Hummer H2. Manual - part 1271

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When adding a length of wire to the existing harness, use the same size wire as the original wire.  

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Perform one of the following items in order to find the correct wire size: 

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Find the wire on the schematic and convert the metric size to the equivalent AWG size.  

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Use an AWG wire gauge.  

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If you are unsure of the wire size, begin with the largest opening in the wire stripper and 
work down until achieving a clean strip of the insulation.  

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Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced.  

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Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.  

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If the wire is damaged, repeat this procedure after removing the damaged section.  

4. Select the proper duraseal splice sleeve according to the wire size. Refer to the above table at the 

beginning of the repair procedure for the color coding of the duraseal splice sleeves and the crimp tool 
nests. 

Fig. 15: Identifying Splice Crimp Tool Nests 
Courtesy of GENERAL MOTORS CORP.

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

5. Use the Splice Crimp Tool from the J-38125 to crimp duraseal splice sleeve. In order to position the 

duraseal splice sleeve in the proper color nest of the Splice Crimp Tool, refer to the table at the beginning 
of this repair procedure. See Special Tools and Equipment . 

Fig. 16: Identifying Durasteel Splice Sleeve 
Courtesy of GENERAL MOTORS CORP. 

6. Place the duraseal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the 

barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) 
from going further. Close the hand crimper handles slightly in order to firmly hold the duraseal splice 
sleeve in the proper nest. 

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

Fig. 17: Crimped Duraseal Splice Sleeve 
Courtesy of GENERAL MOTORS CORP. 

7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.  

8. Tightly close the handles of the crimp tool until the crimper handles open when released. 

The crimper handles will not open until you apply the proper amount of pressure to the duraseal splice 
sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 

Fig. 18: Identifying Heated Splice Sleeve 
Courtesy of GENERAL MOTORS CORP. 

9. Using the heat torch, apply heat to the crimped area of the barrel.  

10. Gradually move the heat barrel to the open end of the tubing: 

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The tubing will shrink completely as the heat is moved along the insulation.  

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A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is 
achieved.  

SIR/SRS System Wire Splice Repair 

Apply a new splice (not sealed) from the J-38125 if damage occurs to any of the original equipment splices (3 
wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper 

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

splice clip application. See Special Tools and Equipment .

Connector Position Assurance (CPA) 

The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the 
SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You 
must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. 

Terminal Position Assurance (TPA) 

The terminal position assurance (TPA) insert resembles the plastic combs used in the control module 
connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from 
the connector body unless you remove a terminal for replacement. 

CONNECTOR REPAIRS 

The Connector Repairs section contains the following types of connector repair information. Using these 
elements together will make connector repair faster and easier: 

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Connector Position Assurance Locks  

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Terminal Position Assurance Locks  

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Push to Seat Connectors  

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Pull to Seat Connectors  

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Weather Pack Connectors  

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Repairing Connector Terminals  

CONNECTOR POSITION ASSURANCE LOCKS 

The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of the 
connector. CPAs are used in various connectors throughout the vehicle. CPAs are also used in all SIR system 
electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA 
in place in order to ensure good contact between the mating terminals, of the connector. 

TERMINAL POSITION ASSURANCE LOCKS 

The terminal position assurance (TPA) insert resembles the plastic combs used in the control module 
connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from 
the connector body unless you remove a terminal for replacement. 

PUSH TO SEAT CONNECTORS 

Terminal Removal 

Follow the steps below in order to repair push to seat connectors.

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2