Mopar Hardtop Wiring Conversion Kit Installation guide

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

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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

to911N∙m(80100in.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.

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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.

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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.

Apr01,2011K6861300

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