Mopar Hardtop Wiring Conversion Kit Installation guide

Type
Installation guide

This manual is also suitable for

1
HARDTOPWIRING
JEEPWRANGLER
CallOutDescriptionPartsQuantity
1DualOutputWasherPumpSuppliedinKit1
2TieStrapSuppliedinkit10
3WireSplicingKitSuppliedinkit1
4WasherHoseConnectorKitSuppliedinkit1
5OverlayHarnessSuppliedinkit1
6HVACControlswithRear
Defrost
Suppliedinkit82212859only1
7MultiFunctionSwitchwith
RearWiper
Suppliedinkit1
TOOLSREQUIRED
7mmand10mm
Socketsand
Ratchet
TrimStickC4755orequivalentTorxBitsT45,T50andDriver
Phillips
ScrewdriverSolderingIronandSolderWireStrippersandCrimpingTool
Apr01,2011K6861300
www.mopar.com
2
PROCEDURESTEPS:
1.Raisethehood.
2.Disconnectandisolatethenegativebatterycable.
3.Removethegrommet(2)fromthehole(1)inthedash
panel.Discardthegrommetbecausetheoverlayhar
nesshasagrommetbuiltintoit.
4.Installtheoverlayharnessthroughtheholeinthedash
panel(3).
5.Instalthegrommetontheharness(4)intotheholeun
tilitseats.
6.Routethewiringharness(2)totherightsideofthe
cowlandsecurewithatiestrap(1).
7.Routetherearwasherhose(5)tothewasherpump
intheleftfrontoftheenginecompartment.
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8.Routethewiringharness(2)alongthecowlandse
cureittotheexistingharnesswithtiestraps(1).
9.Routetheendoftheharness(3)neartheTotallyInte
gratedPowerModule(TIPM).
10.ReleasetheTotallyIntegratedPowerModule(TIPM)
coverretainingclips(1)andopentheTIPMcover.
11.RemovetheTIPMpositivecableretainingnut(2)and
removethecable(4)fromthestud.
12.Removethegroundnut(2).
13.Installthegroundstrap(3)tothestud(1)andreinstall
thenut(2).
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14.PositiontheTIPMtoaccesstheunderside.
15.ReleasetheconnectorlatchandremoveconnectorE
(1)fromtheTIPM.
16.ForconnectorE,usingtrimstickC4755orequiva
lent,carefullyinsertbetweenconnectorcoverlatch(2)
andthelocktab(3)torelease,andslidetheconnector
housing(1)offtheconnector.
17.Identifypins32(1)and27(2)onconnectorE.
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NOTE:Cavity32maybepopulated.Ifso,theexisting
wiremustberemovedusingaterminalremovalkit,or
equivalenttoinstalltheDB/WTwire.
18.InserttheDB/WTwire(1)intocavity32onconnector
E.
19.SpliceandsoldertheBR/LGwire(3)intotheBR/DB
wire(2)thatisincavity27byfollowingtheprocedure
inStep#20throughStep#23.
20.Preparetocrimp/splicetheBR/LGwiretotheBR/DB
wireasfollows:
a.CuttheBR/DBwireandremove13mm(0.5in.)
ofinsulationoneachsideofthecut.
b.Remove13mm(0.5in.)ofinsulationfromthe
BR/LGwire.
c.Placeapieceofadhesivelinedheatshrinktubing
(2)ononesideofthewire.Makesurethetubing
willbelongenoughtocoverandsealtheentire
repairarea.
d.Placethestrandsofwireoverlappingeachother
insideofthespliceclip(1).
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21.Usingcrimpingtool(1),Mopar®p/n05019912AAor
equivalent,crimpthespliceclipandwirestogether.
CAUTION:Donotuseacidcoresolder.
22.Usingasoldertool(3),soldertheconnection(2)to
getherwithrosincoresolder(1).
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23.Centertheheatshrinktubing(2)overthesolderjoint
andheatusingaheatgun.Heatthejointuntilthetub
ingistightlysealedandsealant(1)comesoutofboth
endsofthetubing.
