Emission Control Systems: Service and Repair

NOTE: Wiring repairs can now be made using service packages available through the Chrysler parts system. These packages allow for repair or replacement of individual wiring harness components rather than replacement of a complete wring harness. Some of these packages were released without instruction sheets. Refer to Chrysler TSB # 08-07-91 DATE May 20, 1991. for instruction sheets if not included in package.


TIP: To establish a more secure terminal engagement the female terminal will need to be removed from the connector housing and the terminal lance will need to be raised.

TIP: A conventional screwdriver may need to be modified to the proper size if the right size driver is not available.


CONTROL UNIT CONNECTORS

Front Holder Disengagement And Removal:

1. Disconnect the harness connector.
2. Disengage and remove the front holder by inserting a 1.4 mm (0.06 in.) width screwdriver as illustrated.

Resetting Wire Harness Connection:

3. Insert and hold the terminal harness to be fixed deep into the connector from the harness side.





4. By inserting the screwdriver into the connector as shown, the housing lance can be raised slightly and the harness can then be pulled out.





5. Raise the contact point of the male terminal by inserting a needle through the hole on the terminal.


ROUND WATERPROOF CONNECTORS

1. Carefully remove the waterproof cap using a blunt instrument.





2. By inserting a 1.4 mm (0.06 in.) or a 2.0 mm (0.08 in.) width screwdriver into the connector as shown, the housing lance can be raised slightly and the harness can then be pulled out.





3. Insert the screwdriver through a hole on the terminal and raise the contact point of the male terminal.


RECTANGULAR WATERPROOF CONNECTORS

Removal of Front Holder Using A Screwdriver:

1. Disengage and remove the front holder by inserting a 1.4 mm (0.06 in.) width screwdriver as illustrated.





2. Insert the tip of a 0.8 mm (0.03 in.) width screwdriver into the connector, as shown. Push lightly to raise lance, then pull out harness wire.





3. Using the screwdriver press the contact point of the male terminal down as shown.


INJECTOR CONNECTORS





1. Remove the waterproof cap.





2. Remove harness wire by inserting the tip of a 1.4 mm (0.06 in.) width screwdriver into the connector and press in lance as shown.





3. While holding the screwdriver as illustrated press the contact point of the male connector down.