C. Wiring Harness Repair
C. Wiring Harness Repair1. Place both front seats to the full forward travel position. This seat position will allow access to all trim panels during the repair procedure.
2. Open the hood and disconnect the negative battery cable.
3. Carefully unsnap the front door sill plate and sliding door sill plate by lifting the inside edge of the sill plates (Figure 12).
NOTE:
Remove the cap plug and nut at the rear of the front driver side sill plate, before attempting to remove the sill plate (Figure 13).
4. Carefully unsnap the lower "B" post trim panel (Figure 13).
5. Disconnect the power sliding door switch, located on the lower "B" post trim panel, from the body wiring harness connector (Figure 13).
6. Disconnect the affected chaffed wiring harness connector from the main wiring harness connector at the lower "B" post.
> If the drive motor wiring harness requires repair, note the method used to tape the convolute and then remove the electrical tape from the convolute. Slide the wires through the split in the convolute to expose the chaffed wires. Continue to Step 10 of this procedure.
> If the power sliding door wiring harness requires repair, continue with Step 7 of this procedure.
7. Disengage the two lower "B" post wiring harness retainers from the retention holes (Figure 14).
8. Remove the wiring harness retainer from the front of the black plastic split tube of the power sliding door wiring harness, noting its original location (Figure 14).
9. Carefully unwrap the power sliding door wiring harness starting at the front end (in car position) of the black plastic split tube (Figure 14). Unwrap enough of the cloth tape to expose the chaffed wires.
10. Select the appropriate wire splice band package based on the wire gauge of the chaffed wire. The power sliding door harness has nine 16-gauge wires. The drive motor harness has two 20-gauge wires and two 12-gauge wires.
11. Using diagonal cutters, cut through the damaged wire in the middle of the chaffed area (Figure 15).
12. Remove approximately one-half (1/2) inch (13 mm) of insulation from both wires using wire strippers.
13. Install a piece of shrink tube over one of the cut wires (Figure 16)
14. Insert both cut wires into the splice band and crimp them together using wire splice crimp tool 10042 (Figure 16).
15. Using rosin core solder and a soldering gun, solder the wiring connection at the splice band (Figure 17).
16. Center the shrink tube over the soldered wire connection made in Step 15.
17. Heat the shrink tube with a heat gun until it shrinks around the wire and glue comes out of both ends of the shrink tube (Figure 18).
18. Repeat Steps 10 - 17 on all chaffed wires.