing, shrinking the tubing completely as the heat is moved along the insulation. A small amount of sealant will come out of the end of the tubing when sufficient shrinking is achieved.
IMPORTANT: The salmon splice can be used on the 0.35 (22 gage) wire if the following additional steps are taken:
1. Remove 19 mm (3/4 in.) of insulation.
2. Bend the stripped portion in half to double the thickness.
3. Twist the stripped, doubled wire and insert into the splice sleeve.