Jeep XJ. Manual - part 158

(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.

(8) Cut the repair wire to the proper length and

remove 1 inch of insulation.

(9) 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.

(10) Spread the strands of the wire apart on each

part of the exposed wires.

(11) Push the two ends of wire together until the

strands of wire are close to the insulation.

(12) Twist the wires together.
(13) Solder the connection together using rosin

core type solder only. Do not use acid core solder.

(14) 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.

(15) Insert the repaired wire into the connector.
(16) Install

the

connector

locking

wedge,

required, and reconnect the connector to its mating
half/component.

(17) Re-tape the wire harness starting 1-1/2 inches

behind the connector and 2 inches past the repair.

(18) Connect battery, and test all affected systems.

DIODE REPLACEMENT

(1) Disconnect the battery.
(2) Locate the diode in the harness, and remove

the protective covering.

(3) Remove the diode from the harness, pay atten-

tion to the current flow direction (Fig. 22).

Fig. 19 Connector Locking Wedge Tab (Typical)

1 – CONNECTOR
2 – CONNECTOR LOCKING WEDGE TAB

Fig. 20 Terminal Removal

1 – CONNECTOR
2 – FROM SPECIAL TOOL KIT 6680

Fig. 21 Terminal Removal Using Special Tool

1 – FROM SPECIAL TOOL KIT 6680
2 – CONNECTOR

8W - 01 - 14

8W - 01 GENERAL INFORMATION

SERVICE PROCEDURES (Continued)

(4) Remove the insulation from the wires in the

harness. Only remove enough insulation to solder in
the new diode.

(5) Install the new diode in the harness, making

sure current flow is correct. If necessary refer to the
appropriate wiring diagram for current flow.

(6) Solder the connection together using rosin core

type solder only. Do not use acid core solder.

(7) Tape the diode to the harness using electrical

tape making, sure the diode is completely sealed
from the elements.

(8) Re-connect the battery, and test affected sys-

tems.

SPECIAL TOOLS

WIRING/TERMINAL

Fig. 22 Diode Identification

1 – CURRENT FLOW
2 – BAND AROUND DIODE INDICATES CURRENT FLOW
3 – DIODE AS SHOWN IN THE DIAGRAMS

Probing Tool Package 6807

Terminal Pick 6680

Terminal Removing Tool 6932

Terminal Removing Tool 6934

8W - 01 GENERAL INFORMATION

8W - 01 - 15

SERVICE PROCEDURES (Continued)

8W-02 COMPONENT INDEX

Component

Page

1-2 And 3-4 Solenoid . . . . . . . . . . . . . . . . . . . 8W-31
2-3 Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
A/C Compressor Clutch Relay . . . . . . . . . . . . 8W-42
A/C Compressor Clutch . . . . . . . . . . . . . . . . . 8W-42
A/C- Heater Control . . . . . . . . . . . . . . . . . . . 8W-42
A/C Pressure Switches . . . . . . . . . . . . . . . . . . 8W-42
Accelerator Pedal Position Sensor . . . . . . . . . 8W-30
Airbag Control Module . . . . . . . . . . . . . . . . . 8W-43
Airbags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43
Ambient Temperature Sensor . . . . . . . . . . . . 8W-49
Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Automatic Shut Down Relay . . . . . . . . . . . . . 8W-30
Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . 8W-51
Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Battery Temperature Sensor . . . . . . . . . . . . . 8W-30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Blend Door Actuator . . . . . . . . . . . . . . . . . . . 8W-42
Blower Motor Relay . . . . . . . . . . . . . . . . . . . . 8W-42
Blower Motor Resistor Block . . . . . . . . . . . . . 8W-42
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Brake Lamp Switch . . . . . . . . . . . . . . . . . . . . 8W-33
Brake Warning Pressure Switch . . . . . . . . . . 8W-40
Camshaft Position Sensor . . . . . . . . . . . . . . . 8W-30
Cargo Lamp/Switch . . . . . . . . . . . . . . . . . . . . 8W-44
Center High Mounted Stop Lamp . . . . . . . . . 8W-51
Cigar Lighter Relay . . . . . . . . . . . . . . . . . . . . 8W-41
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Circuit Breakers (JB) . . . . . . . . . . . . . . . . . . 8W-12
City Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Clockspring . . . . . . . . . . . . . . . . . . 8W-30, 33, 41, 43
Cluster Illumination Lamps . . . . . . . . . . . . . 8W-40
Clutch Interlock Switch Jumper . . . . . . . . 8W-12, 21
Clutch Interlock Switch . . . . . . . . . . . . . . 8W-12, 21
Combination Flasher . . . . . . . . . . . . . . . . . . . 8W-52
Compass . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49
Controller Anti-Lock Brake Relay . . . . . . . . . 8W-35
Controller Anti-Lock Brake . . . . . . . . . . . . . . 8W-35
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . 8W-44
Crankshaft Position Sensor . . . . . . . . . . . . . . 8W-30
Data Link Connector . . . . . . . . . . . . . . . . . . . 8W-30
Daytime Running Lamp Module . . . . . . . . . . 8W-50
Diode Module . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Dome Lamps Switch . . . . . . . . . . . . . . . . . . . 8W-44
Door Jamb Switches . . . . . . . . . . . . . . . . . 8W-39, 44
Door Lock Motors . . . . . . . . . . . . . . . . . . . . . 8W-61
Duty Cycle Evap/Purge Solenoid . . . . . . . . . . 8W-30
Engine Control Module . . . . . . . . . . . . . . . . . 8W-30
Engine Coolant Temperature Gauge . . . . . . . 8W-40
Engine Coolant Temperature Sensors . . . . . . 8W-30
Engine Oil Pressure Sensor . . . . . . . . . . . . . . 8W-30
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . 8W-30

