STARTING SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION STARTER MOTOR ........................ 2 STARTER RELAY ........................ 3 STARTING SYSTEM ...................... 1 DIAGNOSIS AND TESTING STARTER MOTOR ........................ 8 STARTER MOTOR NOISE - 2.5L ENGINE ..... 7 STARTER RELAY ........................ 9 STARTING SYSTEM ...................... 3 REMOVAL AND INSTALLATION STARTER MOTOR ....................... 10 STARTER RELAY ....................... 12 SPECIFICATIONS STARTING SYSTEM ..................... 13 DESCRIPTION AND OPERATION STARTING SYSTEM DESCRIPTION An electrically operated engine starting system is standard factory-installed equipment on this model. The starting system is designed to provide the vehi- cle operator with a convenient, efficient and reliable means of cranking and starting the internal combus- tion engine used to power the vehicle and all of its accessory systems from within the safe and secure confines of the passenger compartment. See the own- er’s manual in the vehicle glove box for more infor- mation and instructions on the recommended use and operation of the factory-installed starting sys- tem. The starting system consists of the following com- ponents: • Battery • Starter relay • Starter motor (including an integral starter sole- noid) • Ignition switch • Clutch pedal position switch (manual transmis- sion) • Park/neutral position switch (automatic trans- mission) • Wire harnesses and connections (including the battery cables). This group provides complete service information for the starter motor and the starter relay. Complete service information for the other starting system components can be located as follows: • Refer to Battery in the proper section of Group 8A - Battery for complete service information for the battery. • Refer to Ignition Switch and Key Lock Cyl- inder in the proper section of Group 8D - Ignition System for complete service information for the igni- tion switch. • Refer to Clutch Pedal Position Switch in the proper section of Group 6 - Clutch for complete ser- vice information for the clutch pedal position switch. • Refer to Park/Neutral Position Switch in the proper section of Group 21 - Transmission for com- plete service information for the park/neutral posi- tion switch. • Refer to the proper section of Group 8W - Wir- ing Diagrams for complete service information and circuit diagrams for the starting system wiring com- ponents. Group 8A covers the Battery, Group 8B covers the Starting Systems, and Group 8C covers the Charging System. We have separated these systems to make it easier to locate the information you are seeking within this Service Manual. However, when attempt- ing to diagnose any of these systems, it is important that you keep their interdependency in mind. The battery, starting, and charging systems in the vehicle operate with one another, and must be tested as a complete system. In order for the vehicle to start and charge properly, all of the components that are used in these systems must perform within specifica- tions. The diagnostic procedures used in each of these groups include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diag- nostics (OBD) built into the Powertrain Control Mod- ule (PCM). Use of an induction-type milliampere ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt test lamp may be required. All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnos- tic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. Refer to On-Board Diagnostic Test For Charging System TJ STARTING SYSTEMS 8B - 1
ESCRIPTIONAn electrically operated engine starting system is
tandard factory-installed equipment on this model.he starting system is designed to provide the vehi-le operator with a convenient, efficient and reliableeans of cranking and starting the internal combus-
ion engine used to power the vehicle and all of itsccessory systems from within the safe and secureonfines of the passenger compartment. See the own-r’s manual in the vehicle glove box for more infor-ation and instructions on the recommended use
nd operation of the factory-installed starting sys-em.
The starting system consists of the following com-onents:• Battery• Starter relay• Starter motor (including an integral starter sole-
oid)• Ignition switch• Clutch pedal position switch (manual transmis-
ion)• Park/neutral position switch (automatic trans-ission)• Wire harnesses and connections (including the
attery cables).This group provides complete service information
or the starter motor and the starter relay. Completeervice information for the other starting systemomponents can be located as follows:• Refer to Battery in the proper section of Group
A - Battery for complete service information for theattery.• Refer to Ignition Switch and Key Lock Cyl-
nder in the proper section of Group 8D - Ignition
ystem for complete service information for the igni-ion switch.
• Refer to Clutch Pedal Position Switch in theroper section of Group 6 - Clutch for complete ser-ice information for the clutch pedal position switch.• Refer to Park/Neutral Position Switch in the
roper section of Group 21 - Transmission for com-lete service information for the park/neutral posi-ion switch.
• Refer to the proper section of Group 8W - Wir-ng Diagrams for complete service information andircuit diagrams for the starting system wiring com-onents.Group 8A covers the Battery, Group 8B covers the
tarting Systems, and Group 8C covers the Chargingystem. We have separated these systems to make itasier to locate the information you are seekingithin this Service Manual. However, when attempt-
ng to diagnose any of these systems, it is importanthat you keep their interdependency in mind.
The battery, starting, and charging systems in theehicle operate with one another, and must be testeds a complete system. In order for the vehicle to startnd charge properly, all of the components that aresed in these systems must perform within specifica-ions.
The diagnostic procedures used in each of theseroups include the most basic conventional diagnosticethods, to the more sophisticated On-Board Diag-
ostics (OBD) built into the Powertrain Control Mod-le (PCM). Use of an induction-type milliamperemmeter, volt/ohmmeter, battery charger, carbon pileheostat (load tester), and 12-volt test lamp may beequired.All OBD-sensed systems are monitored by the
CM. Each monitored circuit is assigned a Diagnos-ic Trouble Code (DTC). The PCM will store a DTC inlectronic memory for any failure it detects. Refer ton-Board Diagnostic Test For Charging System
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8B - 2 STARTING SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
n the Diagnosis and Testing section of Group 8C -harging System for more information.
PERATIONThe starting system components form two separate
ircuits. A high-amperage feed circuit that feeds thetarter motor between 150 and 350 amperes, and aow-amperage control circuit that operates on lesshan 20 amperes. The high-amperage feed circuitomponents include the battery, the battery cables,he contact disc portion of the starter solenoid, andhe starter motor. The low-amperage control circuitomponents include the ignition switch, the clutchedal position switch (manual transmission), theark/neutral position switch (automatic transmis-ion), the starter relay, the electromagnetic windingsf the starter solenoid, and the connecting wire har-ess components.If the vehicle is equipped with a manual transmis-
ion, it has a clutch pedal position switch installed ineries between the ignition switch and the coil bat-ery terminal of the starter relay. This normally openwitch prevents the starter relay from being ener-ized when the ignition switch is turned to theomentary Start position, unless the clutch pedal is
epressed. This feature prevents starter motor oper-tion while the clutch disc and the flywheel arengaged. The starter relay coil ground terminal islways grounded on vehicles with a manual trans-ission.If the vehicle is equipped with an automatic trans-ission, battery voltage is supplied through the low-
mperage control circuit to the coil battery terminalf the starter relay when the ignition switch isurned to the momentary Start position. The park/eutral position switch is installed in series betweenhe starter relay coil ground terminal and ground.his normally open switch prevents the starter relay
rom being energized and the starter motor fromperating unless the automatic transmission gearelector is in the Neutral or Park positions.When the starter relay coil is energized, the nor-ally open relay contacts close. The relay contacts
onnect the relay common feed terminal to the relayormally open terminal. The closed relay contactsnergize the starter solenoid coil windings.The energized solenoid pull-in coil pulls in the sole-
oid plunger. The solenoid plunger pulls the shiftever in the starter motor. This engages the starterverrunning clutch and pinion gear with the startering gear on the manual transmission flywheel or onhe automatic transmission torque converter drivelate.As the solenoid plunger reaches the end of its
ravel, the solenoid contact disc completes the high-mperage starter feed circuit and energizes the sole-
noid plunger hold-in coil. Current now flows betweenthe solenoid battery terminal and the starter motor,energizing the starter.
Once the engine starts, the overrunning clutch pro-tects the starter motor from damage by allowing thestarter pinion gear to spin faster than the pinionshaft. When the driver releases the ignition switch tothe On position, the starter relay coil is de-energized.This causes the relay contacts to open. When therelay contacts open, the starter solenoid plungerhold-in coil is de-energized.
When the solenoid plunger hold-in coil is de-ener-gized, the solenoid plunger return spring returns theplunger to its relaxed position. This causes the con-tact disc to open the starter feed circuit, and the shiftlever to disengage the overrunning clutch and piniongear from the starter ring gear.
Following are general descriptions of the majorcomponents in the starting system.
STARTER MOTOR
DESCRIPTIONThe starter motors used for both the 2.5L and the
4.0L engines available in this model are not inter-changeable. Both starter motors are mounted withtwo screws, but the 2.5L starter motor is mounted tothe right rear corner of the engine block, while the4.0L starter motor is mounted to the manual trans-mission clutch housing or automatic transmissiontorque converter housing on the right side of theengine.
Each of these starter motors incorporates severalof the same features to create a reliable, efficient,compact, lightweight and powerful unit. The electricmotors of both starters have four brushes contactingthe motor commutator. The 2.5L starter motor usesfour permanent magnets for the field poles, while the4.0L starter motor features four electromagnetic fieldcoils wound around four pole shoes. The 2.5L startermotor is rated at 1.2 kilowatts (about 1.6 horse-power) output at 12 volts, while the 4.0L startermotor is rated at 1.4 kilowatts (about 1.9 horse-power) output at 12 volts.
Both of these starter motors are serviced only as aunit with their starter solenoids, and cannot berepaired. If either component is faulty or damaged,the entire starter motor and starter solenoid unitmust be replaced.
OPERATIONThese starter motors are equipped with a plane-
tary gear reduction (intermediate transmission) sys-tem. The planetary gear reduction system consists ofa gear that is integral to the output end of the elec-tric motor armature shaft that is in continual
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TJ STARTING SYSTEMS 8B - 3
DESCRIPTION AND OPERATION (Continued)
ngagement with a larger gear that is splined to thenput end of the starter pinion gear shaft. This fea-ure makes it possible to reduce the dimensions ofhe starter. At the same time, it allows higher arma-ure rotational speed and delivers increased torquehrough the starter pinion gear to the starter ringear.The starter motors for both engines are activated
y an integral heavy duty starter solenoid switchounted to the overrunning clutch housing. This
lectromechanical switch connects and disconnectshe feed of battery voltage to the starter motor andctuates a shift fork that engages and disengages thetarter pinion gear with the starter ring gear.Both starter motors use an overrunning clutch and
tarter pinion gear unit to engage and drive a startering gear that is integral to the flywheel (manualransmission) or torque converter drive plate (auto-atic transmission) mounted on the rear crankshaft
lange. Shims are available and can be used to adjusthe 2.5L starter motor mounting position to corrector improper starter pinion gear to starter ring gearngagement.
TARTER RELAY
ESCRIPTIONThe starter relay is an electromechanical device
hat switches battery current to the pull-in coil of thetarter solenoid when the ignition switch is turned tohe Start position. The starter relay is located in theower Distribution Center (PDC), in the engine com-artment. See the fuse and relay layout label affixedo the inside surface of the PDC cover for starterelay identification and location.The starter relay is a International Standardsrganization (ISO) relay. Relays conforming to the
SO specifications have common physical dimensions,urrent capacities, terminal patterns, and terminalunctions.
The starter relay cannot be repaired or adjustednd, if faulty or damaged, it must be replaced.
PERATIONThe ISO relay consists of an electromagnetic coil, a
esistor or diode, and three (two fixed and one mov-ble) electrical contacts. The movable (common feed)
relay contact is held against one of the fixed contacts(normally closed) by spring pressure. When the elec-tromagnetic coil is energized, it draws the movablecontact away from the normally closed fixed contact,and holds it against the other (normally open) fixedcontact.
When the electromagnetic coil is de-energized,spring pressure returns the movable contact to thenormally closed position. The resistor or diode is con-nected in parallel with the electromagnetic coil in therelay, and helps to dissipate voltage spikes that areproduced when the coil is de-energized.
DIAGNOSIS AND TESTING
STARTING SYSTEM
DIAGNOSISThe battery, starting, and charging systems oper-
ate with one another, and must be tested as a com-plete system. In order for the vehicle to start andcharge properly, all of the components involved inthese systems must perform within specifications.
Group 8A covers the Battery, Group 8B covers theStarting Systems, and Group 8C covers the ChargingSystem. We have separated these systems to make iteasier to locate the information you are seekingwithin this Service Manual. However, when attempt-ing to diagnose any of these systems, it is importantthat you keep their interdependency in mind.
The diagnostic procedures used in these groupsinclude the most basic conventional diagnostic meth-ods, to the more sophisticated On-Board Diagnostics(OBD) built into the Powertrain Control Module(PCM). Use of an induction-type milliampere amme-ter, volt/ohmmeter, battery charger, carbon pile rheo-stat (load tester), and 12-volt test lamp may berequired.
All OBD-sensed systems are monitored by thePCM. Each monitored circuit is assigned a Diagnos-tic Trouble Code (DTC). The PCM will store a DTC inelectronic memory for any failure it detects. Refer toOn-Board Diagnostic Test For Charging Systemin the Diagnosis and Testing section of Group 8C -Charging System for more information.
1. Refer to Battery in the Diagnosis and Testing section ofGroup 8A - Battery. Charge or replace the battery, ifrequired.2. Refer to Starting System in Group 8W - WiringDiagrams. Test and repair the starter feed and/or controlcircuits, if required.3. Refer to Starter Relay in the Diagnosis and Testingsection of this group. Replace the starter relay, ifrequired.4. Refer to Ignition Switch and Key Lock Cylinder in theDiagnosis and Testing section of Group 8D - IgnitionSystem. Replace the ignition switch, if required.5. Refer to Clutch Pedal Position Switch in the Diagnosisand Testing section of Group 6 - Clutch.6. Refer to Park/Neutral Position Switch in the Diagnosisand Testing section of Group 21 - Transmission. Replacethe park/neutral position switch, if required.7. Refer to Starter Motor in the Diagnosis and Testingsection of this group. Replace the starter motor assembly,if required.8. If all other starting system components and circuits testOK, replace the starter motor assembly.
1. Refer to Battery in the Diagnosis and Testing section ofGroup 8A - Battery. Charge or replace the battery, ifrequired.2. Refer to Starting System in Group 8W - WiringDiagrams. Test and repair the starter feed and/or controlcircuits, if required.3. If all other starting system components and circuits testOK, replace the starter motor assembly.4. Refer to Engine Diagnosis in the Diagnosis and Testingsection of Group 9 - Engine.
STARTER ENGAGES,SPINS OUT BEFOREENGINE STARTS.
1. Starter ring gear faulty.2. Starter motor faulty.
1. Refer to Starter Motor in the Removal and Installationsection of this group. Remove the starter motor to inspectthe starter ring gear. Replace the starter ring gear, ifrequired.2. If all other starting system components and circuits testOK, replace the starter motor assembly.
1. Refer to Starter Motor in the Removal and Installationsection of this group. Tighten the starter mountinghardware to the correct tightness specifications.2. Refer to Starter Relay in the Diagnosis and Testingsection of this group. Replace the starter relay, ifrequired.3. Refer to Ignition Switch and Key Lock Cylinder in theDiagnosis and Testing section of Group 8D - IgnitionSystem. Replace the ignition switch, if required.4. If all other starting system components and circuits testOK, replace the starter motor assembly.
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TJ STARTING SYSTEMS 8B - 5
DIAGNOSIS AND TESTING (Continued)
NSPECTIONFor complete circuit diagrams, refer to Starting
ystem in the Contents of Group 8W - Wiring Dia-rams. Before removing any unit from the startingystem for repair or diagnosis, perform the followingnspections:
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
• Battery - Visually inspect the battery for indi-ations of physical damage and loose or corrodedable connections. Determine the state-of-charge andranking capacity of the battery. Charge or replacehe battery, if required. Refer to Battery in theroper section of Group 8A - Battery for complete ser-ice information for the battery.• Ignition Switch - Visually inspect the ignition
witch for indications of physical damage and looser corroded wire harness connections. Refer to Igni-ion Switch and Key Lock Cylinder in the properection of Group 8D - Ignition System for completeervice information for the ignition switch.• Clutch Pedal Position Switch - If the vehicle
s equipped with a manual transmission, visuallynspect the clutch pedal position switch for indica-ions of physical damage and loose or corroded wirearness connections. Refer to Clutch Pedal Posi-ion Switch in the proper section of Group 6 -lutch for complete service information for the clutchedal position switch.• Park/Neutral Position Switch - If the vehicle
s equipped with an automatic transmission, visuallynspect the park/neutral position switch for indica-ions of physical damage and loose or corroded wirearness connections. Refer to Park/Neutral Posi-ion Switch in the proper section of Group 21 -ransmission for complete service information for theark/neutral position switch.• Starter Relay - Visually inspect the starter
elay for indications of physical damage and loose ororroded wire harness connections.• Starter Motor - Visually inspect the starterotor for indications of physical damage and loose or
olenoid for indications of physical damage and looser corroded wire harness connections.• Wiring - Visually inspect the wire harnesses for
amage. Repair or replace any faulty wiring, as
required. Refer to the proper section of Group 8W -Wiring Diagrams for complete service informationand circuit diagrams for the starting system wiringcomponents.
TESTING
COLD CRANKING TESTFor complete circuit diagrams, refer to Starting
System in the Contents of Group 8W - Wiring Dia-grams. The battery must be fully-charged and load-tested before proceeding. Refer to Battery in theDiagnosis and Testing section of Group 8A - Batteryfor the procedures.
(1) Connect a suitable volt-ampere tester to thebattery terminals (Fig. 1). See the instructions pro-vided by the manufacturer of the volt-ampere testerbeing used.
(2) Fully engage the parking brake.(3) If the vehicle is equipped with a manual trans-
mission, place the gearshift selector lever in the Neu-tral position and block the clutch pedal in the fullydepressed position. If the vehicle is equipped with anautomatic transmission, place the gearshift selectorlever in the Park position.
(4) Verify that all lamps and accessories areturned off.
(5) To prevent the engine from starting, removethe Automatic ShutDown (ASD) relay. The ASD relayis located in the Power Distribution Center (PDC), inthe engine compartment. Refer to the fuse and relaylayout label affixed to the underside of the PDC coverfor ASD relay identification and location.
(6) Rotate and hold the ignition switch in the Startposition. Note the cranking voltage and current(amperage) draw readings shown on the volt-amperetester.
(a) If the voltage reads below 9.6 volts, refer toStarter Motor in the Diagnosis and Testing sec-tion of this group. If the starter motor is OK, refer
Fig. 1 Volts-Amps Tester Connections - Typical
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8B - 6 STARTING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
to Engine Diagnosis in the Diagnosis and Testingsection of Group 9 - Engine for further testing ofthe engine. If the starter motor is not OK, replacethe faulty starter motor.
(b) If the voltage reads above 9.6 volts and thecurrent (amperage) draw reads below specifica-tions, refer to Feed Circuit Test in this section.
(c) If the voltage reads 12.5 volts or greater andthe starter motor does not turn, refer to ControlCircuit Testing in this section.
(d) If the voltage reads 12.5 volts or greater andthe starter motor turns very slowly, refer to FeedCircuit Test in this section.
OTE: A cold engine will increase the starter cur-ent (amperage) draw reading, and reduce the bat-ery voltage reading.
EED CIRCUIT TESTThe starter feed circuit test (voltage drop method)ill determine if there is excessive resistance in theigh-amperage feed circuit. For complete circuit dia-rams, refer to Starting System in the Contents ofroup 8W - Wiring Diagrams.When performing these tests, it is important to
emember that the voltage drop is giving an indica-ion of the resistance between the two points athich the voltmeter probes are attached.Example: When testing the resistance of the bat-
ery positive cable, touch the voltmeter leads to theattery positive cable clamp and the cable connectort the starter solenoid. If you probe the battery pos-tive terminal post and the cable connector at thetarter solenoid, you are reading the combined volt-ge drop in the battery positive cable clamp-to-termi-al post connection and the battery positive cable.The following operation will require a voltmeter
ccurate to 1/10 (0.10) volt. Before performing theests, be certain that the following procedures areccomplished:• Battery is fully-charged and load-tested. Refer toattery in the Diagnosis and Testing section ofroup 8A - Battery for the procedures.• Fully engage the parking brake.• If the vehicle is equipped with a manual trans-ission, place the gearshift selector lever in the Neu-
ral position and block the clutch pedal in the fullyepressed position. If the vehicle is equipped with anutomatic transmission, place the gearshift selectorever in the Park position.
• Verify that all lamps and accessories are turnedff.• To prevent the engine from starting, remove theutomatic ShutDown (ASD) relay. The ASD relay is
ocated in the Power Distribution Center (PDC), inhe engine compartment. Refer to the fuse and relay
layout label affixed to the underside of the PDC coverfor ASD relay identification and location.
(1) Connect the positive lead of the voltmeter tothe battery negative terminal post. Connect the neg-ative lead of the voltmeter to the battery negativecable clamp (Fig. 2). Rotate and hold the ignitionswitch in the Start position. Observe the voltmeter. Ifvoltage is detected, correct the poor contact betweenthe cable clamp and the terminal post.
(2) Connect the positive lead of the voltmeter tothe battery positive terminal post. Connect the nega-tive lead of the voltmeter to the battery positive cableclamp (Fig. 3). Rotate and hold the ignition switch inthe Start position. Observe the voltmeter. If voltageis detected, correct the poor contact between thecable clamp and the terminal post.
(3) Connect the voltmeter to measure between thebattery positive terminal post and the starter sole-noid battery terminal stud (Fig. 4). Rotate and hold
Fig. 2 Test Battery Negative Connection Resistance- Typical
Fig. 3 Test Battery Positive Connection Resistance -Typical
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TJ STARTING SYSTEMS 8B - 7
DIAGNOSIS AND TESTING (Continued)
he ignition switch in the Start position. Observe theoltmeter. If the reading is above 0.2 volt, clean andighten the battery cable connection at the solenoid.epeat the test. If the reading is still above 0.2 volt,eplace the faulty battery positive cable.
(4) Connect the voltmeter to measure between theattery negative terminal post and a good cleanround on the engine block (Fig. 5). Rotate and holdhe ignition switch in the Start position. Observe theoltmeter. If the reading is above 0.2 volt, clean andighten the battery negative cable attachment on thengine block. Repeat the test. If the reading is stillbove 0.2 volt, replace the faulty battery negativeable.
(5) Connect the positive lead of the voltmeter tohe starter housing. Connect the negative lead of theoltmeter to the battery negative terminal post (Fig.). Rotate and hold the ignition switch in the Startosition. Observe the voltmeter. If the reading isbove 0.2 volt, correct the poor starter to enginelock ground contact.
Fig. 4 Test Battery Positive Cable Resistance -Typical
Fig. 5 Test Ground Circuit Resistance - Typical
If the resistance tests detect no feed circuit prob-lems, refer to Starter Motor in the Diagnosis andTesting section of this group.
CONTROL CIRCUIT TESTINGThe starter control circuit components should be
tested in the order in which they are listed, as fol-lows:
• Starter Relay - Refer to Starter Relay in theDiagnosis and Testing section of this group for theprocedures.
• Starter Solenoid - Refer to Starter Motor inthe Diagnosis and Testing section of this group forthe procedures.
• Ignition Switch - Refer to Ignition Switchnd Key Lock Cylinder in the Diagnosis and Test-
ng section of Group 8D - Ignition System for the pro-edures.• Clutch Pedal Position Switch - If the vehicle
s equipped with a manual transmission, refer tolutch Pedal Position Switch in the Diagnosisnd Testing section of Group 6 - Clutch for the pro-edures.• Park/Neutral Position Switch - If the vehicle
is equipped with an automatic transmission, refer toPark/Neutral Position Switch in the Diagnosisand Testing section of Group 21 - Transmission forthe procedures.
• Wire harnesses and connections - Refer toStarting System in the Contents of Group 8W -Wiring Diagrams for complete circuit diagrams.
STARTER MOTOR NOISE - 2.5L ENGINESee the Starter Motor Noise Diagnosis chart (Fig.
7). If the complaint is similar to Conditions 1 and 2in the chart, correction can be made by placing shimsbetween the starter motor and the engine block usingthe following procedures:
(1) If the complaint is similar to Condition 1, thestarter motor must be moved toward the starter ring
Fig. 6 Test Starter Ground - Typical
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8B - 8 STARTING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
ear by removing shims from both starter mountingads on the engine block (Fig. 8). Refer to Starterotor in the Removal and Installation section of
his group for the procedures.
OTE: The shim thickness is 0.381 mm (0.015 in.).hese shims may be stacked if additional thickness
s required.
(2) If the complaint is similar to Condition 2, thetarter motor must be moved away from the startering gear. This is done by installing shim(s) acrossoth starter mounting pads on the engine block.ore than one shim may be required. Refer totarter Motor in the Removal and Installation sec-ion of this group for the procedures.
Fig. 7 Starter Mot
Fig. 8 Starter Motor Shim
NOTE: This is a condition that will generally causebroken starter (flywheel/torque converter driveplate) ring gear teeth or broken starter motor hous-ings.
STARTER MOTORCorrect starter motor operation can be confirmed
by performing the following free running bench test.This test can only be performed with the startermotor removed from the vehicle. Refer to StartingSystem in the Specifications section of this group forthe starter motor specifications.
CAUTION: The 2.5L engine uses a permanent mag-net starter. Permanent magnet starters are highlysensitive to hammering, shocks, external pressureand reverse polarity. This starter motor must neverbe clamped in a vise by the starter field frame. Thestarter should only be clamped by the mountingflange. Do not reverse the battery cable connec-tions to this starter motor when testing. The perma-nent magnets may be damaged and the starterrendered unserviceable if it is subjected to any ofthese conditions.
