Removal; Standard Procedure; Wire Splicing - Dodge Sprinter 2006 Manual

8W - 01 - 10
T ERM I N AL

REMOVAL

(1) F ollow st eps for r em ovin g t er m in a ls descr ibed
in t h e con n ect or r em ova l sect ion .
(2) Cu t t h e wir e 6 in ch es fr om t h e ba ck of t h e con -
n ect or.
INSTALLA TION
(1) Select a wir e fr om t h e t er m in a l r epa ir kit t h a t
best m a t ch es t h e color a n d ga ge of t h e wir e bein g
r epa ir ed.
(2) Cu t t h e r epa ir wir e t o t h e pr oper len gt h a n d
r em ove on e–h a lf (1/2) in ch of in su la t ion .
(3) Splice t h e r epa ir wir e t o t h e wir e h a r n ess (see
wir e splicin g pr ocedu r e) .
(4) In ser t t h e r epa ir ed wir e in t o t h e con n ect or.
(5) In st a ll t h e con n ect or lockin g wedge, if r equ ir ed,
a n d r econ n ect t h e con n ect or t o it s m a t in g h a lf/com po-
n en t .
(6) Re-t a pe t h e wir e h a r n ess st a r t in g a t 1–1/2
in ch es beh in d t h e con n ect or a n d 2 in ch es pa st t h e
r epa ir.
(7) Con n ect ba t t er y a n d t est a ll a ffect ed syst em s.
WI RE
STAN DARD PROCEDU RE

WIRE SPLICING

Wh en splicin g a wir e, it is im por t a n t t h a t t h e cor-
r ect ga ge be u sed a s sh own in t h e wir in g dia gr a m s.
(1) Rem ove on e-h a lf (1/2) in ch of in su la t ion fr om
ea ch wir e t h a t n eeds t o be spliced.
(2) P la ce a piece of a dh esive lin ed h ea t sh r in k t u b-
in g on on e side of t h e wir e. Ma ke su r e t h e t u bin g will
be lon g en ou gh t o cover a n d sea l t h e en t ir e r epa ir
a r ea .
(3) P la ce t h e st r a n ds of wir e over la ppin g ea ch
ot h er in side of t h e splice clip (F ig. 12).
Fig. 12 1 SPLICE BAND
1 - SPLICE BAND
8W-01 WIRING DIAGRAM INFORMA TION
(4) Usin g cr im pin g t ool, Mopa r p/n 05019912AA,
cr im p t h e splice clip a n d wir es t oget h er (F ig. 13).
1 - CRIMPING TOOL
(5) Solder t h e con n ect ion t oget h er u sin g r osin cor e
t ype solder on ly (F ig. 14).
CAUTION: DO NOT USE ACID CORE SOLDER.
1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
(6) Cen t er t h e h ea t sh r in k t u bin g over t h e join t
a n d h ea t u sin g a h ea t gu n . H ea t t h e join t u n t il t h e
t u bin g is t igh t ly sea led a n d sea la n t com es ou t of bot h
en ds of t h e t u bin g (F ig. 15).
1 - SEALANT
2 - HEAT SHRINK TUBE
Fig. 13 2 CRIMPING TOOL
Fig. 14 3 SOLDER SPLICE
Fig. 15 4 HEAT SHRINK TUBE
VA