24.ReassembletheconnectorandinstallconnectorE(1)
totheTIPMandsecurethelatch.
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25.DisconnectthelatchandremoveconnectorG(1)from
theTIPM.
26.Identifycavity31(1)inconnectorG.
NOTE:Cavity31maybepopulated.Ifso,theexisting
wiremustberemovedusingaterminalremovalkit,or
equivalenttoinstalltheBR/DBwire
27.Removetheseal(2)fromconnectorG.
28.InstalltheBR/DBwire(1)fromtheharnessintocavity
31(3)inconnectorG.
29.Afterinstallingtheterminal,installtheseal(2)back
intotheconnector.
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30.InstallconnectorG(1)totheTIPMandsecurethe
latch.
31.PositiontheTIPMbackintoitsoriginalposition.
32.PositiontheTIPMpositivecable(4)ontothemounting
studandinstalltheretainingnut(2).Tightenthenut
to911N∙m(80100in.lbs.).
33.ClosetheTIPMcoverandsnaptheretainingclips(1)
totheTIPM.
34.Siphonthewasherfluidfromthewasherreservoir(6)
ontheforwardendofthecomponenttray(3)onthe
leftsideoftheenginecompartmentintoacleancon
tainerforreuse.
35.Reachintothewellofthecomponenttraydirectlybe
hindthewasherreservoirtoaccessanddisconnect
theenginecompartmentwireharnessconnectorfrom
thewasherpump/motorunit(1)connectorreceptacle
(2)onthetopofthemotorhousing.
36.Disconnectthefrontwasherhose(4)fromthewasher
pump/motorunitoutletnipple.
37.Pullthetopofthewasherpump/motorunitawayfrom
thereservoirfarenoughtodisengagethesnappost
(5)onthetopofthemotorhousingfromthereceptacle
inthereservoir.
38.Pullthewasherpump/motorunitstraightupandout
ofthewasherreservoirfarenoughtodisengagethe
inletnipplefromtherubbergrommetseal/filterscreen
inthereservoir.Caremustbetakennottodamagethereservoir.
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39.Removetherubbergrommetseal/filterscreenforthewasherpumpfromthepumpmountingholeinthewasher
reservoiranddiscard.
40.Reachintothewellofthecomponenttray(3)directly
behindthewasherreservoirtoaccessandInstalla
newrubbergrommetseal/filterscreenunitintothe
washerpumpmountingholeinthewasherreservoir
(6).Alwaysuseanewrubbergrommetseal/filter
screenonthereservoir.
41.Positiontheinletnippleofthewasherpump(1)tothe
rubbergrommetseal/filterscreeninthewasherreser
voir.
42.Usinghandpressure,pressfirmlyandevenly
downwardonthewasherpump/motorunituntilthe
inletnippleisfullyseatedintherubbergrommet
seal/filterscreeninthepumpmountingholeofthe
reservoir.
43.Pressthetopofthewasherpump/motorunittoward
thereservoirfarenoughtoengagethesnappost(5)
onthetopofthemotorhousingintothereceptaclein
thereservoir.
44.Connecttherearwasherhose(7)tothebarbedpump
outletnipple.
45.Connectthefrontwasherhose(4)tothebarbedpumpoutletnipple.
46.Connecttheenginecompartmentwireharnessconnectorforthewasherpump/motorunittotheconnectorrecepta
cle(2)onthetopofthemotorhousing.
47.Refillthewasherreservoirwiththewasherfluidsiphonedfromthereservoirduringtheremovalprocedure.
WARNING:Toavoidseriousorfatalinjuryduringandfollowinganyseatbeltorchildrestraintanchorservice,
carefullyinspectallseatbelts,buckles,mountinghardware,retractors,tetherstraps,andanchorsforproperin
stallation,operation,ordamage.Replaceanybeltthatiscut,frayed,ortorn.Straightenanybeltthatistwisted.