(1) Remove the starter motor from the vehicle.Refer to Starter Motor in the Removal and Instal-lation section of this group for the procedures.
(2) Mount the starter motor securely in a soft-jawed bench vise. The vise jaws should be clampedon the mounting flange of the starter motor. Neverclamp on the starter motor by the field frame.
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DIAGNOSIS AND TESTING (Continued)
(3) Connect a suitable volt-ampere tester and a2-volt battery to the starter motor in series, and sethe ammeter to the 100 ampere scale. See thenstructions provided by the manufacturer of theolt-ampere tester being used.(4) Install a jumper wire from the solenoid termi-
al to the solenoid battery terminal. The starterotor should operate. If the starter motor fails to
perate, replace the faulty starter motor assembly.(5) Adjust the carbon pile load of the tester to
btain the free running test voltage. Refer to Start-ng System in the Specifications section of thisroup for the starter motor free running test voltagepecifications.(6) Note the reading on the ammeter and compare
his reading to the free running test maximummperage draw. Refer to Starting System in thepecifications section of this group for the starterotor free running test maximum amperage draw
pecifications.(7) If the ammeter reading exceeds the maximum
mperage draw specification, replace the faultytarter motor assembly.
TARTER SOLENOIDThis test can only be performed with the starterotor removed from the vehicle.(1) Remove the starter motor from the vehicle.efer to Starter Motor in the Removal and Instal-
ation section of this group for the procedures.(2) Disconnect the wire from the solenoid field coil
erminal.(3) Check for continuity between the solenoid ter-inal and the solenoid field coil terminal with a con-
inuity tester (Fig. 9). There should be continuity. IfK, go to Step 4. If not OK, replace the faulty starterotor assembly.
(4) Check for continuity between the solenoid ter-inal and the solenoid case (Fig. 10). There should
e continuity. If not OK, replace the faulty starterotor assembly.
TARTER RELAYThe starter relay (Fig. 11) is located in the Poweristribution Center (PDC), in the engine compart-
Fig. 9 Continuity Test Between Solenoid Terminaland Field Coil Terminal - Typical
ment. Refer to the fuse and relay layout label affixedto the underside of the PDC cover for starter relayidentification and location. For complete circuit dia-grams, refer to Starting System in the Contents ofGroup 8W - Wiring Diagrams.
(1) Remove the starter relay from the PDC. Referto Starter Relay in the Removal and Installationsection of this group for the procedures.
(2) A relay in the de-energized position shouldhave continuity between terminals 87A and 30, andno continuity between terminals 87 and 30. If OK, goto Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-tromagnet) should be 75 6 5 ohms. If OK, go to Step. If not OK, replace the faulty relay.(4) Connect a battery to terminals 85 and 86.
here should now be continuity between terminals0 and 87, and no continuity between terminals 87And 30. If OK, perform the Relay Circuit Test thatollows. If not OK, replace the faulty relay.
RELAY CIRCUIT TEST(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at alltimes. If OK, go to Step 2. If not OK, repair the opencircuit to the fuse in the PDC as required.
Fig. 10 Continuity Test Between Solenoid Terminaland Solenoid Case - Typical
Fig. 11 Starter Relay
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8B - 10 STARTING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
(2) The relay normally closed terminal (87A) isonnected to terminal 30 in the de-energized position,ut is not used for this application. Go to Step 3.(3) The relay normally open terminal (87) is con-
ected to the common feed terminal (30) in the ener-ized position. This terminal supplies battery voltageo the starter solenoid field coils. There should beontinuity between the cavity for relay terminal 87nd the starter solenoid terminal at all times. If OK,o to Step 4. If not OK, repair the open circuit to thetarter solenoid as required.(4) The coil battery terminal (86) is connected to
he electromagnet in the relay. It is energized whenhe ignition switch is held in the Start position. Onehicles with a manual transmission, the clutchedal must be fully depressed for this test. Check forattery voltage at the cavity for relay terminal 86ith the ignition switch in the Start position, and nooltage when the ignition switch is released to then position. If OK, go to Step 5. If not OK with anutomatic transmission, check for an open or shortircuit to the ignition switch and repair, if required.f the circuit to the ignition switch is OK, refer tognition Switch and Key Lock Cylinder in theiagnosis and Testing section of Group 8D - Ignitionystem for testing of the ignition switch. If not OKith a manual transmission, check the circuitetween the relay and the clutch pedal positionwitch for an open or a short. If the circuit is OK,efer to Clutch Pedal Position Switch in the Diag-osis and Testing section of Group 6 - Clutch for test-
ng of the switch.(5) The coil ground terminal (85) is connected to
he electromagnet in the relay. On vehicles with aanual transmission, it is grounded at all times. On
ehicles with an automatic transmission, it isrounded through the park/neutral position switchnly when the gearshift selector lever is in the Parkr Neutral positions. Check for continuity to groundt the cavity for relay terminal 85. If not OK with aanual transmission, repair the circuit to ground as
equired. If not OK with an automatic transmission,heck for an open or short circuit to the park/neutralosition switch and repair, if required. If the circuito the park/neutral position switch is OK, refer toark/Neutral Position Switch in the Diagnosisnd Testing section of Group 21 - Transmission foresting of the park/neutral position switch.
REMOVAL AND INSTALLATION
STARTER MOTOR
REMOVAL
2.5L ENGINE(1) Disconnect and isolate the battery negative
cable.(2) Raise and support the vehicle.(3) While supporting the starter motor with one
hand, use the other hand to remove the two screwsthat secure the starter motor to the engine block(Fig. 12).
(4) Lower the starter motor from the engine blockfar enough to access and remove the nut that securesthe solenoid wire harness connector eyelet to thesolenoid terminal stud. Always support the startermotor during this process, do not let the startermotor hang from the wire harness.
(5) Remove the nut that secures the battery cableharness connector eyelet to the solenoid battery ter-minal stud. Always support the starter motor duringthis process, do not let the starter motor hang fromthe wire harness.
(6) Remove the battery cable and solenoid wireconnector eyelets from the solenoid terminal studs.
(7) Remove the starter motor and any startermotor shims (if used) from the engine compartment.
Fig. 12 Starter Motor Remove/Install - 2.5L Engine
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TJ STARTING SYSTEMS 8B - 11
REMOVAL AND INSTALLATION (Continued)
.0L ENGINE(1) Disconnect and isolate the battery negative
able.(2) Raise and support the vehicle.(3) Remove the lower (forward facing) mounting
crew from the starter motor (Fig. 13).
(4) While supporting the starter motor with oneand, use the other hand to remove the upper (rearacing) mounting screw from the starter motor.
(5) Lower the starter motor from the front of theransmission clutch housing or torque converterousing far enough to access and remove the nuthat secures the battery cable eyelet to the solenoidattery terminal (Fig. 14). Always support the starterotor during this process, do not let the starterotor hang from the wire harness.(6) Remove the battery cable eyelet from the sole-
oid battery terminal. Always support the starterotor during this process, do not let the starterotor hang from the wire harness.(7) Disconnect the solenoid terminal wire harness
onnector from the connector receptacle on thetarter solenoid. Always support the starter motoruring this process, do not let the starter motor hangrom the wire harness.
(8) Remove the starter motor from the engine com-artment.
NSTALLATION
.5L ENGINE(1) Position the starter motor in the engine com-
Fig. 13 Starter Motor Remove/Install - 4.0L Engine
artment.
(2) Install the battery cable and solenoid wire con-nector eyelets onto the solenoid terminal studs.
(3) Install and tighten the nut that secures thebattery cable harness connector eyelet to the solenoidbattery terminal stud. Tighten the nut to 10 N·m (90in. lbs.). Always support the starter motor duringthis process, do not let the starter motor hang fromthe wire harness.
(4) Install and tighten the nut that secures thesolenoid wire harness connector eyelet to the solenoidterminal stud. Tighten the nut to 6 N·m (55 in. lbs.).Always support the starter motor during this process,do not let the starter motor hang from the wire har-ness.
(5) Position the starter motor and any startermotor shims that were removed to the engine blockand loosely install both of the mounting screws.
NOTE: Shim thickness available is 0.381 mm (0.015in.). Refer to Starter Motor Noise - 2.5L Engine inthe Diagnosis and Testing section of this group formore information.
(6) Tighten both of the starter motor mountingscrews. Tighten the screws to 45 N·m (33 ft. lbs.).
(7) Lower the vehicle.(8) Reconnect the battery negative cable.
4.0L ENGINE(1) Position the starter motor in the engine com-
partment.(2) Reconnect the solenoid terminal wire harness
connector to the connector receptacle on the startersolenoid. Always support the starter motor duringthis process, do not let the starter motor hang fromthe wire harness.
(3) Install the battery cable eyelet onto the sole-noid battery terminal. Always support the starter
otor during this process, do not let the starterotor hang from the wire harness.(4) Install and tighten the nut that secures the
attery cable eyelet to the solenoid battery terminal.ighten the nut to 10 N·m (90 in. lbs.). Always sup-ort the starter motor during this process, do not lethe starter motor hang from the wire harness.
(5) Position the starter motor to the front of theransmission clutch housing or torque converterousing and loosely install both the upper and lowerounting screws.(6) Tighten the lower (forward facing) starterotor mounting screw. Tighten the screw to 41 N·m
30 ft. lbs.).(7) Tighten the upper (rearward facing) starterotor mounting screw. Tighten the screw to 54 N·m
40 ft. lbs.).(8) Lower the vehicle.(9) Reconnect the battery negative cable.
TARTER RELAY
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the cover from the Power Distributionenter (PDC) (Fig. 15).
Fig. 15 Power Distribution Center
(3) See the fuse and relay layout label affixed tothe underside of the PDC cover for starter relay iden-tification and location.
(4) Remove the starter relay from the PDC.
INSTALLATION(1) See the fuse and relay layout label affixed to
the underside of the PDC cover for the proper starterrelay location.
(2) Position the starter relay in the proper recep-tacle in the PDC.
(3) Align the starter relay terminals with the ter-minal cavities in the PDC receptacle.
(4) Push down firmly on the starter relay until theterminals are fully seated in the terminal cavities inthe PDC receptacle.
(5) Install the cover onto the PDC.(6) Reconnect the battery negative cable.
HARGING SYSTEM OPERATIONThe charging system consists of:• Generator• Electronic Voltage Regulator (EVR) circuitryithin the Powertrain Control Module (PCM)• Ignition switch (refer to Group 8D, Ignition Sys-
em for information)• Battery (refer to Group 8A, Battery for informa-
ion)• Battery temperature sensor• Generator Lamp (if equipped)• Check Gauges Lamp (if equipped)• Voltmeter (refer to Group 8E, Instrument Panel
nd Gauges for information)• Wiring harness and connections (refer to Group
W, Wiring for information)The charging system is turned on and off with the
gnition switch. The system is on when the engine isunning and the ASD relay is energized. When theSD relay is on, voltage is supplied to the ASD relayense circuit at the PCM. This voltage is connectedhrough the PCM and supplied to one of the genera-or field terminals (Gen. Source +) at the back of theenerator.The amount of DC current produced by the gener-
tor is controlled by the EVR (field control) circuitryontained within the PCM. This circuitry is con-ected in series with the second rotor field terminalnd ground.A battery temperature sensor, located in the bat-
ery tray housing, is used to sense battery tempera-ure. This temperature data, along with data fromonitored line voltage, is used by the PCM to vary
ground path to control the strength of the rotor mag-netic field. The PCM then compensates and regulatesgenerator current output accordingly.
All vehicles are equipped with On-Board Diagnos-tics (OBD). All OBD-sensed systems, including EVR(field control) circuitry, are monitored by the PCM.Each monitored circuit is assigned a Diagnostic Trou-ble Code (DTC). The PCM will store a DTC in elec-tronic memory for certain failures it detects. Refer toOn-Board Diagnostics in Group 25, Emission ControlSystem for more DTC information.
The Check Gauges Lamp (if equipped) monitors:charging system voltage, engine coolant tempera-ture and engine oil pressure. If an extreme conditionis indicated, the lamp will be illuminated. This isdone as reminder to check the three gauges. The sig-nal to activate the lamp is sent via the CCD bus cir-cuits. The lamp is located on the instrument panel.Refer to Group 8E, Instrument Panel and Gauges foradditional information.
GENERATORThe generator is belt-driven by the engine using a
serpentine type drive belt. It is serviced only as acomplete assembly. If the generator fails for any rea-son, the entire assembly must be replaced.
As the energized rotor begins to rotate within thegenerator, the spinning magnetic field induces a cur-rent into the windings of the stator coil. Once thegenerator begins producing sufficient current, it alsoprovides the current needed to energize the rotor.
The Y type stator winding connections deliver theinduced AC current to 3 positive and 3 negativediodes for rectification. From the diodes, rectified DCcurrent is delivered to the vehicle electrical systemthrough the generator battery terminal.
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8C - 2 CHARGING SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
Although the generators appear the same exter-ally, different generators with different output rat-
ngs are used on this vehicle. Be certain that theeplacement generator has the same output ratingnd part number as the original unit. Refer to Gen-rator Ratings in the Specifications section at theack of this group for amperage ratings and partumbers.Noise emitting from the generator may be caused
y: worn, loose or defective bearings; a loose or defec-ive drive pulley; incorrect, worn, damaged or misad-usted fan drive belt; loose mounting bolts; a
isaligned drive pulley or a defective stator or diode.
ATTERY TEMPERATURE SENSORThe battery temperature sensor is used to deter-ine the battery temperature and control battery
harging rate. This temperature data, along withata from monitored line voltage, is used by the PCMo vary the battery charging rate. System voltage wille higher at colder temperatures and is graduallyeduced at warmer temperatures.
LECTRONIC VOLTAGE REGULATOR
ESCRIPTIONThe Electronic Voltage Regulator (EVR) is not a
eparate component. It is actually a voltage regulat-ng circuit located within the Powertrain Control
odule (PCM). The EVR is not serviced separately. Ifeplacement is necessary, the PCM must be replaced.
PERATIONThe amount of DC current produced by the gener-
tor is controlled by EVR circuitry contained withinhe PCM. This circuitry is connected in series withhe generators second rotor field terminal and itsround.Voltage is regulated by cycling the ground path to
ontrol the strength of the rotor magnetic field. TheVR circuitry monitors system line voltage and bat-
ery temperature (refer to Battery Temperature Sen-or for more information). It then compensates andegulates generator current output accordingly. Alsoefer to Charging System Operation for additionalnformation.
IAGNOSIS AND TESTING
HARGING SYSTEMThe following procedures may be used to diagnose
he charging system if:• the generator lamp (if equipped) is illuminatedith the engine running• the voltmeter (if equipped) does not register
roperly
• an undercharged or overcharged battery condi-tion occurs.
Remember that an undercharged battery is oftencaused by:
• accessories being left on with the engine notrunning
• a faulty or improperly adjusted switch thatallows a lamp to stay on. See Ignition-Off Draw Testin Group 8A, Battery for more information.
INSPECTIONTo perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-dures service manual and the DRB scan tool. Per-form the following inspections before attaching thescan tool.
(1) Inspect the battery condition. Refer to Group8A, Battery for procedures.
(2) Inspect condition of battery cable terminals,battery posts, connections at engine block, startersolenoid and relay. They should be clean and tight.Repair as required.
(3) Inspect all fuses in both the fuseblock andPower Distribution Center (PDC) for tightness inreceptacles. They should be properly installed andtight. Repair or replace as required.
(4) Inspect generator mounting bolts for tightness.Replace or tighten bolts if required. Refer to the Gen-erator Removal/Installation section of this group fortorque specifications.
(5) Inspect generator drive belt condition and ten-sion. Tighten or replace belt as required. Refer toBelt Tension Specifications in Group 7, Cooling Sys-tem.
(6) Inspect automatic belt tensioner (if equipped).Refer to Group 7, Cooling System for information.
(7) Inspect generator electrical connections at gen-erator field, battery output, and ground terminal (ifequipped). Also check generator ground wire connec-tion at engine (if equipped). They should all be cleanand tight. Repair as required.
BATTERY TEMPERATURE SENSORTo perform a complete test of this sensor and its
circuitry, refer to the appropriate Powertrain Diag-nostic Procedures manual. To test the sensor only,refer to the following:
(1) The sensor is located under the battery and isattached to the battery tray (Fig. 1). A two-wire pig-tail harness is attached directly to the sensor. Theopposite end of this harness connects the sensor tothe engine wiring harness.
(2) Disconnect the two-wire pigtail harness fromthe engine harness.
(3) Attach ohmmeter leads to the wire terminals ofthe pigtail harness.
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TJ CHARGING SYSTEM 8C - 3
DIAGNOSIS AND TESTING (Continued)
(4) At room temperature of 25° C (75–80° F), anhmmeter reading of 9,000 (9K) to 11,000 (11K) ohmshould be observed.(5) If reading is above or below the specification,
eplace the sensor.(6) Refer to the Removal and Installation section
or procedures.
N-BOARD DIAGNOSTIC TEST FOR CHARGINGYSTEMThe Powertrain Control Module (PCM) monitors
ritical input and output circuits of the charging sys-em, making sure they are operational. A Diagnosticrouble Code (DTC) is assigned to each input andutput circuit monitored by the On-Board DiagnosticOBD) system. Some circuits are checked continu-usly and some are checked only under certain con-itions.For DTC information, refer to Diagnostic Troubleodes in Group 25, Emission Control System. Thisill include a complete list of DTC’s including DTC’s
or the charging system.
EMOVAL AND INSTALLATION
ENERATOR
EMOVAL
ARNING: DISCONNECT NEGATIVE CABLE FROMATTERY BEFORE REMOVING BATTERY OUTPUTIRE (B+ WIRE) FROM GENERATOR. FAILURE TOO SO CAN RESULT IN INJURY OR DAMAGE TOLECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery.(2) Remove generator drive belt. Refer to Group 7,ooling System for procedure.
Fig. 1 Battery Temperature Sensor Location
(3) Remove generator pivot and mounting bolts/nut(Fig. 2). Position generator for access to wire connec-tors.
(4) If equipped, unsnap plastic cover from B+ ter-minal.
(5) Remove B+ terminal mounting nut at rear ofgenerator (Fig. 3). Disconnect terminal from genera-tor.
(6) Disconnect field wire connector at rear of gen-erator by pushing on connector tab.
(7) Remove generator from vehicle.
INSTALLATION(1) Position generator to engine and snap field
wire connector into rear of generator.(2) Install B+ terminal to generator mounting
stud. Tighten mounting nut to 8.5 N·m (75 in. lbs.)torque.
(3) If equipped, snap plastic cover to B+ terminal.(4) Install generator mounting fasteners and
tighten as follows:• Generator mounting bolt—55 N·m (41 ft. lbs.)
torque.• Generator pivot bolt/nut—55 N·m (41 ft. lbs.)
torque.
CAUTION: Never force a belt over a pulley rimusing a screwdriver. The synthetic fiber of the beltcan be damaged.
CAUTION: When installing a serpentine accessorydrive belt, the belt MUST be routed correctly. Thewater pump will be rotating in the wrong direction ifthe belt is installed incorrectly, causing the engineto overheat. Refer to belt routing label in enginecompartment, or refer to Belt Schematics in Group7, Cooling System.
(5) Install generator drive belt. Refer to Group 7,Cooling System for procedure.
(6) Install negative battery cable to battery.
BATTERY TEMPERATURE SENSORThe battery temperature sensor is located under
the vehicle battery and is attached to a mountinghole on battery tray.
REMOVAL(1) Remove battery. Refer to Group 8A, Battery for
procedures.(2) Disconnect sensor pigtail harness from engine
wire harness.(3) Pry sensor straight up from battery tray
mounting hole.
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8C - 4 CHARGING SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
Fig. 2 Generato
Fig. 3 Generator Connectors (Typical)
INSTALLATION(1) Feed pigtail harness through hole in top of bat-
tery tray and press sensor into top of battery tray.(2) Connect pigtail harness.(3) Install battery. Refer to Group 8A, Battery for
procedures.
move/Install
Fig. 4 Battery Temperature Sensor Remove/Install
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TJ CHARGING SYSTEM 8C - 5
PECIFICATIONS
ENERATOR RATINGS
TYPE PART NUMBER RATED SAE AMPS ENGINES MINIMUM TEST AMPS
GNITION SYSTEMThe ignition systems used on the 2.5L 4–cylinder
nd the 4.0L 6–cylinder engine are basically identi-al. Similarities and differences between the systemsill be discussed.The ignition system is controlled by the powertrain
ontrol module (PCM) on all engines.The ignition system consists of:• Spark Plugs• Ignition Coil• Secondary Ignition Cables• Distributor (contains rotor and camshaft position
ensor)• Powertrain Control Module (PCM)• Crankshaft Position, Camshaft Position, Throt-
le Position and MAP Sensors
OWERTRAIN CONTROL MODULEThe Powertrain Control Module (PCM) is located
n the engine compartment (Fig. 1).The ignition system is controlled by the PCM.
Fig. 1 Powertrain Control Module (PCM) Location
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8D - 2 IGNITION SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
OTE: Base ignition timing by rotation of distribu-or is not adjustable.
The PCM opens and closes the ignition coil groundircuit to operate the ignition coil. This is done todjust ignition timing, both initial (base) anddvance, and for changing engine operating condi-ions.
The amount of electronic spark advance providedy the PCM is determined by five input factors:ngine coolant temperature, engine rpm, intake man-fold temperature, manifold absolute pressure andhrottle position.
ISTRIBUTORAll engines are equipped with a camshaft drivenechanical distributor containing a shaft driven dis-
ributor rotor. All distributors are equipped with annternal camshaft position (fuel sync) sensor (Fig. 2).his sensor provides fuel injection synchronizationnd cylinder identification.
The distributors on both the 2.5L 4-cylinder andhe 4.0L-6 cylinder engines do not have built in cen-rifugal or vacuum assisted advance. Base ignitioniming and all timing advance is controlled by theowertrain control module (PCM). Because ignitioniming is controlled by the PCM, base ignition tim-ng is not adjustable on any of these engines.
The distributor is locked in place by a fork with alot located on the distributor housing base. The dis-ributor holddown clamp bolt passes through this slothen installed. Because the distributor position is
ocked when installed, its rotational position can note changed. Do not attempt to modify the dis-ributor housing to get distributor rotation.
Fig. 2 Distributor and Camshaft Position Sensor-Typical
Distributor position will have no effect on igni-tion timing. The position of the distributor willdetermine fuel synchronization only.
All distributors contain an internal oil seal thatprevents oil from entering the distributor housing.The seal is not serviceable.
SPARK PLUGSAll engines use resistor type spark plugs. Remove
the spark plugs and examine them for burned elec-trodes and fouled, cracked or broken porcelain insu-lators. Keep plugs arranged in the order in whichthey were removed from the engine. A single plugdisplaying an abnormal condition indicates that aproblem exists in the corresponding cylinder. Replacespark plugs at the intervals recommended in GroupO, Lubrication and Maintenance.
Spark plugs that have low milage may be cleanedand reused if not otherwise defective, carbon or oilfouled. Refer to the Spark Plug Condition section ofthis group.
SPARK PLUG CABLESSpark plug cables are sometimes referred to as sec-
ondary ignition wires. These cables transfer electricalcurrent from the ignition coil(s) and/or distributor, toindividual spark plugs at each cylinder. The resistivespark plug cables are of nonmetallic construction.The cables provide suppression of radio frequencyemissions from the ignition system.
IGNITION COILBattery voltage is supplied to the ignition coil pos-
itive terminal from the ASD relay.The Powertrain Control Module (PCM) opens and
closes the ignition coil ground circuit for ignition coiloperation.
Base ignition timing is not adjustable on anyengine. By controlling the coil ground circuit, thePCM is able to set the base timing and adjust theignition timing advance. This is done to meet chang-ing engine operating conditions.
The ignition coil is not oil filled. The windings areembedded in an epoxy compound. This provides heatand vibration resistance that allows the ignition coilto be mounted on the engine.
AUTOMATIC SHUTDOWN (ASD) RELAYAs one of its functions, the ASD relay will supply
battery voltage to the ignition coil. The ground cir-cuit for the ASD relay is controlled by the PowertrainControl Module (PCM). The PCM regulates ASDrelay operation by switching the ground circuiton-and-off.
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TJ IGNITION SYSTEM 8D - 3
DESCRIPTION AND OPERATION (Continued)
RANKSHAFT POSITION SENSORThe crankshaft position sensor is mounted to the
ransmission bellhousing at the left/rear side of thengine block (Fig. 3), (Fig. 4), or (Fig. 5).
Fig. 3 Crankshaft Position Sensor—4.0L 6-Cyl.Engine—Auto. Trans.
Fig. 4 Crankshaft Position Sensor—2.5L 4-Cyl.Engine—Auto. Trans.
Engine speed and crankshaft position are providedthrough the crankshaft position sensor. The sensorgenerates pulses that are the input sent to the pow-ertrain control module (PCM). The PCM interpretsthe sensor input to determine the crankshaft posi-tion. The PCM then uses this position, along withother inputs, to determine injector sequence and igni-tion timing.
The sensor is a hall effect device combined with aninternal magnet. It is also sensitive to steel within acertain distance from it.
