GENERAL WARNINGS
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced.
| WARNING | Always wear safety glasses for eye protection. |
| WARNING | Use safety stands anytime a procedure requires being under a vehicle. |
| WARNING | Be sure that the ignition switch is always in the off position, unless the procedure requires it to be on. |
| WARNING | Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. |
| WARNING | Operate the engine only in a well-ventilated area. |
| WARNING | Keep away from moving parts when the engine is running, especially the fan and belts. |
| WARNING | To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. |
| WARNING | Do not allow flame or sparks near the battery. Gases are always present in and around the battery. |
| WARNING | Always remove rings, watches, loose hanging jewelry and avoid loose clothing. |
CIRCUIT FUNCTIONS
All circuits in the wiring diagrams use an alpha/numeric code to identify the wire and its function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart.
Note. This chart shows the main circuits only and does not show the secondary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
| CIRCUIT CODE | FUNCTION |
|---|
| A | BATTERY FEED |
| B | BRAKE CONTROLS |
| C | CLIMATE CONTROLS |
| D | DIAGNOSTIC CIRCUITS |
| E | DIMMING ILLUMINATION CIRCUITS |
| F | FUSED CIRCUITS |
| G | MONITORING CIRCUITS (GAUGES) |
| H | MULTIPLE |
| I | NOT USED |
| J | OPEN |
| K | POWERTRAIN CONTROL MODULE |
| L | EXTERIOR LIGHTING |
| M | INTERIOR LIGHTING |
| N | MULTIPLE |
| O | NOT USED |
| P | POWER OPTION (BATTERY FEED) |
| Q | POWER OPTIONS (IGNITION FEED) |
| R | PASSIVE RESTRAINT |
| S | SUSPENSION/STEERING |
| T | TRANSMISSION/TRANSAXLE/ TRANSFER CASE |
| U | OPEN |
| V | SPEED CONTROL, WIPER/WASHER |
| W | WIPERS |
| X | AUDIO SYSTEMS |
| Y | TEMPORARY |
| Z | GROUNDS |
CIRCUIT INFORMATION
Each wire shown in the wiring diagrams contains a code which identifies the main circuit, a specific portion of the main circuit, gauge of wire, and color.
As an example, circuit A 2 18 LB/YL is decoded in the following manner
| Circuit Type | A (Battery Feed Circuit) |
|---|
| Circuit Level | 2 (Level Two) |
| Wire Size | 18 (Eighteen Gauge Wire) |
| Wire Color | LB/YL (Light Blue with Yellow Tracer) |
| COLOR CODE | COLOR |
|---|
| BL | BLUE |
| BK | BLACK |
| BR | BROWN |
| DB | DARK BLUE |
| DG | DARK GREEN |
| GY | GRAY |
| LB | LIGHT BLUE |
| LG | LIGHT GREEN |
| OR | ORANGE |
| PK | PINK |
| RD | RED |
| TN | TAN |
| VT | VIOLET |
| WT | WHITE |
| YL | YELLOW |
| * | WITH TRACER |
INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem.
Before condemning a component or wiring assembly, check the following items
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked into position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem
- Damaged connector/component casing exposing the item to dirt or moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation
- Wiring broken inside of the insulation
WIRE SPLICING
A multimedia supplement to the instructions contained in this article is available. To the multimedia example of the condition described go to; http://www.youtube.com/user/Mitchell1Tips then type "A00646331.vid1" into the "Search Channel" box
Scheme 40
| CAUTION | If additional wire is needed when making a splice repair to any wire, it is important that the same or next larger size wire gauge be used. Refer to the appropriate wiring diagram for the original wire gauge size. |
Scheme 41
Scheme 42
Scheme 43
Scheme 44
- Remove 13 millimeters (0.50 inch) of insulation from each wire that needs to be spliced.
- Place a piece of adhesive sealant-lined heat shrink tubing (Part Number 04778570 or equivalent) over the wire on one side of the splice. Be certain the length of tubing will be sufficient to cover and seal the entire repair area.
- Place the strands of the wires being spliced so that they are overlapping each other within the splice band (1).
- Using a crimping tool (1) (MOPAR Part Number 05019912AA, Miller Special Tool Number (special tool #10042, Crimper, Wire/Terminal) or equivalent) crimp the splice band and wires together securely. CAUTION: Never use acid core solder for electrical wiring repairs.
- Using Rosin Core type solder (1) only and a suitable soldering iron (3), solder the wire and splice band connection (2) together.
- Center the heat shrink tubing (2) over the splice joint repair and heat using a suitable heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) begins to ooze out of both ends of the tubing.
Scheme 45
Scheme 45: CONNECTOR TERMINAL REMOVAL
| 1 - DRESS COVER |
|---|
| 2 - CONNECTOR LOCK |
| 3 - CONNECTOR |
Scheme 46
Scheme 47
- Disconnect battery.
- Release Connector Lock (2).
- Disconnect the connector (3) being repaired from its mating half/component.
- Remove the dress cover (if applicable) (1). 1 - Secondary Terminal Lock
- Release the Secondary Terminal Lock, if required (1). 1 - TYPICAL CONNECTOR 2 - PICK FROM TERMINAL REMOVER KIT 10300 3 - APEX CONNECTOR 4 - PICK FROM TERMINAL REMOVER KIT 10300 5 - AUGAT CONNECTOR 6 - ELECTRICAL TERMINAL REMOVAL TOOL 7 - MOLEX CONNECTOR 8 - PICK FROM TERMINAL REMOVER KIT 10300 9 - THOMAS AND BETTS CONNECTOR 10 - TERMINAL REMOVER 11 - CONNECTOR 12 - ELECTRICAL TERMINAL REMOVER
- Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector.
