Function

1

1

BK

1850

2

1

RD/BU

4540

3

1

RD/GN

4440

Battery Positive Voltage

Note: This Table is a representative view and does not include all 26 Connector Pins.

these parts to help in confirming the correct parts are
ordered. Battery cables, infotainment cables and hoses
are also listed in the EPC.
Tip: GM is now releasing washer hoses as a
subassembly to the main harness when a hose is
imbedded in the harness. For example: The chassis
harness has a hose going to the rear wiper.

Video

Ordering Parts
Process for ordering part(s) in the EPC:
1. Go to > Service Manual > Power and Signal
Distribution > Wiring Systems and Power
Management > Component Locator > Master
Electrical Component List > Connector End View
(last column on the right) in SI.
2. Select the Connector End View being serviced.

5380982

Connector Repair Video Opening Screen
The video (if available) will illustrate how to use the
tools for probing and releasing the terminals with a
demonstration on the exact connector.

Electronic Parts Catalog
Overview
Continual updates to the EPC will allow better
searchability for wiring repair components. In addition,
pictures will be added when available to the EPC for
5381355

Bulletin No.: 13-00-89-008B

August, 2019

Page 7

3. Locate the Service Connector Number which is just
below and to the left of the Connector End View
drawing.

5385197

5381448

6. Select the Part Group Index.
Select 02.530 CONNECTOR-CONNECTOR
KIT-SEAL-TAPE-WIRE, Chassis Electrical

4. In the Electronic Parts Catalog (EPC) enter the VIN
for the vehicle OR select the Make, Year and
Model.

5385460

5381500

5. At the Major Group screen, select:
02 – STARTER - GENERATOR IGNITION_ELECTRICAL - LAMPS

7. Copy and paste the Service Connector Number
into the Type To Narrow search box.

Page 8

August, 2019

Bulletin No.: 13-00-89-008B

Terminal Test Probe Kit J-35616-F (EL-35616 Global
Tool Number)

5386219

8. Typical view of 19352910 CONNECTOR KIT,
BODY WRG HARN (14V POWER MODULE X1)
(BLACK) (.75MM2) (8-WAY FEMALE)
(W/LEADS)
Click View Image to see the connector image to
verify the correct part is being purchased. If an
image is not available, there will be a generic
image in its place. Review the Description field to
determine if it matches application required for
repair.
9. Add the Service Connector to the Shopping List.

Terminal Tools and Kits
Overview
The metal piece soldered or crimped to the end of a
wire is called a terminal. It provides the electrical
connection between wires and components. Any
damage to the terminals could cause inaccurate test
results, difficult diagnosis and failures after the vehicle
has been returned to the customer.
When servicing a suspected wire/terminal issue, It is
important to inspect for the following conditions:
– Any signs of connector damage.
– Excessive wear to the terminal locking mechanism.
– Loose or backed out terminals.
– Damaged terminated lead due to improper probing
tool use.
Terminal Tools
The following Special Tools can be used for the
diagnosis, testing and removal of terminals. These
items can be ordered through Bosch or Kent-Moore. Be
advised that the kit and tool numbers are always
subject to change when they are updated by the
supplier.

5386340

When probing a terminal for testing procedures, it is
critical to use the appropriate size probe from the
J-35616-F Terminal Test Probe Kit. The probes in the
kit are sized to fit various terminal sizes and their
shapes properly.
Terminals are becoming increasingly smaller and more
complex in design. Using an improper test kit probe
may cause damage to the terminals being probed and
false readings during a diagnostic procedure. Using an
instrument other than the correct probe will, in most
cases, cause irreversible damage to the terminal by
enlarging or deforming it to the point that it will no
longer mate correctly.
Refer to Power and Signal Distribution > Wiring
Systems and Power Management > Diagnostic
Information and Procedures > Probing Electrical
Connectors in SI. Refer to the Test Adapter and
Description Table as a guide in selecting the correct
test adapter for front probing connectors.

