Harness and Wire Repair Manual

DSM.0036 Ver 1.0
October 26, 2021

Table of Contents
Overview

3

Warning Statements Used in this Manual

3

Required Tools

3

Required Materials

3

Preliminary Instructions

4

General Instructions

4

On-vehicle Heat Shrink and Soldering Precautions

4

Splice Procedure

5

Termination Procedure
A. Sealed Connectors

8

B. Unsealed Connectors

11

Contact Information

13

Proprietary Statement

13

Trademark Notice

13
Hexagon Agility Inc. © 2021. All rights reserved

DSM.0036 Ver 1.0
October 26, 2021

Harness and Wire Repair Manual
PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED

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Overview
This document provides instruction on approved components, materials, tools, and methods to repair damaged
fuel system harnesses and associated wire circuits, terminals, and connectors.

Warning Statements Used in this Manual
NOTICE is used to address practices not related to physical injury, such as best
practices or tips to help an operation or procedure go smoothly and prevent
equipment damage.
WARNING indicates a hazardous situation which, if not avoided, could result in death
or serious injury.

Required Tools (most repairs*)
Item

Purpose

side cutters

cut wires

wire strippers

remove insulation from wires

soldering iron

tin over terminal connections

heat gun with reflector

melt heat shrink tubing and splice connector adhesive

insulated terminal crimper

crimp splice connectors and terminals

thermal blanket or other appropriate
heat shielding

protect fuel system components when using soldering iron or heat gun

sewing seam ripper

remove harness wrap or loom to access wire splices

(Steinel® HL 1910E/HL 2010E or equivalent)

(Raychem® AD-1522 or equivalent)

*Some repairs may require a specific OEM crimping tool or die; please refer to individual connectors for details.

Required Materials
Item

Purpose

splice sleeve, 18-22 AWG (red)

approved method for wire splice repairs

splice sleeve, 14-16 AWG (blue)

approved method for wire splice repairs

splice sleeve, 10-12 AWG (yellow)

approved method for wire splice repairs

wire loom (braided, mesh or split
corrugated tubing)

cover repaired portions of wire harness

electrical tape

secure wire loom to harness

dielectric grease

prevent corrosion on electrical contacts

wire terminals and seals

replace damaged terminals; prevent water/debris intrusion and corrosion

(3M® Scotch® Super 33+ or equivalent)

(Refer to OEM specifications)

DSM.0036 Ver 1.0
October 26, 2021

Harness and Wire Repair Manual
PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED

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Preliminary Instructions
Secure Vehicle
Wear approved personal protective equipment (PPE) including safety glasses.
Set emergency brake and place wheel chocks in front of and behind vehicle tires.
Only perform work on fueled vehicles in well-ventilated facilities designed for the
specific vehicle fuel type or in safe spaces outdoors in accordance with all
jurisdictional and industry regulations.
When performing service or repairs on any portion of the fuel system, install proper
lockout/tagout (LOTO) device(s) and observe all LOTO practices.

General Instructions
Always disconnect negative battery cable when repairing electrical components
installed on the vehicle.

1. Only use OEM specified tools for depinning and crimping connector terminals.
2. When extending or replacing a section of wire, the replacement section of wire should be the same gauge
or larger than the original section.
3. Corroded components must be repaired by replacing the affected connector assembly—terminals, seals,
and connector body—or with an OEM pigtail assembly designed for the repair.
4. If reusing a connector, always verify new seals are properly installed, all plugs (if applicable) are in place,
and all terminals are completely seated and locked.
5. When required apply a small amount of dielectric grease to all connector junctions when reconnecting
harnesses and components.

On-Vehicle Soldering and Heat Shrink Precautions
1. Verify vehicle is leak-free. Refer to DSM.0037 Leak Check procedure.
2. Refer to ENP-422 Welding and Hot Work Precautions Near CNG and LNG Vehicles
to determine whether vehicle must be depressurized or defueled prior to beginning
any repair procedure requiring heat, sparks, flame, or other thermal activity.
3. Always cover fuel system plumbing and cylinders with a thermal blanket or other
appropriate heat shielding when applying solder or working with a heat gun.
4. Never use a torch or other open flame to apply heat to heat shrink tubing.

DSM.0036 Ver 1.0
October 26, 2021

Harness and Wire Repair Manual
PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED

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Splice Procedure
When performing multiple splices in a harness, plan to offset splice locations to
minimize the possibility of creating a bulge or ridged section in the harness.

splice

splice
Step 11

 Identify the harness location where the splice connector is to be installed.
Step 21

 Use a sewing seam ripper to open harnesses protected by layers of electrical tape, heat shrink material,
wire loom, etc. to allow unobstructed access to the wire(s).
Remove electrical tape first and leave as much wire loom intact as possible.

electrical tape

Sewing seam ripper

wire loom

harness
Step 31

 Use side cutters to cut the suspect/damaged wire harness circuit.
Leave as much wire intact as possible.
Step 41

 Use wire strippers to remove approximately 5/16-in (8 mm) of insulation from the wire end and twist the
wire stands together.
Do not cut or damage any wire strands during this process.

wire

DSM.0036 Ver 1.0
October 26, 2021

5/16-in
(8 mm)

Harness and Wire Repair Manual
PRINTED AND DOWNLOADED COPIES ARE UNCONTROLLED

insulation

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Step 51

 Select correct splice sleeve size and crimping die based on wire gauge size listed in Table 1:
TABLE 1: Splice Sleeve by Wire Size, Sleeve Color, and Die Size

Wire Size
(AWG)
18 – 22

Splice
Color
red

Crimping
Die
red

14 – 16

blue

blue

10 - 12

yellow

yellow

Step 61

 Verify crimping die corresponding to the splice sleeve is installed in crimping tool jaws; install correct die if
necessary. Refer to manufacturer instructions.
blue die

jaws
yellow die

red die
Step 71

 Insert splice sleeve into crimping tool jaws rest slightly on the terminal near the middle of the crimping area.
splice sleeve

crimping
tool
jaw

DSM.0036 Ver 1.0