13-00-89-008

Bulletin No.: 13-00-89-008
Date: Jul-2013
Subject:
GM Wiring Repair Strategy Information
Models:
2009-2014 GM Cars and Trucks
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 SPX at 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 and is presented to two ways.
The legacy method (which is typically associated with the "TIFF viewer" supported graphics) looks like this:
Connector Part Information
–
Harness Type: Engine
–
OEM Connector: 13519051 (OE Supplier PN)
–
Service Connector: 19151498 (Service Part available through CCA Parts)
–
Description: 5-Way F GT 150 Series, Sealed (BK) (Product description)
Terminal Part Information
–
Terminated Lead: 13575413 (Available through CCA Parts)
1
–
Release Tool: J-38125-553
–
Diagnostic Test Probe: J-35616-2A (GY)
–
Terminal/Tray: 12191819/8 (Available in J-38125 Terminal Repair Kit Tray 8)
–
Core/Insulation Crimp: E/1
Note: This terminal is available as both a Terminated Lead and in the J-38125 Terminal Repair Kit.
The new format (which is typically associated with the "CGM viewer" supported graphics) looks like this:
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
19300628
J-35616-65B (LBU)
J-38125-215A
Not Available
Pending
Not Available
Not Available
II
13575291
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 – TXL wire and fuses are now found in the Chemicals – Fuses - Wire - book section. To locate this section in the EPC, select Make (Chevrolet, Buick,
etc.) then Year, then under Model select Chemicals – Fuses – Wire catalog. TXL Wire will be called out under group 8.966 Wire, Primary wire. Fuses are
located under group 8.965 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) / 19168446
1.0–2.0 (14–16)
Blue 19168447
3.0–5.0 (10–12)
Yellow 19168448
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
2
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.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may
occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that
your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.
WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION
3