1994 JEEP CHEROKEE Service Repair Manual

FUSIBLE LINK REPLACEMENT
CAUTION: Do not replace blown fusible links with a
standard wire. Only use fusible type wire with hypa-
lon insulation or damage to the electrical system
could occur. Also make sure correct gauge of wir-
ing is used. Refer to the wiring diagrams for proper
gauge and color.
When a fusible link blows it is important to find
out what the problem is. They are placed in the elec-
trical system for protection against shorts to ground.
This can be caused by a component failure or various
wiring failures.Do not just replace the fusible
link to correct the problem.
When diagnosing a faulty fusible link it is impor-
tant to check the wire carefully. In some instances
the link may be blown and it will not show through
the insulation, the wire should be checked over its
entire length for internal breaks.
(1) Disconnect battery negative cable.
(2) Cut out the blown portion of the fusible link.
(3) Strip 1 inch of insulation from each end of the
existing fusible link.
(4) Place a piece of heat shrink tubing over one
side of the fusible link. Make sure the tubing will be
long enough to cover and seal the entire repair area.
(5) Cut a replacement piece of fusible link approx-
imately two inches longer than the piece removed.
(6) Remove one inch of insulation from each end of
the replacement fusible link.
(7) Spread the strands of wire apart on each of the
exposed wires (Fig. 7 example 1).
(8) Push the two ends of the wire together until
the strands of wire are close to the insulation (Fig. 7
example 2).
(9) Twist the wires together (Fig. 7 example 3).
(10) Solder the wires together using rosin core type
solder only.Do not use acid core type solder.
(11) 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.
(12) Secure the fusible link to the existing ones to
prevent chafing or damage to the insulation.
(13) Connect battery and test affected systems.
WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wir-
ing diagrams. The wires must also be held securely
in place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) 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.(4) Spread the strands of the wire apart on each of
the exposed wires (Fig. 7 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex-
ample 2).
(6) Twist the wires together (Fig. 7 example 3).
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) 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.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test affected systems.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector to be repaired from its
mating half.
(3) Remove connector locking wedge (Fig. 8).
(4) Position the connector locking finger away from
the terminal while pulling on the wire to remove the
terminal from the connector (Fig. 9).
(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector.
(7) Repeat steps four through six for each wire in
the connector, being sure that all wires are inserted
into the proper cavities. For additional connector pin
out identification refer to the wiring diagrams.
(8) Insert the connector locking wedge into the re-
paired connector.
(9) Connect connector to its mating half.
Fig. 7 Wire Repair
8W - 4 WIRING DIAGRAMSJ

(10) Connect battery and test affected systems.
CONNECTOR AND TERMINAL ASSEMBLY
REPLACEMENT
(1) Disconnect Battery.
(2) Disconnect the connector being repaired from
its mating half.
(3) Cut off the existing wire connector directly be-
hind the insulator and remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side about
1/2 inch apart (Fig. 10).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair (allow extra length
for soldered connections). Check that the overall
length is the same as the original (Fig. 10).
(7) Remove 1 inch of insulation from each wire.(8) 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.
(9) Spread the strands of the wire apart on each of
the exposed wires (Fig. 7 example 1).
(10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex-
ample 2).
(11) Twist the wires together (Fig. 7 example 3).
(12) Solder the connection together using rosin
core type solder only.Do not use acid core solder.
(13) 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.
(14) Repeat steps 8 through 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Reconnect the repaired connector.
(17) Connect battery and test affected systems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired from
its mating half.
(3) Remove connector locking wedge (Fig. 8).
(4) Position the connector locking finger away from
the terminal while pulling on the wire to remove the
terminal from the connector (Fig. 9).
(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 assembly
that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length and re-
move 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.
Fig. 8 Connector Locking Wedge Tab (Typical)
Fig. 9 Connector Locking Finger and Locking
Wedge (Typical)
Fig. 10 Stagger Cutting Wires
JWIRING DIAGRAMS 8W - 5

(10) Spread the strands of the wire apart on each
of the exposed wires (Fig. 7 example 1).
(11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 7 ex-
ample 2).
(12) Twist the wires together (Fig. 7 example 3).
(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 and recon-
nect the connector to its mating half.
(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 affected systems.
SYMBOLS, FUSES AND ABBREVIATIONS
Various symbols are used throughout the wiring di-
agrams. These symbols can be identified by referring
to the symbol identification chart (Fig. 11).
Certain abbreviations are also used in the dia-
grams. These have been developed in such a way
that there meaning should be clear. For fuse block,
relay bank, and power distribution center informa-
tion refer to the fuse charts and relay bank index.
CAUTION: When replacing a blown fuse it is impor-
tant to replace it with a fuse having the correct am-
perage rating. The use of a fuse with a rating other
than indicated may result in an electrical overload.
If a proper rated fuse continues to blow, it indicates
a problem that should be corrected.
8W - 6 WIRING DIAGRAMSJ

Fig. 11 Symbol Identification
JWIRING DIAGRAMS 8W - 7

FUSE CHARTS AND RELAY BANKS
INDEX
Fig. Fig.
Fuse Panel XJ........................... 2
Fuse Panel YJ........................... 1Power Distribution Center YJ................. 3
Power Distribution Center XJ................. 4
8W - 8 WIRING DIAGRAMSJ

Fig. 1 Fuse Panel YJ
JWIRING DIAGRAMS 8W - 9

Fig. 2 Fuse Panel XJ
8W - 10 WIRING DIAGRAMSJ

Fig. 3 Power Distribution Center YJ
Fig. 4 Power Distribution Center XJ
JWIRING DIAGRAMS 8W - 11