Bulletin No.: 13-00-89-008B

August, 2019

Page 9

selection. Crimp nest selection is determined based on
wire size. Crimp nest selection is critical to splice crimp
quality.
Use the J-38125–580 Terminal Repair Kit with the
following tools:
– J-38125-6 Crimp Tool
– J-38125-7 Crimp Tool
– J-38125-8 Crimp Tool
– J-38125-64 Crimp Tool
– J-38125-101 Crimp Tool
– J-38125-641 Crimp Tool
– J-38125-642 Crimp Tool
– J-38125-643 Crimp Tool

Terminal Release Tool Kit: J-38125-550
(EL-38125-550 North America Only)

Splice Sleeve Crimp Tool — Special Tool Numbers
– J-38125-8 (North America Only)
– EL-38125–EU (Europe)
– EL-38125–10 (Non-North America/Non Europe)

5386378

This Terminal Release Tool Kit contains various tools
designed to release the terminals from the connector.
The terminals have a metal arm or tang that locks into
the connector body. When the release tool is inserted
into the canal, it moves the tang against the terminal.
This movement allows the connector body to be
released and moved outward. Tangless terminals are
released in a similar fashion with the only difference
being that the tool pushes the arm of the connector
body to release the terminal.
Splice Sleeve Crimp Tool

Best Practices
Some steps that should be considered as best
practices are:
1. Compress handles until the ratchet automatically
opens.
2. Determine the correct holder per the crimp matrix
section.
3. Crimp the core wings first. Lay the back of the
terminal core wings on the appropriate anvil. Be
sure the core wings are pointing toward the
forming jaws.
4. Gently apply pressure to the handles until the
crimpers slightly secure the terminal core wings.
5. Insert stripped cable through as needed.

Wire Repair Components
Overview
Note: GM DOES NOT recommend soldering of
terminals or connections unless specifically called
out in a repair procedure.
The following components are used to repair damaged
circuits. Each piece is used for a specific application
depending on which parts are damaged and how they
are damaged. Some pieces may also be used together
depending on the repair procedures.

5389158

J-38125-8 Splice Sleeve Crimping Tool (GMNA)
The splice sleeve crimp tools are part of the process
necessary for repairing terminals and connectors. It is
very important to use these tools in conjunction with the
information contained in the Service Manual. The
Service Manual contains information for crimp nest

Page 10

August, 2019

Terminated Lead

Bulletin No.: 13-00-89-008B

Connector Kit

5389168

Machine Crimped Terminated Lead
Replacement may be needed due to a spread terminal
condition, corrosion, or it will not stay retained in the
connector body.
Pigtail

5389320

8-Way or Less Pigtail
Used when replacing a damaged connector that has
8-circuits or less. This connector assembly has
terminated leads installed. The most common cause of
replacement could be terminal corrosion or body
damage.

5389332

9-Way and More Connector Kits
Used when replacing a plastic connector body that has
nine or greater circuits. These kits include the plastic
connector body, CPA, and TPA, but do not have
terminals or terminated leads included. The most likely
cause requiring replacement is a damaged retainer or
corrosion.
DuraSeal Splices
Important: Use only DuraSeal splice sleeves to
form a one-to-one splice on all types of insulation
except high voltage and specialty cables. Use
DuraSeal splice sleeves where there are special
requirements such as moisture sealing.
The use of DuraSeal splice sleeves is required to form
a one-to-one splice on all types of insulation, except
Tefzel® and coaxial. The current procedure helps to
install the DuraSeal splice sleeves once the wire or
circuit has been identified.
DuraSeal splice sleeves have the following 2 critical
features:
• A special heat shrink sleeve environmentally seals
the splice. The heat shrink sleeve contains a
sealing adhesive inside.
• A cross hatched (knurled) core crimp provides the
necessary low resistance contact integrity for
these sensitive, low energy circuits.

Bulletin No.: 13-00-89-008B

August, 2019

Page 11

DuraSeal Splice Colors and Sizes

5389895

Use the instructions in the Table below to splice copper
wire using DuraSeal splice sleeves.

Splice Sleeve Selection
Crimp Tool Nest Color
Splice Sleeve Color

3 Crimp Nests

4 Crimp Nests

Wire Gauge mm² / (AWG)

Salmon (Yellow-Pink)
19300089

Red (1) or Red/Green (1)

Red (2)

0.22–0.8/(18–26)

Blue
19168447

Blue (2)

Blue (3)

1.0–2.0/(14–16)

Yellow
19168448

Yellow (3)

Yellow (4)

3.0–5.0/(10–12)

