Hummer H2. Manual - part 1347

4. Strip the insulation. 

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

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Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1).  

5. Select the proper duraseal splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal 

Splice Table.  

6. Place the duraseal splice sleeve in the J-38125-8 (12085115) crimp tool nest so that the crimp falls at 

point 1 on the splice.  

7. Close the hand crimper handles slightly in order to hold the duraseal splice sleeve firmly in the proper 

crimp tool nest.  

8. Insert the wires into the duraseal splice sleeve until the wire hits the barrel stop. The splice sleeve has a 

stop in the middle of the barrel in order to prevent the wire from passing through the splice (3).  

9. Close the handles of the J-38125-8 (12085115) until the crimper handles open when released. The 

crimper handles will not open until the proper amount of pressure is applied to the splice sleeve.  

10. Shrink the insulation around the splice. 

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

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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.  

SPLICING TWISTED OR SHIELDED CABLE 

Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this 
construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications 
where low level, sensitive signals must be carried. Follow the instructions below in order to repair the 
twisted/shielded cable. 

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

Fig. 11: Outer Wiring Jacket 
Courtesy of GENERAL MOTORS CORP. 

1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape.  

2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the 

splice is made. 

Fig. 12: Inspecting Wiring Connections 
Courtesy of GENERAL MOTORS CORP. 

3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. 

Staggering the splices by 65 mm (2.5 in) is recommended. 

IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good 

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

Fig. 13: View Of Diode On Wire 
Courtesy of GENERAL MOTORS CORP. 

4. Re-assemble the cable. 

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Rewrap the conductors with the mylar tape.  

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Use caution not to wrap the drain wire in the tape (1).  

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Follow the splicing instructions for copper wire and splice the drain wire.  

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Wrap the drain wire around the conductors and tape with mylar tape.  

Fig. 14: Repaired Wire Covered With Electrical Tape 
Courtesy of GENERAL MOTORS CORP. 

5. Tape over the entire cable. Use a winding motion when you apply the tape.  

SPLICING INLINE HARNESS DIODES 

Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. 

electrical contact with the drain wire.

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2

  

When installing a new diode use the following procedure.

1. Open the harness. 

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If the harness is taped, remove the tape.  

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To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness.  

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If the harness has a black plastic conduit, pull out the diode.  

2. If the diode is taped to the harness, remove all of the tape.  

3. Check and record the current flow direction and orientation of diode.  

4. Remove the inoperative diode from the harness with a suitable soldering tool. 

5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove 

any more than is needed to attach the new diode.  

6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference 

the appropriate service manual wiring schematic to obtain the correct diode installation position.  

7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks 

(aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the 
manufacturer's instruction for the soldering equipment.  

8. Reinstall terminal(s) into the connector body if previously removed. 

9. Tape the diode to the harness or connector using electrical tape.  

SIR/SRS WIRING REPAIRS 

Tools Required 

J-38125 Terminal Repair Kit. See Special Tools and Equipment . 

The Supplemental Inflatable Restraint (SIR) System/Supplemental Restraint System (SRS) requires special 
wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and 
instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors 
and terminals). 

The tool kit J-38125 contains the following items:. See Special Tools and Equipment . 

IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) 

from the connector to prevent damage from the soldering tool.

IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all 

exposed wire and diode attachment points with tape.

IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system 

terminals unless specifically indicated by the terminal package.

 

2004 Hummer H2 

2004 ACCESSORIES & EQUIPMENT Wiring Systems - Hummer H2