Component

Page

Engine Starter Motor Relay . . . . . . . . . . . . . 8W-21
Engine Starter Motor . . . . . . . . . . . . . . . . . . 8W-21
Evap Leak Detection Pump . . . . . . . . . . . . . . 8W-30
Extended Idle Switch . . . . . . . . . . . . . . . . . . 8W-30
Fog Lamp Relays . . . . . . . . . . . . . . . . . . . . . . 8W-50
Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 51
Forward/Rearward Motor . . . . . . . . . . . . . . . 8W-63
Front Fog Lamp Switch . . . . . . . . . . . . . . 8W-44, 50
Front Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63
Front Wiper Motor . . . . . . . . . . . . . . . . . . . . 8W-53
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Module . . . . . . . . . . . . . . . . . . . . 8W-30
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Fuses (JB) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
Fuses (PDC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Fusible Link A11 . . . . . . . . . . . . . . . . . . . . . . 8W-10
Fusible Link . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
G Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Glow Plug Assembly . . . . . . . . . . . . . . . . . . . 8W-30
Glow Plug Relay . . . . . . . . . . . . . . . . . . . . . . 8W-30
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Headlamp Beam Select Switch . . . . . . . . . . . 8W-50
Headlamp Delay Module . . . . . . . . . . . . . . . . 8W-50
Headlamp Leveling Motors . . . . . . . . . . . . . . 8W-50
Headlamp Leveling Switch . . . . . . . . . . . . . . 8W-50
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . 8W-50
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-50, 50
Heated Seat Backs . . . . . . . . . . . . . . . . . . . . 8W-63
Heated Seat Cushions . . . . . . . . . . . . . . . . . . 8W-63
Heated Seat Relay . . . . . . . . . . . . . . . . . . . . . 8W-63
Heated Seat Switches . . . . . . . . . . . . . . . . . . 8W-63
Heater Control . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Horns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Idle Air Control Motor . . . . . . . . . . . . . . . . . . 8W-30
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40
Input Speed Sensor . . . . . . . . . . . . . . . . . . . . 8W-31
Instrument Cluster . . . . . . . . . . . . . . . . . . . . 8W-40
Intake Air Temperature Sensor . . . . . . . . . . . 8W-30
Junction Block . . . . . . . . . . . . . . . . . . . . . . . . 8W-12
License Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8W-51
Liftgate Lock Motor . . . . . . . . . . . . . . . . . . . . 8W-61
Liftgate Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-44
Lock-Up Solenoid . . . . . . . . . . . . . . . . . . . . . . 8W-31

8W - 02 COMPONENT INDEX

8W - 02 - 1