Hummer H2. Manual - part 1345

2. Cut the wire. 

z

Cut as little wire off the harness as possible.  

z

Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and 
connectors. This helps prevent moisture from bridging adjacent splices and causing damage.  

3. Select the proper size and type of wire. 

z

The wire must be of equal or greater size than the original (except fusible link).  

z

The wire's insulation must have the same or higher temperature rating. 

„

Use general purpose insulation for areas that are not subject to high temperatures.  

„

Use a cross-linked polyethylene insulated wire for areas where high temperatures are 
expected. 

4. Strip the insulation. 

z

Select the correct size opening in the wire stripper or work down from the largest size.  

z

Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced.  

5. Select the proper clip to secure the splice. Follow the instructions in the J-38125 in order to determine the 

proper clip size crimp tool and anvil. See Special Tools and Equipment .  

6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 

IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not 

replace cross-linked polyethylene with PVC. 
Cross-linked polyethylene wire is not fuel resistant. Do not use 
to replace wire where there is the possibility of fuel contact.

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

Fig. 4: Identifying Splice Clip & Stripped Wires 
Courtesy of GENERAL MOTORS CORP. 

7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. 

z

Ensure that the wires extend beyond the clip in each direction.  

z

Ensure that no insulation is caught under the clip. 

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

Fig. 5: Centering Crimp Tool Over Splice Clip & Wires 
Courtesy of GENERAL MOTORS CORP. 

8. Center the crimp tool over the splice clip and wires.  

9. Apply steady pressure until the crimp tool closes. 

Ensure that no strands of wire are cut.

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

Fig. 6: Crimping Splice Clip & Wires 
Courtesy of GENERAL MOTORS CORP. 

10. Crimp the splice on each end (2). 

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2