Tightenanyloosefasteners.Replaceanybeltthathasadamagedorineffectivebuckleorretractor.Replace
anybeltthathasabentordamagedlatchplateoranchorplate.Replaceanychildrestraintanchorortheunit
towhichtheanchorisintegralthathasbeenbentordamaged.Neverattempttorepairaseatbeltorchild
restraintcomponent.Alwaysreplacedamagedorineffectiveseatbeltandchildrestraintcomponentswiththe
correct,newandunusedreplacementpartslistedintheChryslerMopar®PartsCatalog.Failuretofollowthese
instructionsmayresultinpossibleseriousorfatalinjury.
48.Unsnapthetrimcover(4)fromthefrontseatbeltturn
ingloop(2)anddiscard.
49.Removethescrew(3)thatsecurestheseatbeltturn
inglooptotheheightadjuster(1)ontheuppersport
bar.
50.Removetheseatbeltturningloop(2)fromtheheight
adjuster(1).
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51.Removetheclipfromtheseatreclininghandle(1)and
removethehandlefromtheseat.
52.Positiontheseatcover(2)toexposetheseatbelt
mountingbolt(3).
53.Removetheseatbeltmountingbolt(3)andseparate
theseatbelt(1)fromtheseat.
54.UsingTrimStickC4755orequivalent,separatethe
retainingclips(2)andremovetheupperBpillartrim
panel(1).
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55.Removethepushpinfasteners(3)andseparatethe
lowerBpillartrimpanel(2).
56.Pulltheseatbelt(1)throughtheslotinthetrim(2)and
removethetrim.
57.Removethepushpin(1)andseparatethecowlpanel
retainingclips.
58.Removethecowltrim(2)fromthevehicle.
Apr01,2011K6861300
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NOTE:Ontwodoormodelsitmaybenecessarytolooptheharnessattherearofthevehicle.
59.Routetheoverlayharness(1)behindthecarpetalongthelengthofthevehicle.Theoverlayharnessconsistsofthe
wiringharness(2)andrearwasherhose(3).
60.Positionthesteeringwheelintothefulldownposition.
61.UsingTrimStickC4755orequivalent,releasetheup
perclips(1)androtatethesteeringcolumnopening
cover(2)downandremovefromlowertabs.
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62.Ifequippedwithpowerwindows,usingatrimstick
C4755orasuitableflatbladedtool,gentlyprythe
switchassembly(2)awayfromtheinstrumentcluster
bezel(1).
63.Forvehicleswithoutpowerwindows,usingatrim
stickC4755orasuitableflatbladedtool,gentlypry
thestoragebinassemblyawayfromthebezeland
remove.
64.Disconnecttheswitchassemblyelectricalconnector
andremovetheswitch.
65.Removethestoragebinmatandremovethetop
screw(1).
66.Removethescrew(2)fromtheswitchopening.
67.Removethescrews(3).
NOTE:Performthisprocedureonthetwocenter
HVACoutlets.
68.Rotatethelouversoftheairoutlet(1)beingserviced
totheelevenoclockposition(2).
69.Placeasmallscrewdriver(4)orequivalentthroughthe
squareopening(5)insideoftheairoutlet,locatedat
thetwelvethirtyposition(3).
70.Carefullyprytheretainingtabtowardthecenterofthe
airoutletandrotatetheoutletcounterclockwise.
NOTE:Ifthefoamsealontheairoutletisdeformedor
damaged,thesealmustbereplaced.
71.Removetheairoutletfromtheinstrumentpanel(6).
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CAUTION:Donotusetoolstoreleasethelowerbezel
retainingclipsordamagetothebezelandreinforc
mentringcanoccur.
72.WithouttheuseoftoolsreachintotheIPcavity
throughtheventopenings(1)andfirmlygraspthe
lowerbezel(2)behindthebezelreinforcementring
andcarefullypullthebezelbacktoreleasethelower
retainingclips(3).
73.Releasetheremaining13retainingclips(1)andre
movethebezel(2).
NOTE:Step#74toStep#81areonlyneededforkit
82212859.
74.UsingatrimstickC4755orequivalent,releasethe
clipsandlowerthecentertrim(1).
