Jeep XJ. Manual — part 157
(4) Start connecting the items in the fuse circuit
one at a time. When the fuse blows the circuit with
the short to ground has been isolated.
TESTING FOR A VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to
the side of the circuit closest to the battery (Fig. 6).
(2) Connect the other lead of the voltmeter to the
other side of the switch or component.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are
six steps which can aid in the procedure. The steps
are listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step check for
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams.
SERVICE PROCEDURES
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gage be used as shown in the wiring
diagrams. The wires must also be held securely in
place to prevent damage to the insulation.
(1) Disconnect battery negative cable
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wire (example 1). (Fig. 7)
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (example
2) (Fig. 7)
(6) Twist the wires together (example 3) (Fig. 7)
(7) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation
(10) Connect battery and test all affected systems.
Fig. 6 Testing for Voltage Drop
Fig. 7 Wire Repair
1 – EXAMPLE 1
2 – EXAMPLE 2
3 – EXAMPLE 3
8W - 01 - 10
8W - 01 GENERAL INFORMATION
XJ
DIAGNOSIS AND TESTING (Continued)
TERMINAL/CONNECTOR REPAIR-MOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 8).
(4) Using special tool 6742 release the locking fin-
gers on the terminal (Fig. 9).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal, as
necessary.
TERMINAL/CONNECTOR REPAIR—THOMAS
AND BETTS CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push in the two lock tabs on the side of the
connector (Fig. 10).
(4) Insert the probe end of special tool 6934 into
the back of the connector cavity (Fig. 11).
(5) Grasp the wire and tool 6934 and slowly
remove the wire and terminal from the connector.
Fig. 8 Molex Connector Repair
1 – CONNECTOR
2 – SPECIAL TOOL 6742
Fig. 9 Using Special Tool 6742
1 – CONNECTOR
2 – SPECIAL TOOL 6742
Fig. 10 Thomas and Betts Connector Lock Release
Tabs
1 – LOCK TABS
Fig. 11 Removing Wire Terminal
1 – SPECIAL TOOL 6934
XJ
8W - 01 GENERAL INFORMATION
8W - 01 - 11
SERVICE PROCEDURES (Continued)
(6) Repair or replace the terminal.
(7) Install the wire and terminal in the connector.
Fully seat the terminal in the connector.
(8) Push in the single lock tab on the side of the
connector (Fig. 12).
TERMINAL/CONNECTOR REPAIR- AUGAT
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Push down on the yellow connector locking tab
to release the terminals (Fig. 13).
(4) Using special tool 6932, push the terminal to
remove it from the connector (Fig. 14).
(5) Repair or replace the connector or terminal as
necessary.
(6) When re-assembling the connector, the locking
wedge must be placed in the locked position to pre-
vent terminal push out.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component
(3) Remove
the
connector
locking
wedge,
if
required (Fig. 15)
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
Fig. 12 Single Lock Tab
1 – SINGLE LOCK TAB
Fig. 13 Augat Connector Repair
1 – LOCKING TAB
2 – CONNECTOR
Fig. 14 Using Special Tool 6932
1 – SPECIAL TOOL 6932
2 – CONNECTOR
Fig. 15 Connector Locking Wedge
1 – CONNECTOR
2 – CONNECTOR LOCKING WEDGE TAB
8W - 01 - 12
8W - 01 GENERAL INFORMATION
XJ
SERVICE PROCEDURES (Continued)
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 16) (Fig. 17).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin-
out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into the
repaired connector, if required.
(9) Connect connector to its mating half/component.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect
the
connector
(that
is
to
be
repaired) from its mating half/component.
(3) Cut off the existing wire connector directly
behind the insulator. Remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side at 1/2
inch intervals (Fig. 18).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 18).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each
part of the exposed wires.
(10) Push the two ends of wire together until the
strands of wire are close to the insulation.
(11) Twist the wires together.
(12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
Fig. 16 Terminal Removal
1 – CONNECTOR
2 – FROM SPECIAL TOOL KIT 6680
Fig. 17 Terminal Removal Using Special Tool
1 – FROM SPECIAL TOOL KIT 6680
2 – CONNECTOR
Fig. 18 Stagger Cutting Wires
1 – REPAIR SIDE WIRES
2 – STAGER CUTS
3 – HARNESS WIRES
XJ
8W - 01 GENERAL INFORMATION
8W - 01 - 13
SERVICE PROCEDURES (Continued)
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст