Wiring Repair-SIR System

Special wiring repair procedures have been developed for use on the Supplemental Inflatable Restraint (SIR) System due to the sensitive nature of the circuitry. These instructions are to be followed whenever servicing the SIR System wiring.

Terminal Repair Kit J 38125
Essential tool kit J 38125 contains special "sealed splices" for use in repairing SIR System wiring. A special crimping tool, heat torch and instruction manual for these splices are also included.

Two critical features of the sealed splices are a special heat shrink sleeve with sealing adhesive to produce an environmentally sealed splice and a cross hatched (Knurled) core crimp to provide necessary contact integrity for the sensitive, LO energy circuits.

Tool Kit J 38125 also serves as a generic terminal repair kit. The kit contains a large sampling of common GM electrical terminals and the correct tools to apply them to wires and remove them from connectors. The terminals in the kit are not to be used to replace damaged SIR System terminals unless otherwise indicated by the terminal package. Specifically, the Diagnostic Energy Reserve Module (DERM)/resistor terminal repair assembly pack is included in the J 38125 for SIR use.

SIR Connector (plastic Body) And Terminal (metal Pin) Repair
If any connector or terminal in the SIR wire harness (except pigtails) is damaged, the component should be repaired using one of the connector repair assembly packs. These kits include an instruction sheet and the sealed splices which will be necessary to splice the new wires, connector, and terminals to the harness. Crimping tool J 38125-8 (the tool which is color keyed to match the splices) from terminal repair kit J 38125 must be used to apply these splices.

The terminals in the SIR System are made of a special metal to provide necessary contact integrity for the sensitive LO energy circuits. These terminals are only available in the connector repair assembly packs and no other terminals should be substituted.

If individual terminals are damaged on the DERM or resistor module, they should be repaired using the DERM/resistor terminal repair assembly pack. If individual terminals are damaged on any other SIR connection, the entire connection should be replaced using the appropriate connector Repair Assembly Pack.

SIR Wire Pigtail Repair
If a component's wire pigtail is damaged, replace the entire component, including the pigtail and the component's connector. A pigtail is the length of wire between the component and the component's connector. Absolutely no wire, connector, or terminal repair is to be attempted on the Dual Sensor, the Forward Discriminating Sensor, the Inflator Module, or the SIR Coil Assembly.

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 gage size (0.5, 0.8, 1.0, etc.). The sealed splices and crimping tool from terminal repair kit J 38125 must be used for theses splices. Carefully follow the wiring repair procedures or the instructions included in the kit for proper sealed application.

SIR System Wire Splice Repair
If any of the original equipment splices (S201, etc., three wires or more) in the SIR System are damaged, they should be repaired by applying a new splice not sealed) from repair kit J 38125. Carefully follow the instructions included in the kit for proper splice clip application. Cloth duct tape may be substituted for splice tape if necessary.