SENSOR OPERATIONThe flywheel/drive plate has groups of four notches
at its outer edge. On 4.0L 6-cylinder engines thereare three sets of notches (Fig. 7) or (Fig. 8). On 2.5L4-cylinder engines there are two sets of notches (Fig.6).
The notches cause a pulse to be generated whenthey pass under the sensor. The pulses are the inputto the PCM. For each engine revolution there are twogroups of four pulses generated on 2.5L 4-cylinderengines. There are 3 groups of four pulses generatedon 4.0L 6-cylinder engines.
The trailing edge of the fourth notch, which causesthe pulse, is four degrees before top dead center(TDC) of the corresponding piston.
The engine will not operate if the PCM does notreceive a crankshaft position sensor input.
Fig. 5 Crankshaft Position Sensor—ManualTransmission (Typical)
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8D - 4 IGNITION SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
AMSHAFT POSITION SENSORThe camshaft position sensor is located in the dis-
The sensor contains a hall effect device called async signal generator to generate a fuel sync signal.This sync signal generator detects a rotating pulsering (shutter) on the distributor shaft. The pulse ringrotates 180 degrees through the sync signal genera-tor. Its signal is used in conjunction with the crank-shaft position sensor to differentiate between fuelinjection and spark events. It is also used to synchro-nize the fuel injectors with their respective cylinders.
When the leading edge of the pulse ring (shutter)enters the sync signal generator, the following occurs:The interruption of magnetic field causes the voltageto switch high resulting in a sync signal of approxi-mately 5 volts.
When the trailing edge of the pulse ring (shutter)leaves the sync signal generator, the following occurs:The change of the magnetic field causes the sync sig-nal voltage to switch low to 0 volts.
IGNITION SWITCH AND KEY LOCK CYLINDERThe ignition switch is located on the steering col-
umn. The Key-In-Switch is located in the ignitionswitch module. For electrical diagnosis of the Key-In-Switch, refer to Group 8U, Chime/Buzzer WarningSystems. For removal/installation of either the keylock cylinder or ignition switch, refer to IgnitionSwitch and Key Cylinder in this group.
On vehicles equipped with an automatic transmis-ion, a cable connects an interlock device within theteering column assembly to the transmission floorhift lever. This interlock device is used to lock theransmission shifter in the PARK position when theey is in the LOCKED or ACCESSORY position. Thenterlock device is not serviceable. If repair is neces-ary, the steering column assembly must be replaced.efer to Group 19, Steering for procedures. Thehifter interlock cable can be adjusted or replaced.efer to Group 21, Transmissions for procedures.On vehicles equipped with a manual transmission,lever is located on the steering column behind the
gnition key lock cylinder. The lever must be operatedo allow rotation of the ignition key lock cylinder. Theever mechanism is not serviced separately. If repairs necessary, the steering column assembly must beeplaced. Refer to Group 19, Steering for procedures.
IAGNOSIS AND TESTING
UTOMATIC SHUTDOWN (ASD) RELAY TESTTo perform a complete test of this relay and its cir-
uitry, refer to the DRB scan tool. Also refer to theppropriate Powertrain Diagnostics Procedures man-al. To test the relay only, refer to Relays—Opera-ion/Testing in the Group 14, Fuel Systems section.
GNITION COIL TESTTo perform a complete test of the ignition coil and
ts circuitry, refer to the DRB scan tool. Also refer tohe appropriate Powertrain Diagnostics Proceduresanual. To test the coil only, refer to the following:The ignition coil (Fig. 9) or (Fig. 10) is designed to
perate without an external ballast resistor.Inspect the ignition coil for arcing. Test the coil
ccording to coil tester manufacturer’s instructions.est the coil primary and secondary resistance.eplace any coil that does not meet specifications.efer to the IGNITION COIL RESISTANCE chart.
IGNITION COIL RESISTANCE
COIL MANUFACTURERPRIMARY RESISTANCE
21-27°C (70-80°F)SECONDARY RESISTANCE
21-27°C (70-80°F)
Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms
Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms
Fig. 10 Ignition Coil—4.0L Engine
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8D - 6 IGNITION SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
If the ignition coil is being replaced, the secondarypark plug cable must also be checked. Replace cablef it has been burned or damaged.
Arcing at the tower will carbonize the cable boot,hich if it is connected to a new ignition coil, will
ause the coil to fail.If the secondary coil cable shows any signs of dam-
ge, it should be replaced with a new cable and newerminal. Carbon tracking on the old cable can causercing and the failure of a new ignition coil.
ISTRIBUTOR CAPRemove the distributor cap and wipe it clean withdry lint free cloth. Visually inspect the cap for
racks, carbon paths, broken towers or damagedotor button (Fig. 11) or (Fig. 12). Also check forhite deposits on the inside (caused by condensationntering the cap through cracks). Replace any caphat displays charred or eroded terminals. Theachined surface of a terminal end (faces toward
otor) will indicate some evidence of erosion fromormal operation. Examine the terminal ends for evi-ence of mechanical interference with the rotor tip.
ISTRIBUTOR ROTORVisually inspect the rotor (Fig. 13) for cracks, evi-
ence of corrosion or the effects of arcing on theetal tip. Also check for evidence of mechanical
nterference with the cap. Some charring is normaln the end of the metal tip. The silicone-dielectric-arnish-compound applied to the rotor tip for radionterference noise suppression, will appear charred.his is normal. Do not remove the charred com-ound. Test the spring for insufficient tension.eplace a rotor that displays any of these adverseonditions.
Fig. 11 Cap Inspection—External—Typical
IGNITION TIMING
NOTE: Base (initial) ignition timing is NOT adjust-able on any 2.5L 4-cylinder or 4.0L 6-cylinderengine. Do not attempt to adjust ignition timing byrotating the distributor.
NOTE: Do not attempt to modify the distributorhousing to get distributor rotation. Distributor posi-tion will have no effect on ignition timing.
All ignition timing functions are controlled by thepowertrain control module (PCM). For additionalinformation, refer to the appropriate PowertrainDiagnostics Procedures service manual for operationof the DRB Scan Tool.
Fig. 12 Cap Inspection—Internal—Typical
Fig. 13 Rotor Inspection—Typical
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TJ IGNITION SYSTEM 8D - 7
DIAGNOSIS AND TESTING (Continued)
RANKSHAFT POSITION SENSORTo perform a complete test of this sensor and its
ircuitry, refer to the DRB scan tool. Also refer to theppropriate Powertrain Diagnostics Procedures man-al.
AMSHAFT POSITION SENSORThe camshaft position sensor is located in the dis-
ributor (Fig. 14) on all engines.
To perform a complete test of this sensor and itsircuitry, refer to the appropriate Powertrain Diag-ostics Procedures service manual. To test the sensornly, refer to the following:For this test, an analog (non-digital) voltme-
er is needed. Do not remove the distributor connec-or from the distributor. Using small paper clips,nsert them into the backside of the distributor wirearness connector to make contact with the termi-als. Be sure that the connector is not damagedhen inserting the paper clips. Attach voltmeter
eads to these paper clips.(1) Connect the positive (+) voltmeter lead into the
ensor output wire. This is at done the distributorire harness connector. For wire identification, refer
o Group 8W, Wiring Diagrams.(2) Connect the negative (-) voltmeter lead into the
round wire. For wire identification, refer to GroupW, Wiring Diagrams.(3) Set the voltmeter to the 15 Volt DC scale.(4) Remove distributor cap from distributor (two
crews). Rotate (crank) the engine until the distribu-or rotor is approximately in the 11 o’clock position.he movable pulse ring should now be within theensor pickup.(5) Turn ignition key to ON position. Voltmeter
hould read approximately 5.0 volts.(6) If voltage is not present, check the voltmeter
eads for a good connection.
Fig. 14 Camshaft Position Sensor—Typical
(7) If voltage is still not present, check for voltageat the supply wire. For wire identification, refer toGroup 8W, Wiring Diagrams.
(8) If 5 volts is not present at supply wire, checkfor voltage at PCM 32-way connector (cavity A-17).Refer to Group 8W, Wiring for location of connector/terminal. Leave the PCM connector connected forthis test.
(9) If voltage is still not present, perform vehicletest using the DRB scan tool.
(10) If voltage is present at cavity A-17, but not atthe supply wire:
(a) Check continuity between the supply wire.This is checked between the distributor connectorand cavity A-17 at the PCM. If continuity is notpresent, repair the harness as necessary.
(b) Check for continuity between the camshaftposition sensor output wire and cavity A-18 at thePCM. If continuity is not present, repair the har-ness as necessary.
(c) Check for continuity between the ground cir-cuit wire at the distributor connector and ground.If continuity is not present, repair the harness asnecessary.(11) While observing the voltmeter, crank the
engine with ignition switch. The voltmeter needleshould fluctuate between 0 and 5 volts while theengine is cranking. This verifies that the camshaftposition sensor in the distributor is operating prop-erly and a sync pulse signal is being generated.
If sync pulse signal is not present, replacement ofthe camshaft position sensor is necessary
SPARK PLUG CABLESCheck the spark plug cable connections for good
contact at the coil(s), distributor cap towers, andspark plugs. Terminals should be fully seated. Theinsulators should be in good condition and should fittightly on the coil, distributor and spark plugs. Sparkplug cables with insulators that are cracked or tornmust be replaced.
Clean high voltage ignition cables with a clothmoistened with a non-flammable solvent. Wipe thecables dry. Check for brittle or cracked insulation.
TESTINGWhen testing secondary cables for damage with an
oscilloscope, follow the instructions of the equipmentmanufacturer.
If an oscilloscope is not available, spark plug cablesmay be tested as follows:
CAUTION: Do not leave any one spark plug cabledisconnected for longer than necessary during test-ing. This may cause possible heat damage to thecatalytic converter. Total test time must not exceed
ten minutes.
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8D - 8 IGNITION SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
With the engine running, remove spark plug cablerom spark plug (one at a time) and hold next to aood engine ground. If the cable and spark plug aren good condition, the engine rpm should drop andhe engine will run poorly. If engine rpm does notrop, the cable and/or spark plug may not be operat-ng properly and should be replaced. Also checkngine cylinder compression.With the engine not running, connect one end of a
est probe to a good ground. Start the engine and runhe other end of the test probe along the entireength of all spark plug cables. If cables are crackedr punctured, there will be a noticeable spark jumprom the damaged area to the test probe. The cableunning from the ignition coil to the distributor capan be checked in the same manner. Cracked, dam-ged or faulty cables should be replaced with resis-ance type cable. This can be identified by the wordsLECTRONIC SUPPRESSION printed on the cable
acket.Use an ohmmeter to test for open circuits, exces-
ive resistance or loose terminals. Remove the dis-ributor cap from the distributor. Do not removeables from cap. Remove cable from spark plug.onnect ohmmeter to spark plug terminal end ofable and to corresponding electrode in distributorap. Resistance should be 250 to 1000 Ohms per inchf cable. If not, remove cable from distributor capower and connect ohmmeter to the terminal ends ofable. If resistance is not within specifications asound in the SPARK PLUG CABLE RESISTANCEhart, replace the cable. Test all spark plug cables inhis manner.
To test ignition coil-to-distributor cap cable, do notemove the cable from the cap. Connect ohmmeter tootor button (center contact) of distributor cap anderminal at ignition coil end of cable. If resistance isot within specifications as found in the Spark Plugable Resistance chart, remove the cable from theistributor cap. Connect the ohmmeter to the termi-al ends of the cable. If resistance is not within spec-
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
ifications as found in the Spark Plug CableResistance chart, replace the cable. Inspect the igni-tion coil tower for cracks, burns or corrosion.
SPARK PLUG CONDITIONS
NORMAL OPERATINGThe few deposits present on the spark plug will
probably be light tan or slightly gray in color. This isevident with most grades of commercial gasoline(Fig. 15). There will not be evidence of electrodeburning. Gap growth will not average more thanapproximately 0.025 mm (.001 in) per 3200 km (2000miles) of operation. Spark plugs that have normalwear can usually be cleaned, have the electrodesfiled, have the gap set and then be installed.
Some fuel refiners in several areas of the UnitedStates have introduced a manganese additive (MMT)for unleaded fuel. During combustion, fuel with MMTcauses the entire tip of the spark plug to be coatedwith a rust colored deposit. This rust color can bemisdiagnosed as being caused by coolant in the com-bustion chamber. Spark plug performance may beaffected by MMT deposits.
COLD FOULING/CARBON FOULINGCold fouling is sometimes referred to as carbon
fouling. The deposits that cause cold fouling are basi-cally carbon (Fig. 15). A dry, black deposit on one ortwo plugs in a set may be caused by sticking valvesor defective spark plug cables. Cold (carbon) foulingof the entire set of spark plugs may be caused by aclogged air cleaner element or repeated short operat-
Fig. 15 Normal Operation and Cold (Carbon) Fouling
ing times (short trips).
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TJ IGNITION SYSTEM 8D - 9
DIAGNOSIS AND TESTING (Continued)
ET FOULING OR GAS FOULINGA spark plug coated with excessive wet fuel or oil
s wet fouled. In older engines, worn piston rings,eaking valve guide seals or excessive cylinder wearan cause wet fouling. In new or recently overhauledngines, wet fouling may occur before break-in (nor-al oil control) is achieved. This condition can usu-
lly be resolved by cleaning and reinstalling theouled plugs.
IL OR ASH ENCRUSTEDIf one or more spark plugs are oil or oil ash
ncrusted (Fig. 16), evaluate engine condition for theause of oil entry into that particular combustionhamber.
LECTRODE GAP BRIDGINGElectrode gap bridging may be traced to loose
eposits in the combustion chamber. These depositsccumulate on the spark plugs during continuoustop-and-go driving. When the engine is suddenlyubjected to a high torque load, deposits partially liq-efy and bridge the gap between electrodes (Fig. 17).his short circuits the electrodes. Spark plugs withlectrode gap bridging can be cleaned using standardrocedures.
Fig. 16 Oil or Ash Encrusted
SCAVENGER DEPOSITSFuel scavenger deposits may be either white or yel-
low (Fig. 18). They may appear to be harmful, butthis is a normal condition caused by chemical addi-tives in certain fuels. These additives are designed tochange the chemical nature of deposits and decreasespark plug misfire tendencies. Notice that accumula-tion on the ground electrode and shell area may beheavy, but the deposits are easily removed. Sparkplugs with scavenger deposits can be considered nor-mal in condition and can be cleaned using standardprocedures.
Fig. 17 Electrode Gap Bridging
Fig. 18 Scavenger Deposits
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8D - 10 IGNITION SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
HIPPED ELECTRODE INSULATORA chipped electrode insulator usually results from
ending the center electrode while adjusting thepark plug electrode gap. Under certain conditions,evere detonation can also separate the insulatorrom the center electrode (Fig. 19). Spark plugs withhis condition must be replaced.
REIGNITION DAMAGEPreignition damage is usually caused by excessive
ombustion chamber temperature. The center elec-rode dissolves first and the ground electrode dis-olves somewhat latter (Fig. 20). Insulators appearelatively deposit free. Determine if the spark plugas the correct heat range rating for the engine.etermine if ignition timing is over advanced or ifther operating conditions are causing engine over-eating. (The heat range rating refers to the operat-
ng temperature of a particular type spark plug.park plugs are designed to operate within specificemperature ranges. This depends upon the thick-ess and length of the center electrodes porcelain
nsulator.)
PARK PLUG OVERHEATINGOverheating is indicated by a white or gray center
lectrode insulator that also appears blistered (Fig.1). The increase in electrode gap will be consider-bly in excess of 0.001 inch per 2000 miles of opera-ion. This suggests that a plug with a cooler heatange rating should be used. Over advanced ignitioniming, detonation and cooling system malfunctionsan also cause spark plug overheating.
Fig. 19 Chipped Electrode Insulator
REMOVAL AND INSTALLATION
SPARK PLUG CABLE REMOVAL
CAUTION: When disconnecting a high voltagecable from a spark plug or from the distributor cap,twist the rubber boot slightly (1/2 turn) to break itloose (Fig. 22). Grasp the boot (not the cable) andpull it off with a steady, even force.
SPARK PLUGS
PLUG REMOVAL(1) Always remove spark plug or ignition coil
cables by grasping at the cable boot (Fig. 22). Turnthe cable boot 1/2 turn and pull straight back in asteady motion. Never pull directly on the cable.Internal damage to cable will result.
Fig. 20 Preignition Damage
Fig. 21 Spark Plug Overheating
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TJ IGNITION SYSTEM 8D - 11
REMOVAL AND INSTALLATION (Continued)
(2) Prior to removing the spark plug, spray com-ressed air around the spark plug hole and the arearound the spark plug. This will help prevent foreignaterial from entering the combustion chamber.(3) Remove the spark plug using a quality socketith a rubber or foam insert.(4) Inspect the spark plug condition. Refer to
park Plugs in the Diagnostics/Service Proceduresection of this group.
LUG CLEANINGThe plugs may be cleaned using commercially
vailable spark plug cleaning equipment. After clean-ng, file the center electrode flat with a small pointile or jewelers file before adjusting gap.
AUTION: Never use a motorized wire wheel brusho clean the spark plugs. Metallic deposits willemain on the spark plug insulator and will causelug misfire.
LUG GAP ADJUSTMENTCheck the spark plug gap with a gap gauge tool. If
he gap is not correct, adjust it by bending theround electrode (Fig. 23). Never attempt to adjusthe gap by bending the center electrode.
PARK PLUG GAP• 2.5L 4-Cylinder Engine Spark Plug Gap: .89 mm
.035 in).• 4.0L 6-Cylinder Engine Spark Plug Gap: .89 mm
.035 in).
LUG INSTALLATIONAlways tighten spark plugs to the specified torque.ver tightening can cause distortion. This may result
n a change in the spark plug gap, or a cracked por-elain insulator.
Fig. 22 Cable Removal
When replacing the spark plug and ignition coilcables, route the cables correctly and secure them inthe appropriate retainers. Failure to route the cablesproperly can cause the radio to reproduce ignitionnoise. It could cause cross ignition of the spark plugs,or short circuit the cables to ground.
(1) Start the spark plug into the cylinder head byhand to avoid cross threading.
(2) Tighten the spark plugs to 35-41 N·m (26-30 ft.lbs.) torque.
(3) Install spark plug cables over spark plugs.
IGNITION COILThe ignition coil is an epoxy filled type. If the coil
is replaced, it must be replaced with the same type.
REMOVALOn the 2.5L 4-cylinder engine, the ignition coil is
mounted to a bracket on side of engine (to rear ofdistributor) (Fig. 24).
On the 4.0L 6-cylinder engine, the ignition coil ismounted to a bracket on side of engine (to front ofdistributor) (Fig. 25).
(2) Disconnect engine harness connector from igni-tion coil.
(3) Remove ignition coil mounting bolts (nuts areused on back side of bracket on some coils).
(4) Remove coil from vehicle.
Fig. 23 Setting Spark Plug Gap—Typical
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8D - 12 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
NSTALLATION(1) Install ignition coil to bracket on cylinder blockith mounting bolts (and nuts if equipped). Ifquipped with nuts and bolts, tighten to 11 N·m (100n. lbs.) torque. If equipped with bolts only, tighten to
N·m (50 in. lbs.) torque.(2) Connect engine harness connector to coil.(3) Connect ignition coil cable to ignition coil.
RANKSHAFT POSITION SENSORThe crankshaft position sensor is mounted to the
ransmission bellhousing at the left/rear side of thengine block (Fig. 26), (Fig. 27), or (Fig. 28).
Fig. 24 Ignition Coil—2.5L Engine
Fig. 25 Ignition Coil—4.0L Engine
On 2.5L 4-cylinder and 4.0L 6-cylinder engineswith manual transmissions, the sensor is attachedwith two bolts. On 2.5L engines with automatictransmissions, the sensor is attached with two nuts.On 4.0L engines with automatic transmissions, thesensor is adjustable and is attached with one bolt.
REMOVAL
Fig. 26 Crankshaft Position Sensor—4.0L 6-Cyl.Engine—Auto. Trans.
Fig. 27 Crankshaft Position Sensor—2.5L 4-Cyl.Engine—Auto. Trans.
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TJ IGNITION SYSTEM 8D - 13
REMOVAL AND INSTALLATION (Continued)
(1) Near rear of intake manifold, disconnect pigtailarness (electrical connector) from main electricalarness.(2) Depending upon application, remove either sen-
or mounting bolt(s) or nuts.(3) Remove sensor from engine.
NSTALLATION2.5L and 4.0L engines with manual transmis-
ion:(1) Install sensor flush against opening in trans-ission housing.(2) Install and tighten two sensor mounting bolts
o 19 N·m (14 ft. lbs.) torque. The two sensor mount-ng bolts are specially machined to correctly spacenit to flywheel. Do not attempt to install any otherolts.2.5L engines with automatic transmission:(3) Install and tighten two sensor mounting nuts
o 19 N·m (14 ft. lbs.) torque.4.0L engines with automatic transmission:New replacement sensors will be equipped with a
aper spacer glued to bottom of sensor. If installingreturning) a used sensor to vehicle, a new paperpacer must be installed to bottom of sensor. Thispacer will be ground off the first time engine istarted. If spacer is not used, sensor will be brokenhe first time engine is started.
(4) New Sensors: Be sure paper spacer is installedo bottom of sensor. If not, obtain spacerN05252229.
Fig. 28 Crankshaft Position Sensor—ManualTransmission (Typical)
(5) Used Sensors: Clean bottom of sensor andinstall spacer PN05252229.
(6) Install sensor into transmission bellhousinghole.
(7) Push sensor against flywheel/drive plate. Withsensor pushed against flywheel/drive plate, tightenmounting bolt to 7 N·m (60 in. lbs.) torque.
(8) Connect sensor pigtail harness electrical con-nector to main wiring harness.
CAMSHAFT POSITION SENSORThe camshaft position sensor is located in the dis-
tributor (Fig. 29).
REMOVALDistributor removal is not necessary to remove
camshaft position sensor.(1) Disconnect negative battery cable at battery.(2) Remove distributor cap from distributor (two
screws).(3) Disconnect camshaft position sensor wiring
harness from main engine wiring harness.
(4) Remove distributor rotor from distributor shaft.(5) Lift camshaft position sensor assembly from
distributor housing (Fig. 29).
INSTALLATION(1) Install camshaft position sensor to distributor.
Align sensor into notch on distributor housing.(2) Connect wiring harness.(3) Install rotor.(4) Install distributor cap. Tighten mounting
screws.
DISTRIBUTORAll distributors contain an internal oil seal that
prevents oil from entering the distributor housing.The seal is not serviceable.
Fig. 29 Camshaft Position Sensor
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8D - 14 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
Factory replacement distributors are equipped withplastic alignment pin already installed. The pin is
ocated in an access hole on the bottom of the distrib-tor housing (Fig. 30). It is used to temporarily lockhe rotor to the cylinder number 1 position duringnstallation. The pin must be removed after install-ng the distributor.
The camshaft position sensor is located in the dis-ributor on all engines (Fig. 31). For removal/instal-ation procedures, refer to Camshaft Position Sensor.istributor removal is not necessary for sensor
emoval.Refer to (Fig. 31) for an exploded view of the dis-
ributor.A fork with a slot is supplied on the bottom of the
istributor housing where the housing base seatsgainst the engine block (Fig. 31). The centerline ofhe slot aligns with the distributor holddown boltole in the engine block. Because of the fork, the dis-ributor cannot be rotated. Distributor rotation is notecessary as all ignition timing requirements areandled by the powertrain control module (PCM).The position of the distributor determines fuel syn-
hronization only. It does not determine ignition tim-ng.
OTE: Do not attempt to modify this fork to attaingnition timing.
EMOVAL—2.5L OR 4.0L ENGINE(1) Disconnect negative battery cable at battery.(2) Disconnect coil secondary cable at coil.(3) Remove distributor cap from distributor (2
crews). Do not remove cables from cap. Do notemove rotor.
(5) Remove cylinder number 1 spark plug.(6) Hold a finger over open spark plug hole. Rotate
engine at vibration dampener bolt until compression(pressure) is felt.
(7) Slowly continue to rotate engine. Do this untiltiming index mark on vibration damper pulley alignswith top dead center (TDC) mark (0 degree) on tim-ing degree scale (Fig. 32). Always rotate engine indirection of normal rotation. Do not rotate enginebackward to align timing marks.
(8) On models equipped with A/C, remove electri-cal cooling fan and shroud assembly from radiator.Refer to Group 7, Cooling System for procedures.
(9) This will provide room to turn engine crank-shaft with a socket and ratchet using vibrationdamper bolt.
(10) Remove distributor holddown bolt and clamp.(11) Remove distributor from engine by slowly lift-
ing straight up.(12) Note that rotor will rotate slightly in a coun-
terclockwise direction while lifting up distributor.The oil pump gear will also rotate slightly in a coun-terclockwise direction while lifting up distributor.This is due to the helical cut gears on distributor andcamshaft.
(13) Note removed position of rotor during distrib-utor removal. During installation, this will bereferred to as the Pre-position.
