Suzuki XL7 2007 Service Manual page 2269

Wiring Repairs
The Wiring Repairs section contains the following types
of wiring repair information. Using these elements
together will make wiring repair faster and easier:
• "Testing for Intermittent Conditions and Poor
Connections"
• "Flat Wire Repairs"
• "GMLAN Wiring Repairs"
• "High Temperature Wiring Repairs"
• "Heated Oxygen Sensor Wiring Repairs: "
• "Splicing Copper Wire Using Splice Clips"
• "Splicing Copper Wire Using Splice Sleeves"
• "Splicing Twisted or Shielded Cable"
• "Splicing Inline Harness Diodes"
• "SIR/SRS Wiring Repairs: "
Repairing Damaged Wire Insulation
If the conductive portion of the wire is not damaged,
locate the problem and apply tape around the wire. If the
damage is more extensive, replace the faulty segment of
the wire. Refer to "Splicing Copper Wire Using Splice
Clips" and follow the instruction to repair the wire.
Wire Size Conversion
Metric Wire Sizes (mm 2)
0.22
0.35
0.5
0.8
1.0
2.0
3.0
5.0
8.0
13.0
19.0
32.0
50.0
Flat Wire Repairs
CAUTION
!
The flat wire within the flex wiring harness is
not serviceable. If an open or short exists
within the flex wiring harness the complete
harness must be replaced.
Repair Instructions
AWG Sizes
24
22
20
18
16
14
12
10
8
6
4
2
1/0
GMLAN Wiring Repairs
Special tool
J-38125 Terminal Repair Kit
The GM Local Area Network (GMLAN) System requires
special wiring repair procedures due to the sensitive
nature of the circuitry. Follow the specific procedures
and instructions when working on GMLAN connectors
and terminals.
The tool kit J-38125 contains the following items in order
to repair the GMLAN wiring:
• DuraSeal splice sleeves
• A wire stripping tool
• J 38125-8 Crimping Tool (GM P/N 12085115)
• J 38125-5 Ultra Torch Special Tool (GM P/N
12085116)
The DuraSeal splice sleeves have the following 2 critical
features:
• A special heat shrink sleeve environmentally seals the
splice. The heat shrink sleeve contains a sealing
adhesive inside.
• A cross hatched (knurled) core crimp provides
necessary contact integrity for the sensitive, low
energy circuits.
The J-38125 also serves as a generic terminal repair kit.
The kit contains the following items:
• A large sampling of common electrical terminals
• The correct tools in order to attach the terminals to the
wires
• The correct tools in order to remove the terminals
from the connectors
GMLAN Repairs
NOTE
When making a repair to any GMLAN
network, the original wire length after the
repair must be the same length as before the
repair. If the network is a twisted pair, the
twist must be maintained after the repair is
completed.
GMLAN has 2 types of networks, low speed and high
speed. Low speed GMLAN has a single wire and works
at slow speeds. High speed GMLAN has 2 wires in a
twisted pair and works at higher speeds. For more
information on GMLAN, refer to "Data Link
Communications Description and Operation: ".
Wiring Systems: 9A-161