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Folded-Over Wire Repair

Folded-Over Wire Repair


Special Tools

EL-38125-10 Splice Sleeve Crimping Tool

For equivalent regional tools, refer to Special Tools .

The GM global wire repair strategy uses connector assemblies (pigtails) and terminated leads to repair wiring harnesses.

To reduce and manage GM Service Parts proliferation, the service pigtails and terminated leads are designed with the largest wire gauge size that can be held by either the terminal or the connector housing.

The folded over wire repair technique, in which the copper wire strands are folded over before being installed into a splice sleeve, allows the service part to be used when repairing a smaller gauge size wire in a vehicle. This technique has passed all GM testing standards.


The larger harness size wires (1) will be placed in one side of the splice sleeve and match the splice sleeve closely in size. The wires are moved into the splice sleeve until they hit the stop (4) in the splice sleeve. The smaller harness size wires (2) will be placed in the other side of the splice sleeve. The smaller harness size wires will be folded over (3) to match up with the splice sleeve size.

Use the folded over wire repair for:


•
Note

Increasing the amount of copper strands in the smaller gauge size will allow for a better crimp


Splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes)

•
Note

Vehicle side needs to be of same or less gauge size (not greater than the service part"s gauge size)


Splicing wires of different gauges


Use the Service Information (SI) connector end-views to determine:


• Gauge size of wiring harness

• Recommended Repair: Terminated Lead or Pigtail


The following table lists the acceptable variance within the gauge size

Folded-Over Wire Selection Table

Harness Wire Gauge Connector Assembly (Pigtail) or Terminated Lead Wire Gauge Size
- Salmon Color Splice Sleeve Blue Color Splice Sleeve Yellow Color Splice Sleeve
Metric - 0.35 mm 0.5-0.8 mm 1.0-2.0 mm 3.0-5.0 mm
- Wire Gauge (AWG) 22 20-18 16-14 12-10
0.13 mm 26 Fold Over Wire Fold Over Wire Fold Over Wire Not Acceptable
0.22 mm 24 Fold Over Wire Fold Over Wire Fold Over Wire Not Acceptable
0.35 mm 22 Fold Over Wire Fold Over Wire Fold Over Wire Not Acceptable
0.5 mm 20 Not Acceptable Wire to Wire Fold Over Wire Not Acceptable
0.75 mm - Not Acceptable Wire to Wire Fold Over Wire Not Acceptable
0.8 mm 18 Not Acceptable Wire to Wire Fold Over Wire Not Acceptable
1.0 mm 16 Not Acceptable Wire to Wire Fold Over Wire Not Acceptable
1.5 mm - Not Acceptable Not Acceptable Wire to Wire Fold Over Wire
2.0 mm 14 Not Acceptable Not Acceptable Wire to Wire Fold Over Wire
2.5 mm - Not Acceptable Not Acceptable Wire to Wire Fold Over Wire
3.0-5.0 mm 12-10 Not Acceptable Not Acceptable Not Acceptable Wire to Wire


Example

For an IP Harness of 0.22 mm (24 gauge on left side of table) wire size, the SI connector end-view recommends a pigtail with leads of 0.8 mm (18 gauge on the top of the table) with a salmon colored DuraSeal splice sleeve of 0.5-1.0 mm (20-16 gauge).

Follow these steps to use the folded over wire (1) technique on an IP Harness.


Strip twice the amount of insulation on the smaller (1) wire (IP Harness is the lower wire) than normally required. Normally, the terminated leads have 5 mm of insulation stripped off the wire.


1.
Note

Use EL-38125-10 splice sleeve crimping tool .


For wiring repair, refer to Splicing Copper Wire Using Splice Sleeves .


2. Twist the wires before you fold them over to prevent the wire strands from opening up. Fold over the copper wire strands of the smaller (1) gauge wire so that it is the same length as the non-folded wire.


3. Insert the folded over wire (1) into the splice sleeve.


4. Use the proper crimp tool to crimp the splice sleeve to the smaller wire (harness side of repair). Complete the crimp as usual (using the heat tool to shrink the tube).