Fig. 31 Distributor—2.5L Or 4.0L Engines—Typical
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TJ IGNITION SYSTEM 8D - 15
REMOVAL AND INSTALLATION (Continued)
(14) 2.5L 4-Cylinder Engine: Observe slot in oilump gear through hole on side of engine. It shoulde slightly before (counterclockwise of) 10 o’clockosition (Fig. 33).(15) 4.0L 6-Cylinder Engine: Observe slot in oil
ump gear through hole on side of engine. It shoulde slightly before (counterclockwise of) 11 o’clockosition (Fig. 34).
Fig. 32 Align Timing Marks
Fig. 33 Slot At 10 O’clock Position—2.5L Engine
(16) Remove and discard the old distributor-to-en-gine block gasket.
INSTALLATION(1) If engine crankshaft has been rotated after dis-
tributor removal, cylinder number 1 must bereturned to its proper firing stroke. Refer to previousREMOVAL Step 5 and Step 6. These steps must bedone before installing distributor.
(2) Check position of slot on oil pump gear. On the2.5L engine, it should be just slightly before (counter-clockwise of) 10 o’clock position (Fig. 33). On the 4.0Lengine, it should be just slightly before (counterclock-wise of) 11 o’clock position (Fig. 34). If not, place aflat blade screwdriver into oil pump gear and rotateit into proper position.
(3) Factory replacement distributors are equippedwith a plastic alignment pin already installed (Fig.30). This pin is used to temporarily hold rotor to cyl-inder number 1 firing position during distributorinstallation. If pin is in place, proceed to Step 8. Ifnot, proceed to next step.
(4) If original distributor is to be reinstalled, suchas during engine overhaul, the plastic pin will not beavailable. A 3/16 inch drift pin punch tool may besubstituted for plastic pin.
(5) Remove camshaft position sensor from distrib-utor housing. Lift straight up.
(6) Four different alignment holes are provided onplastic ring (Fig. 35). Note that 2.5L and 4.0Lengines have different alignment holes (Fig.35).
Fig. 34 Slot At 11 O’clock Position—4.0L Engine
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8D - 16 IGNITION SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
(7) Rotate distributor shaft and install pin punchool through proper alignment hole in plastic ringFig. 35) and into mating access hole in distributorousing. This will prevent distributor shaft and rotorrom rotating.
(8) Clean distributor mounting hole area of enginelock.(9) Install new distributor-to-engine block gasket
tor into engine while holding centerline of base slotn 1 o’clock position (Fig. 36). Continue to engage dis-ributor into engine. The rotor and distributor willotate clockwise during installation. This is due tohe helical cut gears on distributor and camshaft.
hen distributor is fully seated to engine block, theenterline of base slot should be aligned to clamp boltounting hole on engine (Fig. 37). The rotor should
lso be pointed slightly past (clockwise of) 3 o’clockosition.4.0L 6-Cylinder Engine: Pre-position distributor
nto engine while holding centerline of base slot in 1’clock position (Fig. 36). Continue to engage distrib-tor into engine. The rotor and distributor will rotatelockwise during installation. This is due to the heli-al cut gears on distributor and camshaft. When dis-ributor is fully seated to engine block, the centerlinef base slot should be aligned to clamp bolt mountingole on engine (Fig. 38). The rotor should also beointed at 5 o’clock position.It may be necessary to rotate rotor and distributor
haft (very slightly) to engage distributor shaft with
Fig. 35 Pin Alignment Holes
slot in oil pump gear. The same may have to be doneto engage distributor gear with camshaft gear.
The distributor is correctly installed when:• rotor is pointed at 3 o’clock position (2.5L
engine), or at 5 o’clock position (4.0L engine).• plastic alignment pin (or pin punch tool) is still
• number 1 cylinder piston is set at top dead cen-er (TDC) (compression stroke).
• centerline of slot at base of distributor is alignedo centerline of distributor holddown bolt hole onngine. In this position, the holddown bolt shouldasily pass through slot and into engine.No adjustments are necessary. Proceed to next
tep.(12) Install distributor holddown clamp and bolt.
ighten bolt to 23 N·m (17 ft. lbs.) torque.(13) Remove pin punch tool from distributor. Or, if
lastic alignment pin was used, remove it straightown from bottom of distributor. Discard plastic pin.(14) If removed, install camshaft position sensor to
AUTION: If the distributor cap is incorrectly posi-ioned on distributor housing, cap or rotor may beamaged when engine is started.
(16) Install distributor cap. Tighten distributor capolddown screws to 3 N·m (26 in. lbs.) torque.(17) If removed, install spark plug cables to dis-
ributor cap. For proper firing order, refer to Specifi-ations section at the end of this group. See Engineiring Order.(18) Connect distributor wiring harness to main
ngine harness.(19) Connect battery cable to battery.
(3) Remove ignition switch mounting screw (Fig.3). Use tamper proof torx bit (Snap-Ont SDMTR10r equivalent) to remove the screw.(4) Using a small screwdriver, push on locking tab
Fig. 41) and remove switch from steering column.(5) Disconnect two electrical connectors at rear of
gnition switch (Fig. 43).
Fig. 41 Ignition Switch Lock Tab
Fig. 42 Switch In ON Position
IGNITION SWITCH INSTALLATION(1) Before installing ignition switch, rotate the slot
in the switch to the ON position (Fig. 42).(2) Connect two electrical connectors to rear of
ignition switch. Make sure that locking tabs are fullyseated into wiring connectors.
(3) Position switch to column and install tamperproof screw. Tighten screw to 3 N·m (26 in. lbs.).
(4) Install steering column lower cover.
KEY CYLINDER INSTALLATION(1) If equipped with an automatic transmission,
place shifter in PARK position.(2) Position key cylinder into steering column as it
would normally be in the ON position.(3) Press key cylinder into column until it snaps
into position.(4) Check mechanical operation of switch. Auto-
matic Transmission: Be sure transmission lever islocked in PARK position after key removal. If key isdifficult to rotate or is difficult to remove, the shiftlever-to-steering column cable may be out of adjust-ment or defective. Refer to Group 21, Transmissionfor procedures. Manual Transmission: Be sure keycannot be removed until release lever is operated. Ifkey can be removed, release lever mechanism may bedefective. Release lever mechanism is not servicedseparately. If repair is necessary, the steering columnmust be replaced. Refer to Group 19, Steering forprocedures.
(5) Connect negative cable to battery.(6) Check electrical operation of switch.
Fig. 43 Ignition Switch Removal/Installation
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TJ IGNITION SYSTEM 8D - 19
REMOVAL AND INSTALLATION (Continued)
HIFTER/IGNITION INTERLOCKOn models equipped with an automatic transmis-
ion, a cable connects the ignition switch with theloor shift lever. The shifter will be locked in theARK position when the ignition key is in the LOCKr ACCESSORY positions. The cable can be adjustedr replaced. Refer to Group 21, Transmissions forrocedures. The ignition interlock device within theteering column is not serviceable. If service is nec-ssary, the steering column must be replaced. Refero Group 19, Steering for procedures.
PECIFICATIONS
GNITION TIMINGIgnition timing is not adjustable on any engine.efer to Ignition Timing in the Diagnostics/Servicerocedures section of this group for more informa-ion.
ENGINE FIRING ORDER—2.5L 4-CYLINDERENGINE
ENGINE FIRING ORDER—4.0L 6-CYLINDERENGINE
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8D - 20 IGNITION SYSTEM TJ
SPECIFICATIONS (Continued)
PARK PLUGS
ENGINE PLUG TYPE ELECTRODE GAP
2.5L/4.0L RC12ECC 0.89 mm (0.035 in.)
SPARK PLUG CABLE RESISTANCE
MINIMUM MAXIMUM
250 Ohms Per Inch 1000 Ohms Per Inch
3000 Ohms Per Foot 12,000 Ohms Per Foot
GNITION COIL RESISTANCE
COIL MANUFACTURERPRIMARY RESISTANCE
21-27°C (70-80°F)SECONDARY RESISTANCE
21-27°C (70-80°F)
Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms
Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms
ORQUE CHART
DESCRIPTION TORQUECrankshaft Position Sensor Bolts—With
Manual Transmission . . . . . . . 19 N·m(14 ft. lbs.)Crankshaft Position Sensor Nuts—2.5L With
Automatic Transmission . . . . . 19 N·m (14 ft. lbs.)Crankshaft Position Sensor Bolt—4.0L With
Automatic Transmission . . . . . 7 N·m (60 in. lbs.)Distributor Hold Down Bolt . . . . 23 N·m (17 ft. lbs.)Distributor Cap Screws . . . . . . . . 3 N·m (26 in. lbs.)Ignition Coil Mounting
(if tapped bolts are used) . . . . . 5 N·m (50 in. lbs.)Ignition Coil Mounting
(if nuts/bolts are used) . . . . . 11 N·m (100 in. lbs.)Spark Plugs (all engines) . . . . . . 41 N·m (30 ft. lbs.)
ESCRIPTIONThe instrument panel serves as the command cen-
er of the vehicle, which necessarily makes it a veryomplex unit. The instrument panel is designed toouse the controls and monitors for standard andptional powertrains, climate control systems, audioystems, lighting systems, safety systems and manyther comfort or convenience items. The instrumentanel is also designed so that all of the various con-rols can be safely reached and the monitors can beasily viewed by the vehicle operator when driving,hile still allowing relative ease of access to each of
hese items for service. See the owner’s manual inhe vehicle glove box for more information on the fea-ures, use and operation of all of the instrumentanel components and systems.This group is responsible for covering service infor-ation for the vehicle instrument panel systems.owever, complete service information coverage forll of the systems and components housed in thenstrument panel in a single section of the service
anual would not be practical. Therefore, the servicenformation for any component will be found in theroup designated to cover the vehicle system that theomponent belongs to, even though the component is
mounted on or in the instrument panel. If you cannotlocate a listing for the component or system you areservicing in the table of contents for this group, or ifyou are uncertain as to which vehicle system a com-ponent belongs to, it is suggested that you refer tothe alphabetical Component and System Indexfound at the back of this service manual.
INSTRUMENT PANEL
DESCRIPTIONModular instrument panel construction allows all
of the gauges and controls to be serviced from thefront of the panel. In addition, most of the instru-ment panel electrical or heating and air conditioningcomponents can be accessed without complete instru-ment panel removal. If necessary, the instrumentpanel can be removed from the vehicle as an assem-bly.
Removal of the steering column opening cover andthe knee blocker provides access to the steering col-umn mounts, the steering column wiring, the gear-shift interlock mechanism, the headlamp switch, andmuch of the instrument panel wiring. Removal of theglove box provides access to the fuseblock module,additional instrument panel wiring, and many of theheating and air conditioning components.
Removal of the instrument cluster bezel allowsaccess to the cluster assembly. Removal of the cluster
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8E - 2 INSTRUMENT PANEL SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
ssembly allows access to the cluster illuminationnd indicator lamp bulbs, and more of the instru-ent panel wiring.Removal of the instrument panel center bezel
llows access to the radio, the heating and air condi-ioning controls, the power outlet or cigar lighter, andhe accessory switches. The power outlet/cigar lighters serviced only as a unit with the accessory switchezel.A bezel on each outboard end of the lower instru-ent panel is removed to service the instrument
anel speakers. Removal of the complete instrumentanel is required for service of the passenger sideirbag module and most internal components of theeating and air conditioning system housing.
NSTRUMENT CLUSTER
ESCRIPTIONA single instrument cluster is offered on thisodel. This cluster is an electromechanical unit thattilizes integrated circuitry and information carriedn the Chrysler Collision Detection (CCD) data busetwork for control of all gauges and many of the
ndicator lamps. This cluster also incorporates a dig-tal Vacuum Fluorescent Display (VFD) for the odom-ter/trip odometer display functions. Some variationsf this cluster exist due to optional equipment andegulatory requirements.The cluster includes the following analog gauges:• Coolant temperature gauge• Fuel gauge• Oil pressure gauge• Speedometer• Tachometer• Voltmeter.This cluster also includes provisions for the follow-
ng indicator lamps:• Airbag indicator lamp• Anti-lock Brake System (ABS) lamp• Brake warning lamp• Check gauges lamp• Cruise-on indicator lamp• Four-wheel drive indicator lamp• Headlamp high beam indicator lamp• Low fuel warning lamp• Malfunction indicator (Check Engine) lamp• Seat belt reminder lamp• Sentry Key Immobilizer System (SKIS) indicator
amp• Turn signal indicator lamps• Upshift indicator lamp (manual transmission).The instrument cluster circuitry has a self-diagnos-
ic actuator test capability, which will test each of theCD bus message-controlled functions of the clustery lighting the appropriate indicator lamps and posi-
tioning the gauge needles at several predeterminedlocations on the gauge faces in a prescribed sequence.For more information on this function, refer toInstrument Cluster in the Diagnosis and Testingsection of this group.
The instrument cluster circuitry also integrates achime tone generator and a timer circuit. Theseitems replace the chime or buzzer module, and theseparate timer circuit for the rear window defoggersystem. Refer to Chime Warning System in theDescription and Operation section of Group 8U -Chime/Buzzer Warning Systems for more informationon the chime functions of the instrument cluster.Refer to Rear Window Defogger System in theDescription and Operation section of Group 8N -Electrically Heated Systems for more information onthe timer function of the instrument cluster.
The instrument cluster for this model is servicedonly as a complete unit. If a cluster gauge or thecluster circuit board are faulty, the entire clustermust be replaced. The cluster lens, the cluster hoodand mask, the rear cluster housing cover, the odom-eter reset knob boot and the incandescent lamp bulbsand holders are available for service replacement.
OPERATION
GAUGEWith the ignition switch in the On or Start posi-
tions, voltage is supplied to all gauges through theinstrument cluster electronic circuit board. With theignition switch in the Off position, voltage is not sup-plied to the gauges. The gauges do not accuratelyindicate any vehicle condition unless the ignitionswitch is in the On or Start positions.
All of the instrument cluster gauges, except theodometer, are air core magnetic units. Two fixed elec-tromagnetic coils are located within the gauge. Thesecoils are wrapped at right angles to each otheraround a movable permanent magnet. The movablemagnet is suspended within the coils on one end of ashaft. The gauge needle is attached to the other endof the shaft.
One of the coils has a fixed current flowingthrough it to maintain a constant magnetic fieldstrength. Current flow through the second coilchanges, which causes changes in its magnetic fieldstrength. The current flowing through the second coilis changed by the instrument cluster electronic cir-cuitry in response to messages received on theChrysler Collision Detection (CCD) data bus network.
The gauge needle moves as the movable permanentmagnet aligns itself to the changing magnetic fieldscreated around it by the electromagnets. The instru-ment cluster circuitry is programmed to move all ofthe gauge needles back to the low end of their respec-
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DESCRIPTION AND OPERATION (Continued)
ive scales after the ignition switch is turned to theff position.
NDICATOR LAMPIndicator lamps are located in the instrument clus-
er and are served by the cluster circuit board andonnectors. Many of the indicator lamps in thenstrument cluster are controlled by the instrumentluster circuitry in response to messages receivedver the Chrysler Collision Detection (CCD) data busetwork.The anti-lock brake system lamp, brake warning
amp, four-wheel drive indicator lamp, headlampigh beam indicator lamp, and turn signal indicator
amps are hard wired. The seat belt reminder lamp isontrolled by the instrument cluster programming.he instrument cluster circuitry uses CCD data busessages from the Powertrain Control Module
PCM), Airbag Control Module (ACM), and the Sen-ry Key Immobilizer Module (SKIM) to control all ofhe remaining indicator lamps.
Each of the indicator lamps in the instrument clus-er uses incandescent bulbs and holders, which arevailable for service replacement.
LUSTER ILLUMINATION LAMPThe cluster illumination lamps are hard wired in
he instrument cluster. When the park or head lampsre turned on, the cluster illumination lamps light.llumination brightness is adjusted by rotating theeadlamp switch knob (clockwise to dim, counter-lockwise to brighten). The instrument cluster illumi-ation lamps receive battery feed from the panelimmer rheostat in the headlamp switch through ause in the fuseblock module.
The instrument cluster electronic circuitry alsoonitors the cluster illumination lamp dimming levelhenever the park or head lamps are turned on. The
nstrument cluster electronic circuitry responds bydjusting the dimming level of the odometer Vacuumluorescent Display (VFD), and sending dimming
evel messages over the Chrysler Collision DetectionCCD) data bus network. When the park lamps oreadlamps are turned off, the VFD is illuminated atull brightness for improved daylight visibility.
Each of the cluster illumination lamps is located onhe instrument cluster circuit board. Each clusterllumination lamp has a replaceable bulb and bulbolder.
NSTRUMENT PANEL CIGAR LIGHTER ANDOWER OUTLET
ESCRIPTIONAn accessory power outlet is standard equipment
n this model. The power outlet is installed in the
instrument panel accessory switch bezel, which islocated near the bottom of the instrument panel cen-ter bezel area, next to the ash receiver. A plastic capsnaps into the power outlet base when the power out-let is not in use. A cigar lighter that fits into thepower outlet is a dealer-installed option.
The cigar lighter/power outlet base is serviced onlyas a part of the accessory switch bezel unit. If thebase is faulty or damaged, the accessory switch bezelunit must be replaced. The cigar lighter knob andheating element unit is available for service. Thiscomponent cannot be repaired and, if faulty or dam-aged, it must be replaced.
OPERATIONThe cigar lighter/power outlet base or receptacle
shell is connected to ground, and an insulated con-tact in the bottom of the shell is connected to batterycurrent. The power outlet receives battery voltagefrom a fuse in the Power Distribution Center (PDC)through the accessory relay only when the ignitionswitch is in the Accessory or On positions. Refer toAccessory Relay in the Description and Operationsection of this group for more information on thiscomponent.
The cigar lighter knob and heating element areencased within a spring-loaded housing, which alsofeatures a sliding protective heat shield. When theknob and heating element are inserted in the recep-tacle shell, the heating element resistor coil isgrounded through its housing to the receptacle shell.If the cigar lighter knob is pushed inward, the heatshield slides up toward the knob exposing the heat-ing element, and the heating element extends fromthe housing toward the insulated contact in the bot-tom of the receptacle shell.
Two small spring-clip retainers are located oneither side of the insulated contact inside the bottomof the receptacle shell. These clips engage and holdthe heating element of the dealer-installed cigarlighter against the insulated contact long enough forthe resistor coil to heat up. When the heating ele-ment is engaged with the contact, battery currentcan flow through the resistor coil to ground, causingthe resistor coil to heat.
When the resistor coil becomes sufficiently heated,excess heat radiates from the heating element caus-ing the spring-clips to expand. Once the spring-clipsexpand far enough to release the heating element,the spring-loaded housing forces the knob and heat-ing element to pop back outward to their relaxedposition. When the cigar lighter knob and elementare pulled out of the receptacle shell, the protectiveheat shield slides downward on the housing so thatthe heating element is recessed and shielded aroundits circumference for safety.
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DESCRIPTION AND OPERATION (Continued)
CCESSORY RELAY
ESCRIPTIONThe accessory relay is an electromechanical device
hat switches fused battery current to the standardccessory power outlet or optional cigar lighter whenhe ignition switch is turned to the Accessory or Onositions. The accessory relay is located in a wirearness connector that is secured to the 100-way con-ector bracket under the driver side of the instru-ent panel, near the cowl side inner panel in the
assenger compartment.The accessory relay is a International Standardsrganization (ISO) relay. Relays conforming to the
SO specifications have common physical dimensions,urrent capacities, terminal patterns, and terminalunctions.
The accessory relay cannot be repaired or adjustednd, if faulty or damaged, it must be replaced.
PERATIONThe ISO relay consists of an electromagnetic coil, a
esistor or diode, and three (two fixed and one mov-ble) electrical contacts. The movable (common feed)elay contact is held against one of the fixed contactsnormally closed) by spring pressure. When the elec-romagnetic coil is energized, it draws the movableontact away from the normally closed fixed contact,nd holds it against the other (normally open) fixedontact.When the electromagnetic coil is de-energized,
pring pressure returns the movable contact to theormally closed position. The resistor or diode is con-ected in parallel with the electromagnetic coil in theelay, and helps to dissipate voltage spikes that areroduced when the coil is de-energized.
IAGNOSIS AND TESTING
NSTRUMENT CLUSTERIf all of the gauges and/or indicator lamps are inop-
rative, perform the Preliminary Diagnosis. If anndividual gauge or Chrysler Collision DetectionCCD) data bus message-controlled indicator lamp isnoperative, go directly to the Actuator Test. If anndividual hard wired indicator lamp is inoperative,efer to Instrument Cluster - Hard Wired Lampiagnosis in the Diagnosis and Testing section of
his group for the procedures to diagnosis that lamp.or complete circuit diagrams, refer to Instrumentluster in the Contents of Group 8W - Wiring Dia-rams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
PRELIMINARY DIAGNOSIS(1) If the indicator lamps operate, but none of the
gauges operate, go to Step 2. If all of the gauges andthe CCD data bus message-controlled indicator lampsare inoperative, go to Step 5.
(2) Check the fused B(+) fuse in the Power Distri-bution Center (PDC). If OK, go to Step 3. If not OK,repair the shorted circuit or component as requiredand replace the faulty fuse.
(3) Check for battery voltage at the fused B(+) fusein the PDC. If OK, go to Step 4. If not OK, repair theopen fused B(+) circuit to the battery as required.
(4) Disconnect and isolate the battery negativecable. Remove the instrument cluster. Connect thebattery negative cable. Check for battery voltage atthe fused B(+) circuit cavity of the instrument clusterwire harness connector A. If OK, refer to Instru-ment Cluster - Actuator Test in the Diagnosis andTesting section of this group. If not OK, repair theopen fused B(+) circuit to the fuse in the PDC asrequired.
(5) Check the fused ignition switch output (run/start) fuse in the fuseblock module. If OK, go to Step6. If not OK, repair the shorted circuit or componentas required and replace the faulty fuse.
(6) Turn the ignition switch to the On position andcheck for battery voltage at the fused ignition switchoutput (run/start) fuse in the fuseblock module. IfOK, go to Step 7. If not OK, repair the open fusedignition switch output (run/start) circuit to the igni-tion switch as required.
(7) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Install the instrument cluster. Connect the batterynegative cable. Turn the ignition switch to the Onposition. Set the park brake. The red brake warninglamp should light. If OK, go to Step 8. If not OK, goto Step 9.
(8) Turn the ignition switch to the Off position.Turn on the park lamps and adjust the panel lampsdimmer rheostat in the headlamp switch to the fullbright position. The cluster illumination lampsshould light. If OK, refer to Instrument Cluster -Actuator Test in the Diagnosis and Testing sectionof this group. If not OK, go to Step 10.
(9) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Remove the instrument cluster. Connect the battery
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TJ INSTRUMENT PANEL SYSTEMS 8E - 5
DIAGNOSIS AND TESTING (Continued)
egative cable. Turn the ignition switch to the Onosition. Check for battery voltage at the fused igni-ion switch output (run/start) circuit cavity of thenstrument cluster wire harness connector A. If OK,efer to Instrument Cluster - Actuator Test in theiagnosis and Testing section of this group. If notK, repair the open fused ignition switch output
run/start) circuit to the fuse in the fuseblock modules required.(10) Disconnect and isolate the battery negative
able. Remove the instrument cluster. Check for con-inuity between the ground circuit cavity of thenstrument cluster wire harness connector A and aood ground. There should be continuity. If OK, refero Instrument Cluster - Actuator Test in theiagnosis and Testing section of this group. If notK, repair the open ground circuit to ground as
equired.
CTUATOR TESTThe instrument cluster actuator test will put the
nstrument cluster into its self-diagnostic mode. Inhis mode the instrument cluster can perform a self-iagnostic test that will confirm that the instrumentluster circuitry, the gauges, and the CCD data busessage controlled indicator lamps are capable of
perating as designed. During the actuator test thenstrument cluster circuitry will position each of theauge needles at various specified calibration points,nd turn all of the CCD data bus message-controlledamps on and off at specified time intervals (Fig. 1).
Successful completion of the actuator test will con-irm that the instrument cluster is operational. How-ver, there may still be a problem with the CCD dataus, the Powertrain Control Module (PCM), the Air-ag Control Module (ACM), the Sentry Key Immobi-izer Module (SKIM) or the inputs to one of theselectronic control modules. Use a DRB scan tool andhe proper Diagnostic Procedures manual for testingf these components.If an individual gauge does not respond properly,
r does not respond at all during the actuator test,he instrument cluster should be removed. However,heck that the gauge mounting screws on the instru-ent cluster electronic circuit board for proper tight-ess before considering instrument clustereplacement. If the gauge mounting screws checkK, replace the faulty cluster.If an individual indicator lamp does not illuminate
uring the actuator test, the instrument clusterhould be removed. However, check that the incan-escent lamp bulb is not faulty and that the bulbolder is properly installed on the instrument clusterlectronic circuit board before considering instrumentluster replacement. If the bulb and bulb holderheck OK, replace the faulty instrument cluster.
(1) Begin the test with the ignition switch in theOff position.
(2) Depress the trip odometer reset button.(3) While holding the trip odometer reset button
depressed, turn the ignition switch to the On posi-tion, but do not start the engine.
(4) Release the trip odometer reset button.(5) Compare the operation of the suspect gauge(s)
and/or indicator lamp(s) with the Instrument ClusterActuator Test chart (Fig. 1).
(6) The instrument cluster will automatically exitthe self-diagnostic mode and return to normal opera-tion at the completion of the test, if the ignitionswitch is turned to the Off position during the test,or if a vehicle speed message indicating that thevehicle is moving is received from the PCM on theCCD data bus during the test.
