Service Information

Volt

High Temperature Wiring Repairs

Danger: This procedure should not be performed on high voltage circuits. Performing this procedure on high voltage circuits may result in serious injury or death.

Note: All wiring repairs need to be 200 mm from the heat zone. Areas for consideration would be any area located near the exhaust manifolds, catalytic converter, exhaust pipes, and turbocharged engines.

Items Required

•	DuraSeal splice sleeves to crimp and seal connections

•	High temperature SCT1 shrink tubing to protect the splice sleeves

•	Terminated leads or pigtails

•	The correct tools to remove the terminals from the connectors

Use high temperature bulk wire rated at 150°C (302°F) continuous temperature of the same or larger gauge size as the original wire when repair damage wire. Also replace any reflective tape that you remove during the repair.

High Temperature Wiring

Wiring that is exposed to high temperatures, 135°C (275°F) or higher, for prolonged periods of time may use materials i.e. wires, connectors, and shielding that has a higher heat rating than typical wiring. When making a repair in a high temperature area observe the following:

•	Use high temperature bulk wire rated at 150°C (302°F) continuous temperature to replace any damaged wire.

•	Replace any heat shielding that is removed.

•	Cover any DuraSeal splice sleeves with SCT1 shrink tubing.

•	After making a wiring repair, ensure that the location of the wiring is not moved closer to the heat source.

Identifying High Temperature Wiring

Note: High temperature areas would be areas located near exhaust manifolds, catalytic converters, exhaust pipes, and turbocharged engines.

Wiring that is exposed to high temperature, 135°C (275°F) or higher, for prolonged periods of time need special considerations when making wiring repairs. Areas that may be exposed to higher temperatures can be identified by heat resistant materials that are being used in those areas. These materials may include heat reflective tape, moon tape, and high temperature shrink tubing. Also conduit and other protective coverings may be used. Because conduit or similar coverings are used throughout the vehicle regardless of the temperature, it may be necessary for the technician to determine if an area is exposed to excessive heat before making a wiring repair.