Wiring Repair

WARNING: This page is about a different car, the 1996 Suzuki Swift, 1996 Pontiac Firefly, and 1996 Geo Metro. However, it is still accessible from the selected car via links, so may be relevant.

Due to level of precision demanded by SIR system, manufacturer requires specific wiring repair procedures. Whenever a wiring repair is performed in SIR circuit, Terminal Repair Kit (J-38125-A) must be used. This special repair kit contains sealed, heat shrink splice, sleeves, knurled splice connectors, a special crimping tool, a heat torch, and an instruction manual for using these parts. Kit also contains special terminals to be used in SIR applications.

Wiring repairs must never be made in component pigtails. If a pigtail connector or wiring is damaged in any way, component must be replaced. If a connector in SIR harness is damaged, it may be repaired using SIR replacement terminals in terminal repair kit. See Fig 1. If a wire in SIR harness is damaged, it may be cut out of harness and replaced with a new piece of wire of same length and thickness. When making an SIR wiring repair, be sure to follow instructions in terminal repair kit. To avoid damaging any insulation in SIR harness, manufacturer suggests use of a sewing seam ripper to open harness.

Fig 1: Sensing Diagnostic Module

Courtesy of GENERAL MOTORS CORP.

Fig 2: SIR Connector Terminals (Face View)

Courtesy of GENERAL MOTORS CORP.

Wiring repairs must never be made in component pigtails. If a pigtail connector or wiring is damaged in any way, component must be replaced. If a connector in SIR harness is damaged, it may be repaired using SIR replacement terminals in terminal repair kit. If a wire in SIR harness is damaged, it may be cut out of harness and replaced with a new piece of wire of same length and thickness. When making an SIR wiring repair, be sure to follow Terminal Repair Kit (J-38125-A) instructions. To avoid damaging any insulation in SIR harness, manufacturer suggests use of a sewing seam ripper to open harness.