(7) Go back to Step 1 to repeat the test, ifrequired.
HARD WIRED LAMP DIAGNOSISEach of the lamps found in this section depends
upon a hard wired circuit input to the instrumentcluster for proper operation. The following procedureswill help to diagnose conditions that may cause aninoperative hard wired lamp circuit condition.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
ANTI-LOCK BRAKE SYSTEM LAMPThe diagnosis found here addresses an inoperative
Anti-lock Brake System (ABS) lamp condition. If theABS lamp stays on with the ignition switch in theOn position, or comes on and stays on while driving,refer to Antilock Brakes in the Diagnosis and Test-ing section of Group 5 - Brakes for diagnosis. If noABS problem is found, the following procedure willhelp locate a short or open in the ABS lamp circuit.For complete circuit descriptions, refer to Instru-ment Cluster in the Contents of Group 8W - WiringDiagrams.
(1) Check the fused ignition switch output (run/start) fuse in the fuseblock module. If OK, go to Step2. If not OK, repair the shorted circuit or componentas required and replace the faulty fuse.
(2) Turn the ignition switch to the On position.Check for battery voltage at the fused ignition switchoutput (run/start) fuse in the fuseblock module. If
8E - 6 INSTRUMENT PANEL SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
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TJ INSTRUMENT PANEL SYSTEMS 8E - 7
DIAGNOSIS AND TESTING (Continued)
K, go to Step 3. If not OK, repair the open fusedgnition switch output (run/start) circuit to the igni-ion switch as required.
(3) Turn the ignition switch to the Off position.isconnect and isolate the battery negative cable.emove the instrument cluster. Connect the batteryegative cable. Turn the ignition switch to the Onosition and within five seconds check for continuityetween the ABS warning indicator driver circuitavity of the instrument cluster wire harness connec-or A and a good ground. There should be continuityor five seconds after ignition On, and then an openircuit. If OK, replace the faulty bulb. If not OK, goo Step 4.
(4) Turn the ignition switch to the Off position.isconnect and isolate the battery negative cable.isconnect the Controller Anti-lock Brake (CAB) wirearness connector. Check for continuity between theBS warning indicator driver circuit cavity of the
nstrument cluster wire harness connector A and aood ground. There should be no continuity. If OK, goo Step 5. If not OK, repair the shorted ABS warningndicator driver circuit as required.
(5) Check for continuity between the ABS warningndicator driver circuit cavities of the instrumentluster wire harness connector A and the CAB wirearness connector. There should be continuity. If OK,efer to Antilock Brakes in the Diagnosis and Test-ng section of Group 5 - Brakes for diagnosis of theAB. If not OK, repair the open ABS warning indi-ator driver circuit as required.
RAKE WARNING LAMPThe diagnosis found here addresses an inoperative
rake warning lamp condition. If the brake warningamp stays on with the ignition switch in the Onosition and the park brake released, or comes onhile driving, refer to Base Brake System for vehi-
les not equipped with the four wheel anti-lock brakeystem, or refer to Antilock Brakes for vehiclesquipped with the four wheel anti-lock brake systemn the Diagnosis and Testing section of Group 5 -rakes for further diagnosis. If no brake systemroblem is found, the following procedure will helpocate a short or open circuit, or a faulty switch. Foromplete circuit diagrams, refer to Instrumentluster in the Contents of Group 8W - Wiring Dia-rams.(1) Check the fused ignition switch output (run/
tart) fuse in the fuseblock module. If OK, go to Step. If not OK, repair the shorted circuit or components required and replace the faulty fuse.(2) Turn the ignition switch to the On position.heck for battery voltage at the fused ignition switchutput (run/start) fuse in the fuseblock module. IfK, go to Step 3. If not OK, repair the open fused
ignition switch output (run/start) circuit to the igni-tion switch as required.
(3) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Disconnect the wire harness connector at the parkbrake switch. With the park brake released, check forcontinuity between the park brake switch terminaland a good ground. There should be no continuity. IfOK, go to Step 4. If not OK, adjust or replace thefaulty park brake switch.
(4) Disconnect the wire harness connector at thebrake warning switch. Check for continuity betweenthe two terminals of the brake warning switch. Thereshould be continuity. If OK, go to Step 5. If not OK,replace the faulty brake warning switch.
(5) Check for continuity between each of the twobrake warning switch terminals and a good ground.In each case, there should be no continuity. If OK, goto Step 6. If not OK, replace the faulty brake warn-ing switch.
(6) With both the park brake switch and the brakewarning switch wire harness connectors still discon-nected, check for continuity between the red brakewarning indicator driver circuit cavity of the parkbrake switch wire harness connector and a goodground. There should be no continuity. If OK, go toStep 7. If not OK, repair the shorted red brake warn-ing indicator driver circuit as required.
(7) With the ignition switch held in the Start posi-tion, check for continuity between the red brakewarning indicator driver circuit cavity of the parkbrake switch wire harness connector and a goodground. There should be continuity. If OK, go to Step8. If not OK, repair the open red brake warning indi-cator driver circuit to the ignition switch as required.
(8) Turn the ignition switch to the Off position.Remove the instrument cluster. Check for continuitybetween the red brake warning indicator driver cir-cuit cavity of the instrument cluster wire harnessconnector A and a good ground. There should be nocontinuity. If OK, go to Step 9. If not OK, repair theshorted red brake warning indicator driver circuit asrequired.
(9) Check for continuity between the red brakewarning indicator driver circuit cavities of the instru-ment cluster wire harness connector A and the brakewarning switch wire harness connector. There shouldbe continuity. If OK, replace the faulty bulb. If notOK, repair the open red brake warning indicatordriver circuit as required.
CLUSTER ILLUMINATION LAMPThe diagnosis found here addresses an inoperative
instrument cluster illumination lamp condition. Ifthe problem being diagnosed includes inoperativeexterior lighting controlled by the headlamp switch,
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DIAGNOSIS AND TESTING (Continued)
hat system needs to be repaired first. If the exterioramps controlled by the headlamp switch are inoper-tive, refer to Headlamp Diagnosis in the Diagno-is and Testing section of Group 8L - Lamps foriagnosis. If no exterior lighting system problems areound, the following procedure will help locate ahort or open in the cluster illumination lamp circuit.f the problem being diagnosed involves a lack ofimming control for the odometer/trip odometer Vac-um Fluorescent Display (VFD), but all of the otherluster illumination lamps can be dimmed, repair thepen headlamp switch output circuit input to thenstrument cluster. For complete circuit diagrams,efer to Instrument Cluster in the Contents ofroup 8W - Wiring Diagrams.(1) Check the panel lamps dimmer fuse in the
useblock module. If OK, go to Step 2. If not OK,epair the shorted circuit or component as requirednd replace the faulty fuse.(2) Turn the park lamps on with the headlamp
witch. Rotate the headlamp switch knob counter-lockwise to just before the interior lamps detent.heck for battery voltage at the panel lamps dimmer
use in the fuseblock module. Rotate the headlampwitch knob clockwise while observing the test volt-eter. The reading should go from battery voltage to
ero volts. If OK, go to Step 3. If not OK, repair thepen panel lamps dimmer switch signal circuit to theeadlamp switch as required. If the circuit tests OK,efer to Headlamp Diagnosis in the Diagnosis andesting section of Group 8L - Lamps to diagnose theeadlamp switch.(3) Disconnect and isolate the battery negative
able. Remove the instrument cluster. Turn the head-amp switch off. Remove the panel lamps dimmeruse from the fuseblock module. Probe the fusedanel lamps dimmer switch signal circuit cavity ofhe instrument cluster wire harness connector A.heck for continuity to a good ground. There shoulde no continuity. If OK, go to Step 4. If not OK,epair the shorted fused panel lamps dimmer switchignal circuit as required.(4) Install the panel lamps dimmer fuse in the
useblock module. Connect the battery negativeable. Turn the park lamps on with the headlampwitch. Rotate the headlamp switch knob counter-lockwise to just before the interior lamps detent.heck for battery voltage at the fused panel lampsimmer switch signal circuit cavity of the instrumentluster wire harness connector A. If OK, replace theaulty cluster illumination lamp bulb(s) and bulbolder(s). If not OK, repair the open fused panel
amps dimmer switch signal circuit as required.
OUR-WHEEL DRIVE INDICATOR LAMPThe diagnosis found here addresses an inoperative
our-wheel drive indicator lamp condition. If theroblem being diagnosed is related to lamp accuracy,e certain to confirm that the problem is with theamp or switch and not with a damaged or inopera-ive transfer case or transfer case linkage. Refer toV231 Diagnosis in the Diagnosis and Testing sec-
ion of Group 21 - Transmission for more informa-ion. If no transfer case problem is found, theollowing procedure will help locate a short or openn the indicator lamp circuit. For complete circuitiagrams, refer to Instrument Cluster in Group 8W
- Wiring Diagrams.(1) Check the fused ignition switch output (run/
start) fuse in the fuseblock module. If OK, go to Step2. If not OK, repair the shorted circuit or componentas required and replace the faulty fuse.
(2) Turn the ignition switch to the On position.Check for battery voltage at the fused ignition switchoutput (run/start) fuse in the fuseblock module. IfOK, go to Step 3. If not OK, repair the open fusedignition switch output (run/start) circuit to the igni-tion switch as required.
(3) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Disconnect the transfer case switch wire harness con-nector. Check for continuity between the ground cir-cuit cavity of the transfer case switch wire harnessconnector and a good ground. There should be conti-nuity. If OK, go to Step 4. If not OK, repair the openground circuit to ground as required.
(4) Connect the battery negative cable. Turn theignition switch to the On position. Install a jumperwire between the part time four wheel drive indicatorlamp driver circuit cavity of the transfer case switchwire harness connector and a good ground. The four-wheel drive indicator lamp should light. If OK,replace the faulty transfer case switch. If not OK, goto Step 5.
(5) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Remove the instrument cluster. With the transfercase switch wire harness connector still disconnected,check for continuity between the part time fourwheel drive indicator lamp driver circuit cavity of theinstrument cluster wire harness connector B and agood ground. There should be no continuity. If OK, goto Step 6. If not OK, repair the shorted part timefour wheel drive indicator lamp driver circuit asrequired.
(6) Check for continuity between the part timefour wheel drive indicator lamp driver circuit cavitiesof the instrument cluster wire harness connector Band the transfer case switch wire harness connector.There should be continuity. If OK, replace the faulty
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ulb. If not OK, repair the open part time four wheelrive indicator lamp driver circuit as required.
EADLAMP HIGH BEAM INDICATOR LAMPThe diagnosis found here addresses an inoperative
eadlamp high beam indicator lamp condition. If theroblem being diagnosed is related to inoperativeeadlamp high beams, refer to Headlamp Diagno-is in the Diagnosis and Testing section of Group 8LLamps for diagnosis of the headlamp system. If noeadlamp system problems are found, the followingrocedure will help locate an open in the high beamndicator lamp circuit. For complete circuit diagrams,efer to Instrument Cluster in the Contents ofroup 8W - Wiring Diagrams.(1) Disconnect and isolate the battery negative
able. Remove the instrument cluster.(2) Connect the battery negative cable. Turn the
eadlamps on and select the high beams with theulti-function switch stalk. Check for battery voltage
t the high beam indicator driver circuit cavity of thenstrument cluster wire harness connector A. If OK,eplace the faulty bulb. If not OK, repair the openigh beam indicator driver circuit to the headlampimmer (multi-function) switch as required.
URN SIGNAL INDICATOR LAMPThe diagnosis found here addresses an inoperative
urn signal indicator lamp condition. For any otherurn signal problem, refer to Turn Signal and Haz-rd Warning Systems in the Diagnosis and Testingection of Group 8J - Turn Signal and Hazard Warn-ng Systems for further diagnosis. If no turn signal orazard warning system problem is found, the follow-
ng procedure will help locate a short or open in thendicator lamp circuit. For complete circuit diagrams,efer to Instrument Cluster in the Contents ofroup 8W - Wiring Diagrams.(1) Disconnect and isolate the battery negative
able. Remove the instrument cluster.(2) Connect the battery negative cable. Activate
he hazard warning system by moving the hazardarning switch button to the On position. Check forattery voltage at the inoperative (right or left) turnignal circuit cavity of the instrument cluster wirearness connector (connector A - left, or connector B -ight). There should be a switching (on and off) bat-ery voltage signal. If OK, replace the faulty (right oreft) indicator lamp bulb. If not OK, repair the openright or left) turn signal circuit to the turn signal/azard warning (multi-function) switch as required.
CCESSORY RELAYThe accessory relay (Fig. 2) is located in a wire
arness connector that is secured to the 100-way con-ector bracket under the driver side of the instru-
ment panel, near the cowl side inner panel in thepassenger compartment. For complete circuit dia-grams, refer to Horn/Cigar Lighter in the Contentsof Group 8W - Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Remove the accessory relay from its wire har-ness connector. Refer to Accessory Relay in theRemoval and Installation section of this group for theprocedures.
(2) A relay in the de-energized position shouldhave continuity between terminals 87A and 30, andno continuity between terminals 87 and 30. If OK, goto Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-tromagnet) should be 75 6 5 ohms. If OK, go to Step4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.There should now be continuity between terminals30 and 87, and no continuity between terminals 87Aand 30. If OK, perform the Relay Circuit Test thatfollows. If not OK, replace the faulty relay.
RELAY CIRCUIT TEST(1) The relay common feed terminal (30) is con-
nected to battery voltage and should be hot at alltimes. Check for battery voltage at the fused B(+) cir-cuit cavity of the accessory relay wire harness con-nector. If OK, go to Step 2. If not OK, repair thefused B(+) circuit to the fuse in the Power Distribu-tion Center (PDC) as required.
Fig. 2 Accessory Relay
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8E - 10 INSTRUMENT PANEL SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
(2) The relay normally closed terminal (87A) isonnected to terminal 30 in the de-energized position,ut is not used for this application. Go to Step 3.(3) The relay normally open terminal (87) is con-
ected to the common feed terminal (30) in the ener-ized position. This terminal supplies battery voltageo the cigar lighter or power outlet when the relay isnergized by the ignition switch. There should beontinuity between the accessory relay wire harnessonnector cavity for relay terminal 87 and the acces-ory relay output circuit cavity in the cigar lighter orower outlet wire harness connector at all times. IfK, go to Step 4. If not OK, repair the open acces-
ory relay output circuit to the cigar lighter or powerutlet wire harness connector as required.(4) The coil battery terminal (86) is connected to
he electromagnet in the relay. The accessory relayire harness connector cavity for this terminal
hould have continuity to ground at all times. If OK,o to Step 5. If not OK, repair the open ground cir-uit to ground as required.(5) The coil ground terminal (85) is connected to
he electromagnet in the relay. It receives batteryeed to energize the accessory relay when the ignitionwitch is in the Accessory or On positions. Turn thegnition switch to the On position. Check for batteryoltage at the fused ignition switch output (acc/run)ircuit cavity of the accessory relay wire harness con-ector. If not OK, repair the open fused ignitionwitch output (acc/run) circuit to the ignition switchs required.
ar Lighter in the Contents of Group 8W - Wiringiagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Remove the protective cap or the cigar lighternob and element from the cigar lighter/power outleteceptacle shell. Check for continuity between thenside circumference of the cigar lighter/power outleteceptacle shell and a good ground. there should beontinuity. If OK, go to Step 2. If not OK, go to Step.
(2) Turn the ignition switch to the On position.Check for battery voltage at the insulated contactlocated at the back of the cigar lighter/power outletreceptacle shell. If OK, replace the faulty cigarlighter knob and element. If not OK, go to Step 3.
(3) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Remove the instrument panel accessory switch bezel.Check for continuity between the ground circuit cav-ity of the cigar lighter/power outlet wire harness con-nector and a good ground. There should becontinuity. If OK, go to Step 4. If not OK, repair theopen ground circuit to ground as required.
(4) Connect the battery negative cable. Turn theignition switch to the Accessory or On positions.Check for battery voltage at the accessory relay out-put circuit cavity of the cigar lighter/power outletwire harness connector. If OK, replace the faultyaccessory switch bezel unit. If not OK, refer toAccessory Relay in the Diagnosis and Testing sec-tion of this group for further diagnosis.
REMOVAL AND INSTALLATION
STEERING COLUMN OPENING COVER
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL(1) Disconnect and isolate the battery negative
cable.(2) If the vehicle is so equipped, move the tilt
steering column to the fully raised position.(3) Remove the knob and shaft from the headlamp
switch. Refer to Headlamp Switch in the Removaland Installation section of this group for the proce-dures.
(4) Remove the two screws that secure the steeringcolumn opening cover to the instrument panel (Fig.3).
(5) Pull the upper edge of the steering columnopening cover straight back and down away from theinstrument panel as far as possible.
(6) Rock the lower edge of the steering columnopening cover rearward to disengage the hinge hookformations on the lower edge of the cover from thehinge pins on the lower edge of the instrument panel.
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TJ INSTRUMENT PANEL SYSTEMS 8E - 11
REMOVAL AND INSTALLATION (Continued)
(7) Remove the steering column opening coverrom the instrument panel.
NSTALLATION(1) Position the steering column opening cover to
he instrument panel.(2) Engage the hinge hook formations on the lower
dge of the steering column opening cover with theinge pins on the lower edge of the instrument panel.(3) Tilt the upper edge of the steering column
pening cover up into position onto the instrumentanel.(4) Install and tighten the two screws that secure
he steering column opening cover to the instrumentanel. Tighten the screws to 2.2 N·m (20 in. lbs.).(5) Reconnect the battery negative cable.
NEE BLOCKER
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the steering column opening cover
rom the instrument panel. Refer to Steering Col-mn Opening Cover in the Removal and Installa-
(3) Remove the four screws that secure the kneeblocker to the instrument panel (Fig. 4).
(4) Remove the knee blocker from the instrumentpanel.
INSTALLATION(1) Position the knee blocker to the instrument
panel.(2) Install and tighten the four screws that secure
the knee blocker to the instrument panel. Tightenthe screws to 2.2 N·m (20 in. lbs.).
(3) Install the steering column opening cover ontothe instrument panel. Refer to Steering ColumnOpening Cover in the Removal and Installation sec-tion of this group for the procedures.
(4) Reconnect the battery negative cable.
HEADLAMP SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
WARNING: IF THE HEADLAMP SWITCH WAS ON,WAIT FIVE MINUTES TO ALLOW THE CERAMICDIMMER RESISTOR TO COOL. IF THE CERAMICDIMMER RESISTOR IS NOT ALLOWED TO COOL, ITCAN BURN YOUR FINGERS.
Fig. 4 Knee Blocker Remove/Install
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8E - 12 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Pull the headlamp switch control knob out to
he On position stop.(3) Reach up under the instrument panel outboard
f the steering column to access and depress theeadlamp switch control knob and shaft release but-on on the top of the switch body (Fig. 5).
(4) While holding the release button depressed,ull the headlamp switch control knob and shaft unitut of the headlamp switch.(5) Remove the knee blocker from the instrument
anel. Refer to Knee Blocker in the Removal andnstallation section of this group for the procedures.
(6) Remove the spanner nut that secures the head-amp switch to the instrument panel mountingracket.(7) Pull the headlamp switch away from the
nstrument panel mounting bracket far enough toccess the instrument panel wire harness connectors.(8) Disconnect the two instrument panel wire har-
ess connectors from the headlamp switch.(9) Remove the headlamp switch from the instru-ent panel.
NSTALLATION(1) Position the headlamp switch to the instru-ent panel.(2) Reconnect the two instrument panel wire har-
ess connectors to the headlamp switch.(3) Position the headlamp switch behind theounting bracket on the instrument panel.(4) Install and tighten the spanner nut that
ecures the headlamp switch to the instrument panelounting bracket. Tighten the nut to 2.7 N·m (24 in.
bs.).
Fig. 5 Headlamp Switch Remove/Install
(5) Install the knee blocker onto the instrumentpanel. Refer to Knee Blocker in the Removal andInstallation section of this group for the procedures.
(6) Insert the shaft of the headlamp switch controlknob and shaft unit through the opening in the steer-ing column opening cover and into the headlampswitch.
(7) Push the headlamp switch control knob andshaft unit all the way into the headlamp switch body.
(8) Reconnect the battery negative cable.
INSTRUMENT PANEL TOP COVER
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL(1) Disconnect and isolate the battery negative
cable.(2) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the instrument panel topcover up and away from the instrument panel farenough to disengage the five snap clip retainers fromtheir receptacles in the instrument panel (Fig. 6).
Fig. 6 Instrument Panel Top Cover Remove/Install
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TJ INSTRUMENT PANEL SYSTEMS 8E - 13
REMOVAL AND INSTALLATION (Continued)
(3) Remove the top cover from the instrumentanel.
NSTALLATION(1) Position the top cover onto the instrument
anel.(2) Align the snap clips on the top cover with the
nap clip receptacles in the instrument panel.(3) Press firmly downward on the top cover over
ach of the snap clip locations until each of the snaplips is fully seated in their receptacles in the instru-ent panel.(4) Reconnect the battery negative cable.
LUSTER BEZEL
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the steering column opening cover
rom the instrument panel. Refer to Steering Col-mn Opening Cover in the Removal and Installa-
ion section of this group for the procedures.(3) Remove the top cover from the instrument
anel. Refer to Instrument Panel Top Cover in theemoval and Installation section of this group for therocedures.(4) Remove the two screws that secure the lowerounting tabs of the cluster bezel to the instrument
anel (Fig. 7).(5) Remove the three screws that secure the upperounting flange of the cluster bezel to the instru-ent panel (Fig. 8).(6) Remove the cluster bezel from the instrument
anel.
NSTALLATION(1) Position the cluster bezel to the instrument
anel.(2) Install and tighten the three screws that secure
he upper mounting flange of the cluster bezel to thenstrument panel. Tighten the screws to 2.2 N·m (20n. lbs.).
(3) Install and tighten the two screws that securehe lower mounting tabs of the cluster bezel to the
instrument panel. Tighten the screws to 2.2 N·m (20in. lbs.).
(4) Install the top cover onto the instrument panel.Refer to Instrument Panel Top Cover in theRemoval and Installation section of this group for theprocedures.
(5) Install the steering column opening cover ontothe instrument panel. Refer to Steering ColumnOpening Cover in the Removal and Installation sec-tion of this group for the procedures.
(6) Reconnect the battery negative cable.
INSTRUMENT CLUSTER
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
Fig. 7 Cluster Bezel Lower Screws Remove/Install
Fig. 8 Cluster Bezel Upper Screws Remove/Install
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8E - 14 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the cluster bezel from the instrument
anel. Refer to Cluster Bezel in the Removal andnstallation section of this group for the procedures.
(3) Remove the four screws that secure the instru-ent cluster to the instrument panel (Fig. 9).
(4) Pull the instrument cluster rearward farnough to disengage the two self-docking instrumentanel wire harness connectors from the connectoreceptacles on the back of the cluster housing.(5) Remove the instrument cluster from the instru-ent panel.
NSTALLATION(1) Position the instrument cluster to the instru-ent panel.(2) Align the instrument cluster with the cluster
pening in the instrument panel and push the clusterirmly and evenly into place. The instrument panelas two self-docking wire harness connectors thatill be automatically aligned with, and connected to
he cluster connector receptacles when the cluster isnstalled in the instrument panel.
(3) Install and tighten the four screws that securehe instrument cluster to the instrument panel.ighten the screws to 2.2 N·m (20 in. lbs.).(4) Install the cluster bezel onto the instrument
anel. Refer to Cluster Bezel in the Removal andnstallation section of this group for the procedures.
(5) Reconnect the battery negative cable.
NSTRUMENT CLUSTER COMPONENTSSome of the components for the instrument cluster
sed in this vehicle are serviced individually. Theerviced components include: the incandescentnstrument cluster indicator lamp and illumination
Fig. 9 Instrument Cluster Remove/Install
lamp bulbs (including the integral bulb holders), theodometer reset knob boot, the cluster lens, the clus-ter hood and mask unit, the instrument cluster hous-ing rear cover, and the instrument cluster housing(including the odometer reset knob, the gauge mask,the gauges and the instrument cluster electronic cir-cuit board). Following are the service procedures forthe instrument cluster components.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL
CLUSTER BULBThis procedure applies to each of the incandescent
cluster illumination lamp or indicator lamp bulb andbulb holder units. However, the illumination lampsand the indicator lamps use different bulb and bulbholder unit sizes. They must never be interchanged.Be certain that any bulb and bulb holder unitremoved from the cluster electronic circuit board isreinstalled in the correct position. Always use thecorrect bulb size and type for replacement. An incor-rect bulb size or type may overheat and cause dam-age to the instrument cluster, the electronic circuitboard and/or the gauges.
(1) Disconnect and isolate the battery negativecable.
(2) Remove the instrument cluster from the instru-ment panel. Refer to Instrument Cluster in the
emoval and Installation section of this group for therocedures.(3) Turn the bulb holder counterclockwise about
ixty degrees on the cluster electronic circuit board.(4) Pull the bulb and bulb holder unit straight
ack to remove it from the bulb mounting hole in theluster electronic circuit board (Fig. 10).