Wire and Fuse Parts
GXL and TXL Wire Overview
There are overlapping qualities between GXL and TXL
wire and there are also some distinct differences. GXL
and TXL wire both consist of multi-stranded bare
copper core conductors, a temperature rating of -59°F
(-51°C) to 257°F (125°C), cross linked polyethylene
(XLPE) along with meeting the SAE specification
ratings. The two main distinct differences between the
two wires is their differences in weight and wall
thickness. GXL is a slightly heavier option due to its
slightly thicker outer wall. TXL on the other hand, is
lighter due to its more lightweight and extra-thin
outer wall.
It is important to use TXL wire to maintain GM factory
specifications for wire harness integrity. TXL wire is
available through the EPC within the Chemical Catalog
section.
Locating TXL Wire and Fuses in EPC
In the EPC the TXL wire and fuses are located in the
Chemicals – Fuses - Wire - book section. To locate this
section, select Make, Year, then under Model select

Chemicals – Fuses – Wire catalog. The TXL Wire will
be called out under Group 8.966 Wire, Primary wire.
Fuses are located under Group 8.965 Fuse.
In the EPC Next Generation the TXL wire and fuses are
in the Q – CHEMICALS – FUSES – WIRES – BULBS
section. To locate this section, select Make, Year, then
under Model select Q – CHEMICALS – FUSES –
WIRES – BULBS and then select 08 – Vehicles
Maintenance. The TXL Wire will be called out under
Group 08.966 WIRE, Primary Wire. Fuses are located
under Group 08.965 FUSE, Fuse.
Part Resource Matrix

Part Resource Matrix
Part Name

Part Number
Resource

Order
Through

Terminal

SI

Bosch
Automotive
Service
Solutions

Crimp Tools

SI

Bosch
Automotive
Service
Solutions

Page 12

August, 2019

Part Resource Matrix (cont'd)
Part Name

Part Number
Resource

Order
Through

Terminated Leads

SI

EPC

Connector w/Leads

SI

EPC

Connector

SI

EPC

Splice Sleeves

SI and EPC

EPC

Harness Assembly

EPC

EPC

Wire, Fuse and
Heat Shrink

EPC

EPC

Electrical Service Information
Reference
Circuit Testing
The Circuit Testing section contains the following
diagnostic testing information. Using this information
along with the diagnostic procedures will identify the
cause of the electrical malfunction.
To navigate to the Circuit Testing section in the Service
Manual, enter a VIN then click Next. Go to > Power and
Signal Distribution > Wiring Systems and Power
Management > Diagnostic Information and Procedures
> Circuit Testing
OR
Go to > Year > Make > Model > Next > Service Manual
> Power and Signal Distribution > Wiring Systems and
Power Management > Diagnostic Information and
Procedures > Circuit Testing
• Using Connector Test Adapters
• Probing Electrical Connectors
• Troubleshooting with a Digital Multimeter
• Troubleshooting with a Test Lamp
• Using Fused Jumper Wires
• Measuring Voltage
• Measuring Voltage Drop
• Measuring Frequency
• Testing Ground and Low Reference Circuits
• Testing for Continuity
• Testing for Short to Ground

•
•
•
•
•
•
•
•

Bulletin No.: 13-00-89-008B

Testing for a Short to Voltage
Testing for Intermittent Conditions and Poor
Connections
Inducing Intermittent Fault Conditions
Testing for Electrical Intermittents
Scan Tool Snapshot Procedure
Circuit Protection - Fuses
Circuit Protection - Circuit Breakers
Circuit Protection - Fusible Links

Supplier Connector Repair Reference List
In addition to connector disassembly videos, some
supplier connector disassembly instructions are found
in SI. The connector repairs are listed by the connector
manufacturer and then by connector type. Knowing the
connector manufacturer will assist in finding the correct
connector repair. If the technician cannot identify the
manufacturer of the connector, refer to Identifying
Connectors below.
To navigate to the Connector Repair Reference section
in the Service Manual, enter a VIN then click Next. Go
to > Power and Signal Distribution > Wiring Systems
and Power Management > Diagnostic Information and
Procedures > Connector Repairs
OR
Go to > Year > Make > Model > Next > Service Manual
> Power and Signal Distribution > Wiring Systems and
Power Management > Diagnostic Information and
Procedures > Connector Repairs
• Connector Position Assurance Locks
• Terminal Position Assurance Locks
• AFL/EPC Connectors
• Bosch Connectors
• Delphi Connectors
• FCI Connectors
• FEP Connectors
• JST Connectors
• Kostal Connectors
• Molex Connectors
• Sumitomo Connectors
• Tyco/AMP Connectors
• Yazaki Connectors
• Repairing Connector Terminals

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these
technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper
service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a
job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your
vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the
information.

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