75.DisconnecttheHVACelectricalconnectorsand
removethebezel.
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NOTE:Taketheproperprecautionstoprotecttheface
ofthecenterbezelfromcosmeticdamagewhileper
formingthisprocedure.
NOTE:ATCcontrolshown.MTCcontrolsimilar.
76.Placetheinstrumentpanelcenterbezel(3)onawork
bench.
77.Removethefourscrews(2and4)thatsecuretheA/C
heatercontrol(1)tothebackofthecenterbezeland
removethecontrol.
NOTE:Taketheproperprecautionstoprotecttheface
ofthecenterbezelfromcosmeticdamagewhileper
formingthisprocedure.
NOTE:ATCcontrolshown.MTCcontrolsimilar.
78.ObtaintheA/Cheatercontrol(1)providedinthekit
andinstallontothebackofthecenterbezel(3).
79.Installthefourscrews(2and4)thatsecuretheA/C
heatercontroltothebezel.Tightenthescrewsto2
N∙m(17in.lbs.).
80.ConnecttheHVACelectricalconnectors.
81.Positionthecenterbezel(1)ontotheI/Pandseatthe
clipsfully.
Apr01,2011K6861300
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82.Removethefourscrews(3)thatsecuretheinstrument
cluster(1)totheinstrumentpanelarmature(2).
83.Pullthetopoftheinstrumentclusterrearwardfar
enoughtoaccessanddisconnecttheinstrument
panelwireharnessconnectorsfromtheconnector
receptaclesonthebackoftheclusterhousing.
84.Removetheinstrumentclusterfromtheinstrument
panel.
85.RoutetheVT/WHwire(2)fromtheharnessintothe
opening(1)fortheinstrumentcluster.
86.IdentifyconnectorC(2)intheinstrumentpanelcluster
opening.
87.Usingapicktool,removetheseal(1)fromthecon
nector.
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NOTE:Cavity18maybepopulated.Ifso,theexisting
wiremustberemovedusingaterminalremovalkit,or
equivalenttoinstalltheVT/WTwire.
88.Identifycavity18(2)inconnectorC(1).
89.InstalltheVT/WTwire(2)intocavity18(1).
90.ReinstallthesealinconnectorC(3)andsecurethe
VT/WTwire(2)totheexistingwiringharnessusinga
tiestrap(1).
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91.Removescrewsfromthelowercolumnshroudandre
moveboththeupper(1)andlower(2)shrouds.
92.Removethescrew(2)thatsecurestheright
multifunctionswitch(1)tothemountingbracket
integraltotherightsideoftheclockspring(3)onthe
steeringcolumn.
93.Slidetheswitchawayfromtheclockspringfarenough
todisengagetheslidetabsontheswitchhousingfrom
thechannelformationsinthemountingbracket.
94.Disconnectthejumperwireharnessconnector(1)
fromtheconnectorreceptacleontheinboardendof
therightmultifunctionswitch(2).
95.Removetheswitchfromtheclockspring(3).
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96.Positiontherightmultifunctionswitch(2)thatis
includedinthekitcloseenoughtothemounting
bracket(3)integraltotherightsideoftheclockspring
toconnectthejumperwireharnessconnector(1)to
theconnectorreceptacleontheinboardsideofthe
switchhousing.
97.Aligntheslidetabsontheswitchhousingwith
thechannelformationsintegraltotheclockspring
mountingbracket,thenslidetheswitchintothe
bracketuntilitisfirmlyseated.
98.Installandtightenthescrew(2)thatsecuresthe
mountingtabonthebackoftherightmultifunction
switch(1)tothemountingbracketontheclockspring
(3).Tightenthescrewto1N∙m(10in.lbs.).
99.Reinstalltheupper(1)andlower(2)shroudsontothe
steeringcolumn.
100.Snaptogetherthecolumnshroudsandinstallthe
mountingscrews.
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Mopar Hardtop Wiring Conversion Kit Installation guide

Type
Installation guide
This manual is also suitable for

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