LUSTER LENS(1) Disconnect and isolate the battery negative
able.(2) Remove the instrument cluster from the instru-ent panel. Refer to Instrument Cluster in theemoval and Installation section of this group for therocedures.(3) Work around the perimeter of the cluster hous-
ng to disengage each of the latches that secure theluster lens to the cluster housing (Fig. 11).
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TJ INSTRUMENT PANEL SYSTEMS 8E - 15
REMOVAL AND INSTALLATION (Continued)
(4) Gently pull the cluster lens away from the clus-er housing.
DOMETER RESET KNOB BOOT(1) Disconnect and isolate the battery negative
able.(2) Remove the instrument cluster from the instru-ent panel. Refer to Instrument Cluster in theemoval and Installation section of this group for therocedures.(3) Remove the cluster lens from the cluster hous-
ng. Refer to Instrument Cluster Components -luster Lens in the Removal and Installation sec-
ion of this group for the procedures.(4) Remove the odometer reset knob boot by pull-
ng it out of the cluster lens.
Fig. 10 Cluster Bulb Locations
Fig. 11 Instrument Clus
CLUSTER HOOD AND MASK(1) Disconnect and isolate the battery negative
cable.(2) Remove the instrument cluster from the instru-
ment panel. Refer to Instrument Cluster in theRemoval and Installation section of this group for theprocedures.
(3) Remove the cluster lens from the cluster hous-ing. Refer to Instrument Cluster Components -Cluster Lens in the Removal and Installation sec-tion of this group for the procedures.
(4) Work around the perimeter of the cluster hous-ing to disengage each of the latches that secure thecluster hood and mask unit to the cluster housing(Fig. 11).
(5) Gently pull the cluster hood and mask unitaway from the cluster housing.
CLUSTER HOUSING REAR COVER(1) Disconnect and isolate the battery negative
cable.(2) Remove the instrument cluster from the instru-
ment panel. Refer to Instrument Cluster in theRemoval and Installation section of this group for theprocedures.
(3) Work around the perimeter of the cluster hous-ing to disengage each of the latches that secure therear cover to the cluster housing (Fig. 11).
(4) Gently pull the rear cover away from the backof the cluster housing.
ter Components
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8E - 16 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
LUSTER HOUSING(1) Disconnect and isolate the battery negative
able.(2) Remove the instrument cluster from the instru-ent panel. Refer to Instrument Cluster in theemoval and Installation section of this group for therocedures.(3) Remove all of the cluster illumination lamp
nd indicator lamp bulb and bulb holder units fromhe electronic circuit board. Refer to Instrumentluster Components - Cluster Bulbs in theemoval and Installation section of this group for therocedures.(4) Remove the cluster hood and mask unit from
he cluster housing. Refer to Instrument Clusteromponents - Cluster Hood and Mask in theemoval and Installation section of this group for therocedures.(5) Remove the rear cover from the cluster hous-
ng. Refer to Instrument Cluster Components -luster Housing Rear Cover in the Removal and
nstallation section of this group for the procedures.
NSTALLATION
LUSTER BULBThis procedure applies to each of the incandescent
luster illumination lamp or indicator lamp bulb andulb holder units. However, the illumination lampsnd the indicator lamps use different bulb and bulbolder unit sizes. They must never be interchanged.e certain that any bulb and bulb holder unitemoved from the cluster electronic circuit board iseinstalled in the correct position.
AUTION: Always use the correct bulb size andype for replacement. An incorrect bulb size or typeay overheat and cause damage to the instrument
luster, the electronic circuit board and/or theauges.
(1) Insert the bulb and bulb holder unit straightnto the correct bulb mounting hole in the clusterlectronic circuit board.(2) With the bulb holder fully seated against the
luster electronic circuit board, turn the bulb holderlockwise about sixty degrees to lock it into place.(3) Install the instrument cluster onto the instru-ent panel. Refer to Instrument Cluster in theemoval and Installation section of this group for therocedures.(4) Reconnect the battery negative cable.
LUSTER LENS(1) Align the cluster lens with the cluster hood andask unit.
(2) Press firmly and evenly on the cluster lens toinstall it onto the cluster housing.
(3) Work around the perimeter of the cluster hous-ing to be certain that each of the latches that securethe cluster lens to the cluster housing is fullyengaged.
(4) Install the instrument cluster onto the instru-ment panel. Refer to Instrument Cluster in theRemoval and Installation section of this group for theprocedures.
(5) Reconnect the battery negative cable.
ODOMETER RESET KNOB BOOT(1) Position the odometer reset knob to the mount-
ing hole from the back of the cluster lens.(2) Pull the odometer reset knob into the mounting
hole from the face of the cluster lens.(3) Install the cluster lens onto the cluster hous-
ing. Refer to Instrument Cluster Components -Cluster Lens in the Removal and Installation sec-tion of this group for the procedures.
(4) Install the instrument cluster onto the instru-ment panel. Refer to Instrument Cluster in theRemoval and Installation section of this group for theprocedures.
(5) Reconnect the battery negative cable.
CLUSTER HOOD AND MASK(1) Align the hood and mask unit with the cluster
housing.(2) Press firmly and evenly on the hood and mask
unit to install it onto the cluster housing.(3) Work around the perimeter of the cluster hous-
ing to be certain that each of the latches that securethe hood and mask unit to the cluster housing isfully engaged.
(4) Install the cluster lens onto the cluster hous-ing. Refer to Instrument Cluster Components -Cluster Lens in the Removal and Installation sec-tion of this group for the procedures.
(5) Install the instrument cluster onto the instru-ment panel. Refer to Instrument Cluster in theRemoval and Installation section of this group for theprocedures.
(6) Reconnect the battery negative cable.
CLUSTER HOUSING REAR COVER(1) Position the rear cover to the back of the clus-
ter housing.(2) Press firmly and evenly on the rear cover until
each of the latches that secure the rear cover to thecluster housing is fully engaged.
(3) Install the instrument cluster onto the instru-ment panel. Refer to Instrument Cluster in theRemoval and Installation section of this group for theprocedures.
(4) Reconnect the battery negative cable.
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TJ INSTRUMENT PANEL SYSTEMS 8E - 17
REMOVAL AND INSTALLATION (Continued)
LUSTER HOUSING(1) Install the rear cover onto the cluster housing.efer to Instrument Cluster Components - Clus-
er Housing Rear Cover in the Removal andnstallation section of this group for the procedures.
(2) Install the cluster hood and mask unit onto theluster housing. Refer to Instrument Cluster Com-onents - Cluster Hood and Mask in the Removalnd Installation section of this group for the proce-ures.(3) Install all of the cluster illumination lamp and
ndicator lamp bulb and bulb holder units into thelectronic circuit board. Refer to Instrument Clus-er Components - Cluster Bulbs in the Removalnd Installation section of this group for the proce-ures.(4) Install the instrument cluster onto the instru-ent panel. Refer to Instrument Cluster in theemoval and Installation section of this group for therocedures.(5) Reconnect the battery negative cable.
NSTRUMENT PANEL CENTER BEZEL
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the top cover from the instrument
anel. Refer to Instrument Panel Top Cover in theemoval and Installation section of this group for therocedures.(3) Remove the ash receiver from the ash receiver
ousing in the lower portion of the instrument panelenter bezel.(4) Remove the one screw from the back of the ash
eceiver housing that secures the lower portion of theenter bezel to the instrument panel (Fig. 12).(5) Remove the two screws that secure the top of
he center bezel to the top of the instrument panel.(6) Using a trim stick or another suitable wide
lat-bladed tool, gently pry the lower edge of the cen-er bezel away from the instrument panel.
(7) Pull the lower edge of the center bezel awayrom the instrument panel far enough to disengagehe four snap clip retainers that secure it from the
eceptacles in the instrument panel.
(8) Remove the center bezel from the instrumentpanel.
INSTALLATION(1) Position the center bezel to the instrument
panel.(2) Align the snap clips on the center bezel with
the receptacles in the instrument panel.(3) Press firmly on the center bezel over each of
the snap clip locations until each of the snap clips isfully engaged in its receptacle on the instrumentpanel.
(4) Install and tighten the two screws that securethe top of the center bezel to the top of the instru-ment panel. Tighten the screws to 2.2 N·m (20 in.lbs.).
Install and tighten the one screw into the back ofthe ash receiver housing that secures the lower por-tion of the center bezel to the instrument panel.Tighten the screw to 2.2 N·m (20 in. lbs.).
(5) Install the ash receiver into the ash receiverhousing in the lower portion of the instrument panelcenter bezel.
(6) Install the top cover onto the instrument panel.Refer to Instrument Panel Top Cover in the
emoval and Installation section of this group for therocedures.(7) Reconnect the battery negative cable.
Fig. 12 Instrument Panel Center Bezel Remove/Install
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8E - 18 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
NSTRUMENT PANEL ACCESSORY SWITCHEZEL
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the center bezel from the instrument
anel. Refer to Instrument Panel Center Bezel inhe Removal and Installation section of this group forhe procedures.
(3) Remove the four screws that secure the acces-ory switch bezel to the instrument panel (Fig. 13).
(4) Pull the accessory switch bezel away from thenstrument panel far enough to access the instru-
ent panel wire harness connectors.(5) Disconnect the instrument panel wire harness
onnectors from the connector receptacles, the acces-ory switches and the cigar lighter/power outlet onhe back of the accessory switch bezel.
(6) Remove the accessory switch bezel from thenstrument panel.
INSTALLATION(1) Position the accessory switch bezel to the
instrument panel.(2) Reconnect the instrument panel wire harness
connectors to the connector receptacles, the accessoryswitches and the cigar lighter/power outlet on theback of the accessory switch bezel.
(3) Position the accessory switch bezel onto theinstrument panel.
(4) Install and tighten the four screws that securethe accessory switch bezel to the instrument panel.Tighten the screws to 2.2 N·m (20 in. lbs.).
(5) Install the center bezel onto the instrumentpanel. Refer to Instrument Panel Center Bezel inthe Removal and Installation section of this group forthe procedures.
(6) Reconnect the battery negative cable.
ACCESSORY RELAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL(1) Disconnect and isolate the battery negative
cable.(2) Reach up under the instrument panel outboard
of the steering column to access the accessory relayand the accessory relay wire harness connector,which is secured to the 100-way wire harness connec-tor mounting bracket (Fig. 14).
Fig. 14 Accessory Relay Remove/Install
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TJ INSTRUMENT PANEL SYSTEMS 8E - 19
REMOVAL AND INSTALLATION (Continued)
(3) Disconnect the accessory relay from the acces-ory relay wire harness connector.(4) Remove the accessory relay from under the
nstrument panel.
NSTALLATION(1) Position the accessory relay to the accessory
elay wire harness connector under the instrumentanel.(2) Align the terminals of the accessory relay with
he cavities in the accessory relay wire harness con-ector.(3) Push on the accessory relay case firmly and
venly until all of the relay terminals are fully seatedithin the cavities of the accessory relay wire har-ess connector.(4) Reconnect the battery negative cable.
LOVE BOX
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Release the glove box latch and open the glove
ox door.(3) While supporting the glove box door with one
and, grasp the check strap as close to the glove boxoor as possible and slide the rolled end of the checktrap out of the slot in the edge of the door (Fig. 15).(4) Lower the glove box door far enough to disen-
age the hinge hook formations on the lower edge ofhe door from the hinge pins on the lower edge of thenstrument panel.
(5) Remove the glove box from the instrumentanel.
NSTALLATION(1) Position the glove box to the instrument panel.(2) Engage the hinge hook formations on the lower
dge of the glove box door with the hinge pins on theower edge of the instrument panel.
(3) Tilt the upper edge of the glove box door upoward the instrument panel far enough to engagehe check strap with the door.
(4) While supporting the glove box door with oneand, grasp the check strap as close to the glove box
door as possible and slide the rolled end of the checkstrap into the slot in the edge of the door.
(5) Close the glove box door.(6) Reconnect the battery negative cable.
GLOVE BOX COMPONENTSService of all of the glove box components (Fig. 16)
must be performed with the glove box removed fromthe instrument panel.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL
GLOVE BOX DOOR AND BIN(1) Disconnect and isolate the battery negative
cable.(2) Remove the glove box from the instrument
panel. Refer to Glove Box in the Removal andInstallation section of this group for the procedures.
(3) Remove the screws that secure the glove boxlatch and handle to the glove box door.
(4) Remove the screws that secure the inner doorand bin unit to the outer glove box door.
Fig. 15 Glove Box Remove/Install
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8E - 20 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(5) Remove the inner door and bin unit from theuter glove box door.
LOVE BOX CHECK STRAP(1) Disconnect and isolate the battery negative
able.(2) Remove the glove box from the instrument
anel. Refer to Glove Box in the Removal andnstallation section of this group for the procedures.
(3) Remove the screw that secures the glove boxheck strap to the instrument panel above the gloveox opening.(4) Remove the check strap from the instrument
anel.
LOVE BOX LATCH AND HANDLE(1) Disconnect and isolate the battery negative
able.(2) Remove the glove box from the instrument
anel. Refer to Glove Box in the Removal andnstallation section of this group for the procedures.
(3) Remove the four screws that secure the gloveox latch and handle to the glove box door from thenside of the glove box.
(4) Remove the latch and handle from the gloveox door.
LOVE BOX LOCK CYLINDER(1) Disconnect and isolate the battery negative
able.(2) Remove the glove box from the instrument
anel. Refer to Glove Box in the Removal andnstallation section of this group for the procedures.
(3) Remove the glove box latch and handle fromhe glove box. Refer to Glove Box Components -love Box Latch and Handle in the Removal and
nstallation section of this group for the procedures.(4) Insert the key into the glove box lock cylinder.
Fig. 16 Glove Box Components
(5) Insert a small screwdriver into the retainingtumbler release slot and depress the retaining tum-bler (Fig. 17).
(6) Pull the lock cylinder out of the glove box latchhandle by using a gentle twisting and pulling actionon the key.
INSTALLATION
GLOVE BOX DOOR AND BIN(1) Position the inner door and bin unit onto the
outer glove box door.(2) Install and tighten the screws that secure the
inner door and bin unit to the outer glove box door.Tighten the screws to 2.2 N·m (20 in. lbs.).
(3) Install and tighten the screws that secure theglove box latch and handle to the glove box door.Tighten the screws to 2.2 N·m (20 in. lbs.).
(4) Install the glove box onto the instrument panel.Refer to Glove Box in the Removal and Installationsection of this group for the procedures.
(5) Reconnect and isolate the battery negativecable.
GLOVE BOX CHECK STRAP(1) Position the check strap to the instrument
panel.(2) Install and tighten the screw that secures the
glove box check strap to the instrument panel abovethe glove box opening. Tighten the screw to 2.2 N·m(20 in. lbs.).
(3) Install the glove box onto the instrument panel.Refer to Glove Box in the Removal and Installationsection of this group for the procedures.
(4) Reconnect the battery negative cable.
GLOVE BOX LATCH AND HANDLE(1) Position the latch and handle onto the glove
box door.
Fig. 17 Glove Box Lock Cylinder Remove/Install
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TJ INSTRUMENT PANEL SYSTEMS 8E - 21
REMOVAL AND INSTALLATION (Continued)
(2) Install and tighten the four screws that securehe glove box latch and handle to the glove box doorrom the inside of the glove box. Tighten the screwso 2.2 N·m (20 in. lbs.).
(3) Install the glove box onto the instrument panel.efer to Glove Box in the Removal and Installationection of this group for the procedures.(4) Reconnect the battery negative cable.
LOVE BOX LOCK CYLINDER(1) Insert the key into the glove box lock cylinder.(2) Push the lock cylinder into the glove box latch
andle by using a gentle twisting and pushing actionn the key.(3) Install the glove box latch and handle onto the
love box. Refer to Glove Box Components - Gloveox Latch and Handle in the Removal and Instal-
ation section of this group for the procedures.(4) Install the glove box onto the instrument panel.efer to Glove Box in the Removal and Installationection of this group for the procedures.(5) Reconnect the battery negative cable.
LOVE BOX LATCH STRIKER
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the glove box from the instrument
anel. Refer to Glove Box in the Removal andnstallation section of this group for the procedures.
(3) Remove the two screws that secure the latchtriker to the grab handle bezel at the top of thenstrument panel glove box opening (Fig. 18).
Fig. 18 Glove Box Latch Striker Remove/Install
(4) Remove the latch striker from the instrumentpanel.
INSTALLATION(1) Position the latch striker onto the instrument
panel.(2) Install and tighten the two screws that secure
the latch striker to the grab handle bezel at the topof the instrument panel glove box opening. Tightenthe screws to 2.2 N·m (20 in. lbs.).
(3) Install the glove box onto the instrument panel.Refer to Glove Box in the Removal and Installationsection of this group for the procedures.
(4) Reconnect the battery negative cable.
INSTRUMENT PANEL GRAB HANDLE
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL(1) Disconnect and isolate the battery negative
cable.(2) Remove the glove box from the instrument
panel. Refer to Glove Box in Removal and Installa-tion section of this group for the procedures.
(3) Reach through and above the glove box openingto access and remove the two nuts that secure thestud on each end of the grab handle to the instru-ment panel (Fig. 19). Discard the used grab handlemounting nuts.
(4) Remove the grab handle from the instrumentpanel.
NSTALLATION(1) Position the grab handle onto the instrument
anel.(2) Reach through and above the glove box opening
o install and tighten the two nuts that secure thetud on each end of the grab handle to the instru-ent panel. Tighten the nuts to 5.6 N·m (50 in. lbs.).(3) Install the glove box onto the instrument panel.efer to Glove Box in Removal and Installation sec-
ion of this group for the procedures.(4) Reconnect the battery negative cable.
NSTRUMENT PANEL GRAB HANDLE BEZEL
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the grab handle from the instrument
anel. Refer to Instrument Panel Grab Handle inhe Removal and Installation section of this group forhe procedures.
(3) Remove the glove box latch striker from thenstrument panel. Refer to Glove Box Latchtriker in the Removal and Installation section ofhis group for the procedures.
(4) Remove the two screws that secure the grabandle bezel to the instrument panel (Fig. 20).
(5) Remove the grab handle bezel from the instru-ent panel.
NSTALLATION(1) Position the grab handle bezel onto the instru-ent panel.(2) Install and tighten the two screws that secure
he grab handle bezel to the instrument panel.ighten the screws to 2.2 N·m (20 in. lbs.).
(3) Install the glove box latch striker onto theinstrument panel. Refer to Glove Box LatchStriker in the Removal and Installation section ofthis group for the procedures.
(4) Install the grab handle onto the instrumentpanel. Refer to Instrument Panel Grab Handle inthe Removal and Installation section of this group forthe procedures.
(5) Reconnect the battery negative cable.
INSTRUMENT PANEL ASSEMBLY
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL
NOTE: Before starting this procedure, be certain toturn the steering wheel until the front wheels are inthe straight-ahead position.
(1) Disconnect and isolate the battery negativecable.
(2) Remove the knee blocker from the instrumentpanel. Refer to Knee Blocker in the Removal andInstallation section of this group for the procedures.
(3) Remove the steering column from the vehicle,but do not remove the driver side airbag module, thesteering wheel, or the switches from the steering col-umn. Be certain that the steering wheel is lockedand secured from rotation to prevent the loss ofclockspring centering. Refer to Steering Column inhe Removal and Installation section of Group 19 -teering for the procedures.(4) From under the driver side of the instrument
anel, perform the following:(a) Disconnect the instrument panel wire har-
ness connectors from the 100-way wire harnessconnector near the left cowl side inner panel.
(b) Disconnect the side window demister hose atthe heater-A/C housing demister/defroster duct(driver side).(5) Remove the glove box from the instrument
anel. Refer to Glove Box in the Removal andnstallation section of this group for the procedures.
(6) Reach through the instrument panel glove boxpening to perform the following:
(a) Disconnect the two halves of the heater-A/Csystem vacuum harness connector.
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TJ INSTRUMENT PANEL SYSTEMS 8E - 23
REMOVAL AND INSTALLATION (Continued)
(b) Disconnect the instrument panel wire har-ness connector from the heater-A/C system wireharness connector.
(c) Disconnect the instrument panel wire har-ness connector from the passenger side airbagmodule wire harness connector.
(d) Disconnect the side window demister hose atthe heater-A/C housing demister/defroster duct(passenger side).
(e) Disconnect the two halves of the radioantenna coaxial cable connector.
(f) Disconnect the two instrument panel wireharness connectors from the passenger airbagon/off switch wire harness connectors.
(g) Disengage the passenger side airbag on/offswitch wire harness from the retainer clip on theplenum bracket that supports the heater-A/C hous-ing just inboard of the fuseblock module.
(h) Remove the two nuts that secure the lowerpassenger side airbag module bracket to the studson the dash panel (Fig. 21).
(7) Remove the top cover from the instrumentanel. Refer to Instrument Panel Top Cover in theemoval and Installation section of this group for therocedures.(8) Remove the three screws that secure each end
f the instrument panel to the door hinge pillars (Fig.2).(9) Remove the four nuts that secure the top of the
nstrument panel to the studs on the top of the dashanel.(10) With the aid of an assistant, lift the instru-ent panel assembly off of the dash panel studs and
INSTALLATION(1) With the aid of an assistant, install the instru-
ment panel assembly onto the dash panel studs inthe vehicle.
(2) Install and tighten the four nuts that securethe top of the instrument panel to the studs on thetop of the dash panel. Tighten the nuts to 12 N·m(105 in. lbs.).
(3) Install and tighten the three screws that secureeach end of the instrument panel to the door hingepillars. Tighten the screws to 12 N·m (105 in. lbs.).
(4) Install the top cover onto the instrument panel.Refer to Instrument Panel Top Cover in the
emoval and Installation section of this group for therocedures.(5) Reach through the instrument panel glove box
pening to perform the following:(a) Install and tighten the two nuts that secure
the lower passenger side airbag module bracket tothe studs on the dash panel. Tighten the nuts to 28N·m (250 in. lbs.).
(b) Engage the passenger side airbag on/offswitch wire harness in the retainer clip on the ple-num bracket that supports the heater-A/C housingjust inboard of the fuseblock module.
(c) Reconnect the two instrument panel wireharness connectors to the passenger airbag on/offswitch wire harness connectors.
(d) Reconnect the two halves of the radioantenna coaxial cable connector.
(e) Reconnect the side window demister hose tothe heater-A/C housing demister/defroster duct(passenger side).
(f) Reconnect the instrument panel wire harnessconnector to the passenger side airbag module wireharness connector.
(g) Reconnect the instrument panel wire harnessconnector to the heater-A/C system wire harnessconnector.
Fig. 22 Instrument Panel Assembly Remove/Install
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8E - 24 INSTRUMENT PANEL SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(h) Reconnect the two halves of the heater-A/Csystem vacuum harness connector.(6) Install the glove box onto the instrument panel.efer to Glove Box in the Removal and Installationection of this group for the procedures.(7) From under the driver side of the instrument
anel, perform the following:(a) Reconnect the side window demister hose to
the heater-A/C housing demister/defroster duct(driver side).
(b) Reconnect the instrument panel wire harnessconnectors to the 100-way wire harness connectornear the left cowl side inner panel.(8) Install the steering column into the vehicle. Be
ertain that the steering wheel is locked and securedrom rotation to prevent the loss of clockspring cen-ering. Refer to Steering Column in the Removalnd Installation section of Group 19 - Steering forhe procedures.
(9) Install the knee blocker onto the instrumentanel. Refer to Knee Blocker in the Removal andnstallation section of this group for the procedures.
(10) Reconnect the battery negative cable.
NSTRUMENT PANEL BASE TRIM
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the instrument cluster from the instru-ent panel. Refer to Instrument Cluster in theemoval and Installation section of this group for therocedures.(3) Remove the accessory switch bezel from the
nstrument panel. Refer to Instrument Panelccessory Switch Bezel in the Removal and Instal-
ation section of this group for the procedures.(4) Remove the grab handle bezel from the instru-ent panel. Refer to Instrument Panel Grab Han-le Bezel in the Removal and Installation section ofhis group for the procedures.
(5) Remove the speaker bezels from the instru-ent panel. Refer to Instrument Panel Speakers
n the Removal and Installation section of Group 8F -udio Systems for the procedures.
(6) Remove the radio from the instrument panel.Refer to Radio in the Removal and Installation sec-tion of Group 8F - Audio Systems for the procedures.
(7) Remove the heater-A/C control from the instru-ment panel. Refer to Heater-A/C Control in theRemoval and Installation section of Group 24 - Heat-ing and Air Conditioning Systems for the procedures.
(8) Remove the outboard heater-A/C panel outletsfrom the instrument panel. Refer to Ducts and Out-lets in the Removal and Installation section of Group24 - Heating and Air Conditioning Systems for theprocedures.
(9) Remove the instrument panel assembly fromthe vehicle. Refer to Instrument Panel Assemblyin the Removal and Installation section of this groupfor the procedures.
(10) Place the instrument panel on a suitable worksurface. Be certain to take the proper precautions toprotect the instrument panel from any possible cos-metic damage.
(11) Remove the passenger side airbag door fromthe instrument panel. Refer to Passenger Side Air-bag Door in the Removal and Installation section ofGroup 8M - Passive Restraint Systems for the proce-dures.
(12) Remove the two screws that secure the16-way data link wire harness connector to theinstrument panel.
(13) Remove the screws around the perimeter thatsecure the base trim to the instrument panel.
