Jeep cherokee 2000 Service Manual page 297

XJ
SERVICE PROCEDURES (Continued)
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
(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.
8W - 01 GENERAL INFORMATION
Fig. 18 Stagger Cutting Wires
1 – REPAIR SIDE WIRES
2 – STAGER CUTS
3 – HARNESS 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.
(16) Re-connect the repaired connector.
(17) Connect the battery, and test all affected sys-
tems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half. Remove connector locking wedge, if
required (Fig. 19).
(3) Remove connector locking wedge, if required
(Fig. 19).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 20) (Fig. 21).
(5) Cut the wire 6 inches from the back of the con-
nector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired.
8W - 01 - 13