(14) Remove the base trim from the instrumentpanel.
INSTALLATION(1) Position the base trim onto the instrument
panel.(2) Install and tighten the screws around the
perimeter that secure the base trim to the instru-ment panel. Tighten the screws to 2.2 N·m (20 in.lbs.).
(3) Install and tighten the two screws that securethe 16-way data link wire harness connector to theinstrument panel. Tighten the screws to 2.2 N·m (20in. lbs.).
(4) Install the passenger side airbag door onto theinstrument panel. Refer to Passenger Side AirbagDoor in the Removal and Installation section ofGroup 8M - Passive Restraint Systems for the proce-dures.
(5) Install the instrument panel assembly into thevehicle. Refer to Instrument Panel Assembly inthe Removal and Installation section of this group forthe procedures.
(6) Install the outboard heater-A/C panel outletsonto the instrument panel. Refer to Ducts and Out-lets in the Removal and Installation section of Group
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TJ INSTRUMENT PANEL SYSTEMS 8E - 25
REMOVAL AND INSTALLATION (Continued)
4 - Heating and Air Conditioning Systems for therocedures.(7) Install the heater-A/C control onto the instru-ent panel. Refer to Heater-A/C Control in theemoval and Installation section of Group 24 - Heat-
ng and Air Conditioning Systems for the procedures.(8) Install the radio onto the instrument panel.efer to Radio in the Removal and Installation sec-
ion of Group 8F - Audio Systems for the procedures.(9) Install the speaker bezels onto the instrument
anel. Refer to Instrument Panel Speakers in theemoval and Installation section of Group 8F - Audioystems for the procedures.(10) Install the grab handle bezel onto the instru-ent panel. Refer to Instrument Panel Grab Han-
dle Bezel in the Removal and Installation section ofthis group for the procedures.
(11) Install the accessory switch bezel onto theinstrument panel. Refer to Instrument PanelAccessory Switch Bezel in the Removal and Instal-lation section of this group for the procedures.
(12) Install the instrument cluster onto the instru-ment panel. Refer to Instrument Cluster in theRemoval and Installation section of this group for theprocedures.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Using a flat blade screwdriver or similar tool
etween the headlamp leveling switch and the steer-ng column cover (Fig. 1). Gently pry the headlampeveling switch out of the steering column cover.
Fig. 1 Headlamp Leveling Switch
(2) Disconnect the headlamp leveling switch elec-trical connector (Fig. 2) and remove the headlampleveling switch.
INSTALLATION(1) Connect the headlamp leveling switch electrical
connector.(2) Install the headlamp leveling switch into the
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Using a flat blade screwdriver or similar flat-laded tool, gently pry the instrument panel topover up and away from the instrument panel toelease the snap clip retainers (Fig. 3).
(2) Remove the instrument panel top cover fromhe vehicle.
(3) Remove the ash receiver from the center bezel.(4) Remove the screw located in back of the ash
eceiver housing that secures the center bezel to theower instrument panel (Fig. 4).
Fig. 3 Instrument Panel Top Cover
(5) Remove the screws that secure the center bezelto the top of the instrument panel (Fig. 5).
Fig. 4 Center Bezel Lower Screw
Fig. 5 Center Bezel Mounting Screws
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TJ INSTRUMENT PANEL SYSTEMS 8E - 3
REMOVAL AND INSTALLATION (Continued)
(6) Remove the instrument panel center bezel.(7) Remove the screws attaching the accessory
witch bezel to the instrument panel (Fig. 6).(8) Disconnect the rear foglamp switch electrical
onnector.(9) Remove the rear foglamp switch from the
ccessory switch bezel.
NSTALLATION(1) Install the rear foglamp switch to the accessory
witch bezel.(2) Connect the rear foglamp switch electrical con-
ector to the switch.(3) Install the screws attaching the accessory
witch bezel to the instrument panel (Fig. 6).(4) Install the instrument panel center bezel and
ttaching screws.(5) Install the ash receiver.(6) Install the instrument panel top cover.
NTRODUCTIONAn audio system is standard factory-installed
quipment on this model, unless the vehicle isrdered with an available radio delete option. Refero 8W-47 - Audio System in Group 8W - Wiring Dia-rams for complete circuit descriptions and diagrams.
ESCRIPTION AND OPERATION
ADIOAvailable factory-installed radio receivers for thisodel include an AM/FM (RAL sales code), and anM/FM/cassette (RAS sales code). All factory-in-talled radio receivers are stereo Electronicallyuned Radios (ETR), and include an electronic digitallock function.The radio can only be serviced by an authorized
adio repair station. Refer to the latest Warranty Pol-cies and Procedures manual for a current listing ofuthorized radio repair stations.For more information on radio features, setting
rocedures, and control functions refer to the owner’sanual in the vehicle glove box.
GNITION-OFF DRAW FUSEAll vehicles are equipped with an Ignition-Offraw (IOD) fuse that is removed when the vehicle is
hipped from the factory. This fuse feeds variousccessories that require battery current when thegnition switch is in the Off position, including thelock and radio station preset memory functions. Theuse is removed to prevent battery discharge duringehicle storage.
When removing or installing the IOD fuse, it isimportant that the ignition switch be in the Off posi-tion. Failure to place the ignition switch in the Offposition can cause the radio display to become scram-bled when the IOD fuse is removed and replaced.Removing and replacing the IOD fuse again, with theignition switch in the Off position, will correct thescrambled display condition.
The IOD fuse should be checked if the radio isinoperative. The IOD fuse is located in the PowerDistribution Center (PDC). Refer to the PDC label forIOD fuse identification and location.
SPEAKERThe standard equipment speaker system includes
two full-range speakers. Each speaker is mountedbehind a removable bezel located on the outboardends of the lower instrument panel.
The sound bar option adds two full-range speakersto the standard speaker system, for a total of fourspeakers. Each of the additional speakers is mountedbehind a grille located on the outboard ends of thesound bar, which is attached from side-to-side to thesport bar above the rear seating area of the vehicle.
ANTENNAAll models use a fixed-length stainless steel rod-
type antenna mast, installed on the right front cowlside panel of the vehicle. The antenna mast is con-nected to the center wire of the coaxial antennacable, and is not grounded to any part of the vehicle.
To eliminate static, the antenna base must have agood ground. The antenna coaxial cable shield (the
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8F - 2 AUDIO SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
uter wire mesh of the cable) is grounded to thentenna base and the radio chassis.The antenna coaxial cable has an additional dis-
onnect, located behind the right end of the instru-ent panel between the radio and the right cowl side
anel. This additional disconnect allows the instru-ent panel assembly to be removed and installedithout removing the radio.The factory-installed Electronically Tuned Radios
ETRs) automatically compensate for radio antennarim. Therefore, no antenna trimmer adjustment isequired or possible when replacing the receiver orhe antenna.
ADIO NOISE SUPPRESSION
ESCRIPTIONRadio Frequency Interference (RFI) and Electro-agnetic Interference (EMI) noise suppression is
ccomplished primarily through circuitry internal tohe radio receivers. These internal suppressionevices are only serviced as part of the radio receiver.External suppression devices that are used on this
ehicle to control RFI or EMI noise include the fol-owing:
• Radio antenna base ground
• Radio receiver chassis ground wire or strap• Engine-to-body ground strap• Engine-to-frame ground strap• Resistor-type spark plugs• Radio suppression-type secondary ignition wir-
ing.For more information on the spark plugs and sec-
ondary ignition components, refer to Ignition Sys-tem in the Description and Operation section ofGroup 8D - Ignition System.
DIAGNOSIS AND TESTING
AUDIO SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
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TJ AUDIO SYSTEMS 8F - 3
DIAGNOSIS AND TESTING (Continued)
Audio System Diagnosis
CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.6. Speakers faulty.
1. Check radio fuses in Power Distribution Center. Replace fuses,if required.2. Check for loose or corroded radio connector. Repair, ifrequired.3. Check for battery voltage at radio connector. Repair wiring, ifrequired.4. Check for continuity between radio chassis and a known goodground. There should be continuity. Repair ground, if required.5. Exchange or replace radio, if required.6. See speaker diagnosis, in this group.
NO DISPLAY. 1. Fuse faulty.
2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
1. Check radio fuses in Power Distribution Center. Replace fuses,if required.2. Check for loose or corroded radio connector. Repair, ifrequired.3. Check for battery voltage at radio connector. Repair wiring, ifrequired.4. Check for continuity between radio chassis and a known goodground. There should be continuity. Repair ground, if required.5. Exchange or replace radio, if required.
CLOCK WILLNOT KEEP SETTIME.
1. Fuse faulty.2. Radio connector faulty.
3. Wiring faulty.
4. Ground faulty.
5. Radio faulty.
1. Check ignition-off draw fuse. Replace fuse, if required.2. Check for loose or corroded radio connector. Repair, ifrequired.3. Check for battery voltage at radio connector. Repair wiring, ifrequired.4. Check for continuity between radio chassis and a known goodground. There should be continuity. Repair ground, if required.5. Exchange or replace radio, if required.
POOR RADIORECEPTION.
1. Antenna faulty.
2. Ground faulty.
3. Radio faulty.
1. See antenna diagnosis, in this group. Repair or replaceantenna, if required.2. Check for continuity between radio chassis and a known goodground. There should be continuity. Repair ground, if required.3. Exchange or replace radio, if required.
1. Insert known good tape and test operation.2. Remove foreign objects and test operation.
3. Clean head with Mopar Cassette Head Cleaner.
4. Exchange or replace radio, if required.
NO COMPACTDISCOPERATION
1. Faulty CD.2. Foreign material onCD.3. Condensation on CDor optics.4. Faulty CD player.
1. Insert known good CD and test operation.2. Clean CD and test operation.
3. Allow temperature of vehicle interior to stabilize and testoperation.4. Exchange or replace radio, if required.
ADIOFor circuit descriptions and diagrams, refer to
W-47 - Audio System in Group 8W - Wiring Dia-rams.
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8F - 4 AUDIO SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
AUTION: The speaker output of the radio is afloating ground” system. Do not allow any speakeread to short to ground, as damage to the radio
ay result.
(1) Check the fuse(s) in the Power Distributionenter (PDC). If OK, go to Step 2. If not OK, repair
he shorted circuit or component as required andeplace the faulty fuse(s).(2) Check for battery voltage at the fuse(s) in the
DC. If OK, go to Step 3. If not OK, repair the openircuit to the battery and/or the ignition switch asequired.(3) Disconnect and isolate the battery negative
able. Remove the radio, but do not unplug the radioire harness connectors. Check for continuityetween the radio chassis and a good ground. Therehould be continuity. If OK, go to Step 4. If not OK,epair the open radio chassis ground circuit asequired.(4) Connect the battery negative cable. Turn the
gnition switch to the On position. Check for batteryoltage at the fused ignition switch output (accesso-y/run) circuit cavity of the left (gray) radio wire har-ess connector. If OK, go to Step 5. If not OK, repairhe open circuit as required.
(5) Turn the ignition switch to the Off position.heck for battery voltage at the fused B(+) circuit cav-
ty of the left (gray) radio wire harness connector. IfK, replace the faulty radio. If not OK, repair the open
ircuit to the Ignition-Off Draw (IOD) fuse as required.
PEAKERFor circuit descriptions and diagrams, refer to
W-47 - Audio System in Group 8W - Wiring Dia-rams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
CAUTION: The speaker output of the radio is a“floating ground” system. Do not allow any speakerlead to short to ground, as damage to the radiomay result.
(1) Turn the ignition switch to the On position.Turn the radio on. Adjust the balance and fader con-trols to check the performance of each individualspeaker. Note the speaker locations that are not per-forming correctly. Go to Step 2.
(2) Turn the radio off. Disconnect and isolate thebattery negative cable. Remove the radio. Unplug thewire harness connectors at the radio. Check both thespeaker feed (+) circuit and return (–) circuit cavitiesfor the inoperative speaker location(s) at the radiowire harness connectors for continuity to ground. Ineach case, there should be no continuity. If OK, go toStep 4. If not OK, go to Step 3.
(3) Leave the radio wire harness connectorsunplugged. Unplug the wire harness connector at theinoperative speaker. Check both the speaker feed (+)circuit and return (–) circuit cavities of the speakerwire harness connector for continuity to ground. Ineach case, there should be no continuity. If OK,replace the shorted speaker. If not OK, repair theshorted circuit as required.
(4) Plug in the speaker wire harness connector.Check the resistance between the speaker feed (+)circuit and return (–) circuit cavities of the radio wireharness connectors for the inoperative speaker loca-tion(s). The meter should read between 3 and 8 ohms(speaker resistance). If OK, go to Step 5. If not OK,go to Step 6.
(5) Install a known good radio. Connect the bat-tery negative cable. Turn the ignition switch to theOn position. Turn on the radio and test the speakeroperation. If OK, replace the faulty radio. If not OK,replace the faulty speaker.
(6) Turn the radio off. Turn the ignition switch tothe Off position. Disconnect and isolate the batterynegative cable. Remove the test radio. Unplug thespeaker wire harness connector at the inoperativespeaker. Check the resistance between the speakerfeed (+) circuit cavities of the radio wire harness con-nector and the speaker wire harness connector.Repeat the check between the speaker return (–) cir-cuit cavities of the radio wire harness connector andthe speaker wire harness connector. In each case,there should be no measurable resistance. If OK,replace the faulty speaker. If not OK, repair thespeaker wire harness circuit(s) as required.
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TJ AUDIO SYSTEMS 8F - 5
DIAGNOSIS AND TESTING (Continued)
NTENNA
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
The following four tests are used to diagnose thentenna with an ohmmeter:• Test 1 - Mast to ground test• Test 2 - Tip-of-mast to tip-of-conductor test• Test 3 - Body ground to battery ground test• Test 4 - Body ground to coaxial shield test.The ohmmeter test lead connections for each test
re shown in Antenna Tests (Fig. 1).
OTE: This model has a two-piece antenna coaxialable. Tests 2 and 4 must be conducted in twoteps to isolate a coaxial cable problem; from theoaxial cable connection under the right end of thenstrument panel near the right cowl side inneranel to the antenna base, and then from the coax-
al cable connection to the radio chassis connec-ion.
EST 1Test 1 determines if the antenna mast is insulated
rom the base. Proceed as follows:(1) Unplug the antenna coaxial cable connector
rom the radio chassis and isolate.
Fig. 1 Antenna Tests
(2) Connect one ohmmeter test lead to the tip ofthe antenna mast. Connect the other test lead to theantenna base. Check for continuity.
(3) There should be no continuity. If continuity isfound, replace the faulty or damaged antenna baseand cable assembly.
TEST 2Test 2 checks the antenna for an open circuit as
follows:(1) Unplug the antenna coaxial cable connector
from the radio chassis.(2) Connect one ohmmeter test lead to the tip of
the antenna mast. Connect the other test lead to thecenter pin of the antenna coaxial cable connector.
(3) Continuity should exist (the ohmmeter shouldonly register a fraction of an ohm). High or infiniteresistance indicates damage to the base and cableassembly. Replace the faulty base and cable, ifrequired.
TEST 3Test 3 checks the condition of the vehicle body
ground connection. This test should be performedwith the battery positive cable removed from the bat-tery. Disconnect both battery cables, the negativecable first. Reconnect the battery negative cable andperform the test as follows:
(1) Connect one ohmmeter test lead to the vehiclefender. Connect the other test lead to the batterynegative post.
(2) The resistance should be less than one ohm.(3) If the resistance is more than one ohm, check
the braided ground strap connected to the engine andthe vehicle body for being loose, corroded, or dam-aged. Repair the ground strap connection, if required.
TEST 4Test 4 checks the condition of the ground between
the antenna base and the vehicle body as follows:(1) Connect one ohmmeter test lead to the vehicle
fender. Connect the other test lead to the outer crimpon the antenna coaxial cable connector.
(2) The resistance should be less then one ohm.(3) If the resistance is more then one ohm, clean
and/or tighten the antenna base to fender mountinghardware.
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8F - 6 AUDIO SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
ADIO FREQUENCY INTERFERENCE
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
For complete circuit diagrams, see Group 8W -iring Diagrams. Inspect the ground paths and con-
ections at the following locations:• Blower motor• Electric fuel pump• Engine-to-body ground strap• Engine-to-frame ground strap• Generator• Ignition module• Radio antenna base ground• Radio receiver chassis ground wire or strap• Wiper motor.If the source of RFI or EMI noise is identified as a
omponent on the vehicle (i.e., generator, blowerotor, etc.), the ground path for that component
hould be checked. If excessive resistance is found inny ground circuit, clean, tighten, or repair theround circuits or connections to ground as requiredefore considering any component replacement.For service and inspection of secondary ignition
omponents, refer to the Diagnosis and Testing sec-ion of Group 8D - Ignition Systems. Inspect the fol-owing secondary ignition system components:
• Distributor cap and rotor• Ignition coil• Spark plugs• Spark plug wire routing and condition.Reroute the spark plug wires or replace the faulty
omponents as required.If the source of the RFI or EMI noise is identified
s two-way mobile radio or telephone equipment,heck the equipment installation for the following:• Power connections should be made directly to
he battery, and fused as closely to the battery asossible.• The antenna should be mounted on the roof or
oward the rear of the vehicle. Remember that mag-etic antenna mounts on the roof panel can adverselyffect the operation of an overhead console compass,f the vehicle is so equipped.
• The antenna cable should be fully shielded coax-al cable, should be as short as is practical, andhould be routed away from the factory-installedehicle wire harnesses whenever possible.
• The antenna and cable must be carefullymatched to ensure a low Standing Wave Ratio(SWR).
Fleet vehicles are available with an extra-cost RFI-suppressed Powertrain Control Module (PCM). Thisunit reduces interference generated by the PCM onsome radio frequencies used in two-way radio com-munications. However, this unit will not resolve com-plaints of RFI in the commercial AM or FM radiofrequency ranges.
REMOVAL AND INSTALLATION
RADIO
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Disconnect and isolate the battery negative cable.(2) Remove the instrument panel top cover from
the instrument panel. Refer to Instrument Panel TopCover in Group 8E - Instrument Panel Systems forthe procedures.
(3) Remove the ash receiver from the ash receiverhousing in the lower instrument panel center bezel.
(4) Remove the one screw located in the back ofthe ash receiver housing that secures the centerbezel to the lower instrument panel (Fig. 2).
(5) Remove the two screws that secure the centerbezel to the top of the instrument panel.
(6) Using a trim stick or another suitable wideflat-bladed tool, gently pry the lower edge of the cen-ter bezel away from the instrument panel.
(7) Lift the lower edge of the center bezel upwardsto release the four snap clip retainers that secure itto the instrument panel.
(8) Remove the center bezel from the instrumentpanel.
(9) Remove the two screws that secure the radio tothe instrument panel (Fig. 3).
(10) Pull the radio out from the instrument panelfar enough to access the wire harness connectors andthe antenna coaxial cable connector (Fig. 4).
(11) Unplug the wire harness connectors and theantenna coaxial cable connector from the rear of theradio.
(12) Remove the screw that secures the groundstrap to the radio chassis.
(13) Remove the radio from the instrument panel.
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TJ AUDIO SYSTEMS 8F - 7
REMOVAL AND INSTALLATION (Continued)
(14) Reverse the removal procedures to install.ighten the radio mounting screws to 5 N·m (45 in.
bs.). Tighten the instrument panel center bezelounting screws to 2.2 N·m (20 in. lbs.).
PEAKER
NSTRUMENT PANEL
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVE RESTRAINTYSTEMS BEFORE ATTEMPTING ANY STEERINGHEEL, STEERING COLUMN, OR INSTRUMENT
ANEL COMPONENT DIAGNOSIS OR SERVICE. FAIL-RE TO TAKE THE PROPER PRECAUTIONS COULDESULT IN ACCIDENTAL AIRBAG DEPLOYMENTND POSSIBLE PERSONAL INJURY.
Fig. 2 Center Bezel Remove/Install
Fig. 3 Radio Remove/Install
(1) Disconnect and isolate the battery negativecable.
(2) Remove the two screws that secure the out-board end of the speaker bezel to the instrumentpanel (Fig. 5).
(3) Using a trim stick or another suitable wideflat-bladed tool, gently pry at the top and bottomedges of the speaker bezel to release the two snapclip retainers that secure the bezel to the instrumentpanel.
(4) Remove the speaker bezel from the instrumentpanel.
(5) Remove the foam rubber speaker baffle fromthe speaker.
(6) Remove the four screws that secure thespeaker to the instrument panel armature (Fig. 6).
(7) Pull the speaker away from the instrumentpanel far enough to access the speaker wire harnessconnector.
(8) Unplug the wire harness connector from thepeaker.(9) Remove the speaker from the instrument
anel.(10) Reverse the removal procedures to install.
ighten the speaker mounting screws to 1.1 N·m (10n. lbs.). Tighten the speaker bezel mounting screwso 2.2 N·m (20 in. lbs.).
OUND BAR(1) Disconnect and isolate the battery negative
able.(2) Remove the four screws that secure the
peaker grille and speaker to the sound bar.(3) Lower the speaker and grille from the sound
ar far enough to access the speaker wire harnessonnector.(4) Unplug the wire harness connector from the
peaker.(5) Remove the speaker and grille from the sound
ar.(6) Remove the speaker grille from the speaker.(7) Reverse the removal procedures to install.
ighten the mounting screws to 1.1 N·m (10 in. lbs.).
OUND BAR(1) Disconnect and isolate the battery negative
able.(2) If the vehicle is equipped with the optional
ard top, remove the hard top from the vehicle. Refero Hard Top in Group 23 - Body for the procedures.
(3) If the vehicle is equipped with the standardoft top, lower the soft top. Refer to Folding Downhe Fabric Top in the Owner’s Manual for the proce-ures.(4) Release the hook and loop closure on each out-
oard end flap of the sound bar trim cover.
Fig. 6 Instrument Panel Speaker Remove/Install
(5) Lift the left outboard end flap of the sound bartrim cover over the top of the sport bar far enough toaccess the wire harness connector (Fig. 7).
(6) Unplug the sound bar wire harness connector.(7) Lift each outboard end flap of the sound bar
cover over the top of the sport bar far enough toaccess the mounting screws (Fig. 8).
(8) Remove the two screws that secure each end ofthe sound bar to the sport bar.
(9) Lift the sound bar up off of the sport bar toremove it from the vehicle.
(10) Reverse the removal procedures to install.Tighten the sound bar mounting screws to 11 N·m(100 in. lbs.).
Fig. 7 Sound Bar Wire Harness Connector Remove/Install
Fig. 8 Sound Bar Remove/Install
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TJ AUDIO SYSTEMS 8F - 9
REMOVAL AND INSTALLATION (Continued)
NTENNA
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable.(2) Remove the glove box from the instrument
anel. Refer to Glove Box in Group 8E - Instrumentanel Systems for the procedures.(3) Reach through the instrument panel glove box
pening to unplug the antenna coaxial cable connec-or. Unplug the connector by pulling it apart whilewisting the metal connector halves. Do not pull onhe cable.
(4) From inside the passenger compartment, pushhe coaxial cable grommet on the antenna body halff the coaxial cable out through the hole in the rightnner cowl side panel (Fig. 9).
(5) Unscrew the antenna mast from the antennaody base on the right outer cowl side panel.(6) Using a trim stick or another suitable wide
lat-bladed tool, gently pry the edge of the antennaase trim cover to unsnap it from the antenna bodyase.
Fig. 9 Antenna Remove/Install
(7) Remove the three screws that secure theantenna body base to the right outer cowl side panel.
(8) From the outside of the vehicle, pull theantenna body base and cable assembly out throughthe hole in the right outer cowl side panel.
(9) Reverse the removal procedures to install.Tighten the antenna body base mounting screws to 2N·m (17 in. lbs.). Tighten the antenna mast to 3.3N·m (30 in. lbs.).
RADIO NOISE SUPPRESSION COMPONENTS
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL
ENGINE-TO-BODY GROUND STRAP(1) Remove the screw that secures the engine-to-
body ground strap eyelet to the hood panel centerreinforcement (Fig. 10).
(2) Remove the screw that secures the engine-to-body ground strap eyelet to the dash panel.
(3) Remove the nut that secures the engine-to-bodyground strap eyelet to the stud on the left upper rearcorner of the engine cylinder head.
(4) Remove the engine-to-body ground strap eyeletrom the stud on the left upper rear corner of thengine cylinder head.(5) Remove the engine-to-body ground strap from
he engine compartment.
NGINE-TO-FRAME GROUND STRAP(1) Remove the nut that secures the engine-to-
rame ground strap eyelet to the forward ignition coilounting stud on the right side of the engine (Fig.
1) or (Fig. 12).
(2) Remove the engine-to-frame ground strap eye-et from the forward ignition coil mounting stud onhe right side of the engine.
(3) Remove the screw that secures the engine-to-rame ground strap eyelet to the top of the rightrame rail.
(4) Remove the engine-to-frame ground strap fromhe engine compartment.
NSTALLATION
NGINE-TO-BODY GROUND STRAP(1) Position the engine-to-body ground strap in the
ngine compartment.(2) Position the engine-to-body ground strap eyelet
ver the stud on the left upper rear corner of thengine cylinder head.
(3) Install and tighten the nut that secures theengine-to-body ground strap eyelet to the stud on theleft upper rear corner of the engine cylinder head.Tighten the nut to 5.6 N·m (50 in. lbs.).
(4) Install and tighten the screw that secures theengine-to-body ground strap eyelet to the dash panel.Tighten the screw to 48.5 N·m (430 in. lbs.).
(5) Install and tighten the screw that secures theengine-to-body ground strap eyelet to the hood panelcenter reinforcement. Tighten the screw to 1.9 N·m(17 in. lbs.).
ENGINE-TO-FRAME GROUND STRAP(1) Position the engine-to-frame ground strap into
the engine compartment. The ground strap eyeletwith a 45 degree bend in it is to be mounted on theright frame rail.
(2) Install and tighten the screw that secures theengine-to-frame ground strap eyelet to the top of theright frame rail. Tighten the screw to 22.6 N·m (200in. lbs.).
(3) Install the engine-to-frame ground strap eyeletover the forward ignition coil mounting stud on theright side of the engine.
(4) Install and tighten the nut that secures theengine-to-frame ground strap eyelet to the forwardignition coil mounting stud on the right side of theengine. Tighten the nut to 22.6 N·m (200 in. lbs.).
ESCRIPTIONA dual-note electric horn system is standard facto-
y-installed equipment on this model. The standardquipment horn system features a one low-note hornnit and one high-note horn unit. The horn systemses a non-switched source of battery current so thathe system will remain functional, regardless of thegnition switch position. The horn system includeshe following components:
• Clockspring• Horn(s)• Horn relay• Horn switchRefer to Clockspring in the Description and Oper-
tion section of Group 8M - Passive Restraint Sys-ems for more information on this component. Refero Horn/Cigar Lighter in the Contents of Group 8WWiring Diagrams for complete circuit diagrams. Fol-
owing are general descriptions of the remainingajor components in the horn system.
PERATIONThe horn system is activated by a horn switch con-
ealed beneath the driver side airbag module trimover in the center of the steering wheel. Depressinghe center of the driver side airbag module trim coverloses the horn switch. Closing the horn switch acti-ates the horn relay. The activated horn relay thenwitches the battery current needed to energize theorns.Refer to the owner’s manual in the vehicle glove
ox for more information on the features, use andperation of the horn system.
are standard equipment on this model. Each horn issecured with a bracket to the left front inner fendershield just ahead of the left front wheel house in theengine compartment. The two horn brackets aremounted in the same location, one on top of theother. The high-note horn for the optional dual-notehorn system is connected in parallel with andsecured with a bracket just forward of the low-notehorn.
The two horns are connected in parallel. Each hornis grounded through its wire harness connector andcircuit to an eyelet secured to the engine compart-ment side of the grille/headlamp mounting panelnear the left headlamp, and receives battery feedthrough the closed contacts of the horn relay.
The horns cannot be repaired or adjusted and, iffaulty or damaged, they must be individuallyreplaced.
OPERATIONWithin the two halves of the molded plastic horn
housing are a flexible diaphragm, a plunger, an elec-tromagnetic coil and a set of contact points. The dia-phragm is secured in suspension around itsperimeter by the mating surfaces of the horn hous-ing. The plunger is secured to the center of the dia-phragm and extends into the center of theelectromagnet. The contact points control the currentflow through the electromagnet.
When the horn is energized, electrical currentflows through the closed contact points to the electro-magnet. The resulting electromagnetic field drawsthe plunger and diaphragm toward it until thatmovement mechanically opens the contact points.When the contact points open, the electromagnetic
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DESCRIPTION AND OPERATION (Continued)
ield collapses allowing the plunger and diaphragm toeturn to their relaxed positions and closing the con-act points again. This cycle continues repeating at aery rapid rate producing the vibration and move-ent of air that creates the sound that is directed
hrough the horn outlet.
ORN RELAY
ESCRIPTIONThe horn relay is a electromechanical device that
witches battery current to the horn when the hornwitch grounds the relay coil. The horn relay isocated in the Power Distribution Center (PDC) inhe engine compartment. If a problem is encounteredith a continuously sounding horn, it can usually beuickly resolved by removing the horn relay from theDC until further diagnosis is completed. See the
use and relay layout label affixed to the inside sur-ace of the PDC cover for horn relay identificationnd location.The horn relay is a International Standards Orga-
ization (ISO) micro-relay. Relays conforming to theSO specifications have common physical dimensions,urrent capacities, terminal patterns, and terminalunctions. The ISO micro-relay terminal functionsre the same as a conventional ISO relay. However,he ISO micro-relay terminal pattern (or footprint) isifferent, the current capacity is lower, and the phys-cal dimensions are smaller than those of the conven-ional ISO relay.
The horn relay cannot be repaired or adjusted and,f faulty or damaged, it must be replaced.
PERATIONThe ISO relay consists of an electromagnetic coil, a
esistor or diode, and three (two fixed and one mov-ble) electrical contacts. The movable (common feed)elay contact is held against one of the fixed contactsnormally closed) by spring pressure. When the elec-romagnetic coil is energized, it draws the movableontact away from the normally closed fixed contact,nd holds it against the other (normally open) fixedontact.When the electromagnetic coil is de-energized,
pring pressure returns the movable contact to theormally closed position. The resistor or diode is con-ected in parallel with the electromagnetic coil in theelay, and helps to dissipate voltage spikes that areroduced when the coil is de-energized.
ype horn switch is secured with heat stakes to the
back side of the driver side airbag module trim coverin the center of the steering wheel (Fig. 1). Theswitch consists of two plastic membranes, one that isflat and one that is slightly convex. These two mem-branes are secured to each other around the perime-ter. Inside the switch, the centers of the facingsurfaces of these membranes each has a grid madewith an electrically conductive material applied to it.One of the grids is connected to a circuit that pro-vides it with continuity to ground at all times. Thegrid of the other membrane is connected to the hornrelay control circuit.
The steering wheel and steering column must beproperly grounded in order for the horn switch tofunction properly. The horn switch is only serviced asa part of the driver side airbag module trim cover. Ifthe horn switch is damaged or faulty, or if the driverside airbag is deployed, the driver side airbag moduletrim cover and horn switch must be replaced as aunit.
OPERATIONWhen the center area of the driver side airbag trim
cover is depressed, the electrically conductive gridson the facing surfaces of the horn switch membranescontact each other, closing the switch circuit. Thecompleted horn switch circuit provides a ground forthe control coil side of the horn relay, which activatesthe relay. When the horn switch is released, theresistive tension of the convex membrane separatesthe two electrically conductive grids and opens theswitch circuit.
Fig. 1 Driver Side Airbag Module Trim Cover andHorn Switch - Typical
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TJ HORN SYSTEMS 8G - 3
IAGNOSIS AND TESTING
ORN RELAYThe horn relay (Fig. 2) is located in the Power Dis-
ribution Center (PDC) behind the battery on theriver side of the engine compartment. If a problems encountered with a continuously sounding horn, itan usually be quickly resolved by removing the hornelay from the PDC until further diagnosis is com-leted. See the fuse and relay layout label affixed tohe inside surface of the PDC cover for horn relaydentification and location. For complete circuit dia-rams, refer to Horn/Cigar Lighter in the Contentsf Group 8W - Wiring Diagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Remove the horn relay from the PDC. Refer toorn Relay in the Removal and Installation section
f this group for the procedures.(2) A relay in the de-energized position should
ave continuity between terminals 87A and 30, ando continuity between terminals 87 and 30. If OK, goo Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-romagnet) should be 75 6 5 ohms. If OK, go to Step. If not OK, replace the faulty relay.(4) Connect a battery to terminals 85 and 86.
here should now be continuity between terminals0 and 87, and no continuity between terminals 87And 30. If OK, perform the Relay Circuit Test thatollows. If not OK, replace the faulty relay.
ELAY CIRCUIT TEST(1) The relay common feed terminal cavity (30) is
onnected to battery voltage and should be hot at allimes. If OK, go to Step 2. If not OK, repair the openircuit to the fuse in the PDC as required.(2) The relay normally closed terminal (87A) is
onnected to terminal 30 in the de-energized position,ut is not used for this application. Go to Step 3.(3) The relay normally open terminal (87) is con-
ected to the common feed terminal (30) in the ener-ized position. This terminal supplies battery voltageo the horn(s). There should be continuity betweenhe cavity for relay terminal 87 and the horn relayutput circuit cavity of each horn wire harness con-
nector at all times. If OK, go to Step 4. If not OK,repair the open circuit to the horn(s) as required.
(4) The coil battery terminal (86) is connected tothe electromagnet in the relay. It is connected to bat-tery voltage and should be hot at all times. Check forbattery voltage at the cavity for relay terminal 86. IfOK, go to Step 5. If not OK, repair the open circuit tothe fuse in the PDC as required.
(5) The coil ground terminal (85) is connected tothe electromagnet in the relay. It is groundedthrough the horn switch when the horn switch isdepressed. Check for continuity to ground at the cav-ity for relay terminal 85. There should be continuitywith the horn switch depressed, and no continuitywith the horn switch released. If not OK, refer toHorn Switch in the Diagnosis and Testing section ofthis group.
HORN SWITCHFor complete circuit diagrams, refer to Horn/Ci-
ar Lighter in the Contents of Group 8W - Wiringiagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable. Remove the knee blocker from the instrumentanel.(2) Check for continuity between the metal steer-
ng column jacket and a good ground. There shoulde continuity. If OK, go to Step 3. If not OK, refer to
Fig. 2 Horn Relay
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8G - 4 HORN SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
teering Column in the Removal and Installationection of Group 19 - Steering for proper installationf the steering column.(3) Remove the driver side airbag module from the
teering wheel. Disconnect the horn switch wire har-ess connectors from the driver side airbag module.(4) Remove the horn relay from the Power Distri-
ution Center (PDC). Check for continuity betweenhe steering column half of the horn switch feed wirearness connector and a good ground. There shoulde no continuity. If OK, go to Step 5. If not OK,epair the shorted horn relay control circuit to theorn relay in the PDC as required.(5) Check for continuity between the steering col-
mn half of the horn switch feed wire harness con-ector and the horn relay control circuit cavity forhe horn relay in the PDC. There should be continu-ty. If OK, go to Step 6. If not OK, repair the openorn relay control circuit to the horn relay in theDC as required.(6) Check for continuity between the horn switch
eed wire and the horn switch ground wire on theriver side airbag module. There should be no conti-uity. If OK, go to Step 7. If not OK, replace theaulty horn switch.
(7) Depress the center of the driver side airbagodule trim cover and check for continuity between
he horn switch feed wire and the horn switchround wire on the driver side airbag module. Therehould now be continuity. If not OK, replace theaulty horn switch.
ORNFor complete circuit descriptions, refer to Horn/Ci-
ar Lighter in the Contents of Group 8W - Wiringiagrams.(1) Disconnect the wire harness connectors from
he horn connector receptacles. Measure the resis-ance between the ground circuit cavity of the hornsire harness connectors and a good ground. There
hould be no measurable resistance. If OK, go to Step. If not OK, repair the open ground circuit to grounds required.(2) Check for battery voltage at the horn relay out-
ut circuit cavity of the horns wire harness connec-ors. There should be zero volts. If OK, go to Step 3.f not OK, repair the shorted horn relay output cir-uit or replace the faulty horn relay as required.(3) Depress the horn switch. There should now be
attery voltage at the horn relay output circuit cavityf the horns wire harness connectors. If OK, replacehe faulty horns. If not OK, repair the open hornelay output circuit to the horn relay as required.
REMOVAL AND INSTALLATION
HORN RELAY
REMOVAL(1) Disconnect and isolate the battery negative
cable.(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 3).
(3) See the fuse and relay layout label affixed tothe underside of the PDC cover for horn relay iden-tification and location.
(4) Remove the horn relay from the PDC.
INSTALLATION(1) See the fuse and relay layout label affixed to
the underside of the PDC cover for the proper hornrelay location.
(2) Position the horn relay in the proper receptaclein the PDC.
(3) Align the horn relay terminals with the termi-nal cavities in the PDC receptacle.
(4) Push down firmly on the horn relay until theterminals are fully seated in the terminal cavities inthe PDC receptacle.
(5) Install the cover onto the PDC.(6) Reconnect the battery negative cable.
Fig. 3 Power Distribution Center
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TJ HORN SYSTEMS 8G - 5
REMOVAL AND INSTALLATION (Continued)
ORN
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Disconnect the wire harness connectors from
he horn connector receptacles (Fig. 4).(3) Remove the two screws that secure the horn
nd mounting bracket units to the left front innerender shield.
(4) Remove the horn and mounting bracket unitsrom the left front inner fender shield.
NSTALLATION(1) Position the horn and mounting bracket units
nto the left front inner fender shield.(2) Install and tighten the screw that secures the
orn and mounting bracket units to the left frontnner fender shield. Tighten the screw to 6.8 N·m (5t. lbs.).
(3) Reconnect the wire harness connectors to theorn connector receptacles.(4) Reconnect the battery negative cable.
PEED CONTROL SERVOThe servo unit consists of a solenoid valve body, a
acuum servo and the mounting bracket. The Power-rain Control Module (PCM) controls the solenoidalve body. The solenoid valve body controls thepplication and release of vacuum to the diaphragmf the vacuum servo. A cable connects the servo withhe throttle linkage. The servo unit cannot beepaired and is serviced only as a complete assembly.
PEED CONTROL SOLENOID CIRCUITSWhen all of the speed control parameters are met,
nd the SET button is pressed, the PCM actuates theent solenoid and “duty-cycles” the vacuum solenoido open the throttle and bring the vehicle up to tar-et speed. When the vehicle is at target speed, it willctuate the vent solenoid with the vacuum solenoide-activated to maintain the vehicle at target speed.hen the vehicle is above target speed, the PCM will
duty-cycle” the vent solenoid with the vacuum sole-oid still de-activated to close the throttle to returno target speed.
PEED CONTROL SWITCHESTwo separate speed control switch modules areounted on the steering wheel to the left and right
ide of the driver’s airbag module. Within the twowitch modules, five momentary contact switches,upporting seven different speed control functions
are used. The outputs from these switches are fil-tered into one input. The Powertrain Control Module(PCM) determines which output has been appliedthrough resistive multiplexing. The input circuitvoltage is measured by the PCM to determine whichswitch function has been selected.
A speed control indicator lamp, located on theinstrument panel cluster is energized by the PCM viathe CCD Bus. This occurs when speed control systempower has been turned ON, and the engine is run-ning.
The two switch modules are labeled: ON/OFF, SET,RESUME/ACCEL, CANCEL and COAST. Refer tothe owner’s manual for more information on speedcontrol switch functions and setting procedures. Theindividual switches cannot be repaired. If one indi-vidual switch fails, the switch module must bereplaced.
STOP LAMP SWITCHVehicles equipped with the speed control option use
a dual function stop lamp switch. The switch ismounted on the brake pedal mounting bracket underthe instrument panel. The PCM monitors the state ofthe dual function stop lamp switch. Refer to theBrake section for more information on stop lampswitch service and adjustment procedures.
SERVO CABLEThe speed control servo cable is connected between
the speed control vacuum servo diaphragm and thethrottle body control linkage. This cable causes the
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8H - 2 SPEED CONTROL SYSTEM TJ
DESCRIPTION AND OPERATION (Continued)
hrottle control linkage to open or close the throttlealve in response to movement of the vacuum servoiaphragm.
OWERTRAIN CONTROL MODULEThe speed control electronic control circuitry is
ntegrated into the Powertrain Control ModulePCM). The PCM is located in the engine compart-ent. The PCM speed control functions are moni-
ored by the On-Board Diagnostics (OBD). All OBD-ensed systems are monitored by the PCM. Eachonitored circuit is assigned a Diagnostic Troubleode (DTC). The PCM will store a DTC in electronicemory for certain failures it detects. See On-Boardiagnostic Test For Speed Control System in thisroup for more information. The PCM cannot beepaired and must be replaced if faulty.
ACUUM RESERVOIRA vacuum reservoir is used to supply the vacuum
eeded to maintain proper speed control operationhen engine vacuum drops, such as in climbing arade while driving. A one-way check valve is used inhe vacuum line between the reservoir and the vac-um source. This check valve is used to trap engineacuum in the reservoir. On certain vehicle applica-ions, this reservoir is shared with the heating/air-onditioning system. The vacuum reservoir cannot beepaired and must be replaced if faulty.
EHICLE SPEED SENSORThe Vehicle Speed Sensor (VSS) is a pulse genera-
or mounted to an adapter near the transmission out-ut shaft. The sensor is driven through the adaptery a speedometer pinion gear. The VSS pulse signalo the speedometer/odometer is monitored by theCM speed control circuitry to determine vehiclepeed and to maintain speed control set speed.
IAGNOSIS AND TESTING
OAD TESTPerform a vehicle road test to verify reports of
peed control system malfunction. The road testhould include attention to the speedometer. Speed-meter operation should be smooth and without flut-er at all speeds.
Flutter in the speedometer indicates a problemhich might cause surging in the speed control sys-
em. The cause of any speedometer problems shoulde corrected before proceeding. Refer to Group 8E,nstrument Panel and Gauges for speedometer diag-osis.If a road test verifies a system problem and the
peedometer operates properly, check for:
• A Diagnostic Trouble Code (DTC). If a DTCexists, conduct tests per the Powertrain DiagnosticProcedures service manual.
• A misadjusted brake (stop) lamp switch. Thiscould also cause an intermittent problem.
• Loose, damaged or corroded electrical connec-tions at the servo. Corrosion should be removed fromelectrical terminals and a light coating of MoparMultiPurpose Grease, or equivalent, applied.
• Leaking vacuum reservoir.• Loose or leaking vacuum hoses or connections.• Defective one-way vacuum check valve.• Secure attachment of both ends of the speed con-
trol servo cable.• Smooth operation of throttle linkage and throttle
body air valve.• Failed speed control servo. Do the servo vacuum
test.
CAUTION: When test probing for voltage or conti-nuity at electrical connectors, care must be takennot to damage connector, terminals or seals. Ifthese components are damaged, intermittent orcomplete system failure may occur.
ON-BOARD DIAGNOSTIC TEST FOR SPEEDCONTROL SYSTEM
The Powertrain Control Module (PCM) monitorscritical input and output circuits of the speed controlsystem, making sure they are operational. A Diagnos-tic Trouble Code (DTC) is assigned to each input andoutput circuit monitored by the On-Board Diagnostic(OBD) system. Some circuits are checked continu-ously and some are checked only under certain con-ditions.
For DTC information, refer to Diagnostic TroubleCodes in Group 25, Emission Control System. Thiswill include a complete list of DTC’s including DTC’sfor the speed control system.
VEHICLE SPEED SIGNALFor diagnosis and testing of the Vehicle Speed Sig-
nal (VSS), refer to the appropriate Powertrain Diag-nostic Procedures service manual. Also refer to theDRB scan tool.
SPEED CONTROL SWITCHESTo perform a complete test of the speed control
switch circuits, refer to the appropriate PowertrainDiagnostic Procedures manual.
STOP LAMP SWITCHFor continuity checks and switch adjustment, refer
to Group 5, Brakes.
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TJ SPEED CONTROL SYSTEM 8H - 3
DIAGNOSIS AND TESTING (Continued)
ACUUM SUPPLY TEST(1) Disconnect vacuum hose at speed control servo
nd install a vacuum gauge into the disconnectedose.(2) Start engine and observe gauge at idle. Vac-
um gauge should read at least ten inches of mer-ury.(3) If vacuum is less than ten inches of mercury,
etermine source of leak. Check vacuum line tongine for leaks. Also check actual engine intakeanifold vacuum. If manifold vacuum does not meet
his requirement, check for poor engine performancend repair as necessary.(4) If vacuum line to engine is not leaking, check
or leak at vacuum reservoir. To locate and gainccess to reservoir, refer to Vacuum Reservoir Remov-l/Installation in this group. Disconnect vacuum linet reservoir and connect a hand-operated vacuumump to reservoir fitting. Apply vacuum. Reservoiracuum should not bleed off. If vacuum is being lost,eplace reservoir.(5) Verify operation of one-way check valve and
heck it for leaks.(a) Locate one-way check valve. The valve is
located in vacuum line between vacuum reservoirand engine vacuum source. Disconnect vacuumhoses (lines) at each end of valve.
(b) Connect a hand-operated vacuum pump toreservoir end of check valve. Apply vacuum. Vac-uum should not bleed off. If vacuum is being lost,replace one-way check valve.
(c) Connect a hand-operated vacuum pump tovacuum source end of check valve. Apply vacuum.Vacuum should flow through valve. If vacuum isnot flowing, replace one-way check valve. Seal thefitting at opposite end of valve with a finger andapply vacuum. If vacuum will not hold, diaphragmwithin check valve has ruptured. Replace valve.
PEED CONTROL SERVOFor complete speed control system diagnosis, refer
o the appropriate Powertrain Diagnostic Proceduresanual. To test the speed control servo only, refer to
he following:The engine must be started and running for the
ollowing voltage tests.(1) Start engine.(2) Disconnect 4–way electrical connector at servo.(3) Turn speed control switch to ON position.(4) Check for battery voltage at pin–3 of wiring
arness 4–way connector (Fig. 1). This is the 12 volteed from the stoplamp switch. When the brake pedals depressed, voltage should not be present at pin–3.f voltage is not present with brake pedal notepressed, check for continuity between servo and
stop lamp switch. Also check stop lamp switchadjustment. Refer to Group 5, Brakes for procedures.
(5) Connect a small gauge jumper wire betweenthe disconnected servo harness 4–way connectorpin–3, and pin–3 on the servo. Check for battery volt-age at pins–1, 2 and 4 of the servo. If battery voltageis not at these pins, replace the servo.
(6) Turn ignition switch to OFF position. Check forcontinuity between disconnected servo harness4–way connector pin–4 and a good ground. Thereshould be continuity. If not OK, repair open circuit toground as required.
OVERSHOOT/UNDERSHOOT FOLLOWINGSPEED CONTROL SET
If the operator repeatedly presses and releases theset button with their foot off of the accelerator (a “liftfoot set” to begin speed control operation), the vehiclemay accelerate and exceed the desired set speed byup to 5 MPH (8 km/h) and then decelerate to lessthan the desired set speed before finally achievingthe desired set speed.
The Speed Control has an adaptive strategy thatcompensates for vehicle-to-vehicle variations in speedcontrol cable lengths. When the speed control is setwith the vehicle operators foot off of the acceleratorpedal, the speed control thinks there is excessivespeed control cable slack and adapts. If the lift footsets are continually used, the speed control over-shoot/undershoot condition will develop.
To “unlearn” the overshoot/undershoot condition,the vehicle operator has to press and release the setbutton while maintaining the desired set speed withthe accelerator pedal (not decelerating or accelerat-ing), and then turn the cruise control switch to the
Fig. 1 Servo 4–Way Harness Connector
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8H - 4 SPEED CONTROL SYSTEM TJ
DIAGNOSIS AND TESTING (Continued)
FF position (or press the CANCEL button ifquipped) after waiting 10 seconds. This procedureust be performed approximately 10–15 times to
ompletely unlearn the overshoot/undershoot condi-ion.
EMOVAL AND INSTALLATION
PEED CONTROL SERVO
EMOVAL(1) Disconnect negative battery cable at battery.(2) Disconnect vacuum line at servo (Fig. 2).(3) Disconnect electrical connector at servo.(4) Disconnect servo cable at throttle body. Refer to
ervo Cable Removal/Installation in this group.(5) Remove 2 mounting nuts holding servo cable
leeve to bracket (Fig. 2) or (Fig. 3).(6) Pull speed control cable sleeve and servo away
rom servo mounting bracket to expose cable retain-ng clip (Fig. 3) and remove clip. Note: The servo
ounting bracket displayed in (Fig. 3) is a typicalracket and may/may not be applicable to this modelehicle.
(7) Remove servo from mounting bracket. Whileemoving, note orientation of servo to bracket.
NSTALLATION(1) Position servo to mounting bracket.(2) Align hole in cable connector with hole in servo
in. Install cable-to-servo retaining clip.(3) Insert servo mounting studs through holes in
ervo mounting bracket.(4) Install servo mounting nuts and tighten to 8.5·m (75 in. lbs.).
Fig. 2 Speed Control Servo Location
(5) Connect vacuum line at servo.(6) Connect electrical connector at servo.(7) Connect servo cable to throttle body. Refer to
Servo Cable Removal/Installation in this group.(8) Connect negative battery cable to battery.(9) Before starting engine, operate accelerator
pedal to check for any binding.
SPEED CONTROL SWITCH
WARNING: BEFORE ATTEMPTING TO DIAGNOSE,REMOVE OR INSTALL ANY AIRBAG SYSTEM ORRELATED STEERING WHEEL AND STEERING COL-UMN COMPONENTS YOU MUST FIRST DISCON-NECT AND ISOLATE THE BATTERY NEGATIVE(GROUND) CABLE. WAIT 2 MINUTES FOR SYSTEMCAPACITOR TO DISCHARGE BEFORE FURTHERSYSTEM SERVICE. FAILURE TO DO SO COULDRESULT IN ACCIDENTAL DEPLOYMENT AND POS-SIBLE PERSONAL INJURY.
REMOVAL(1) Disconnect and isolate negative battery cable
from battery.(2) Remove airbag module. Refer to Group 8M,
Passive Restraint Systems for procedures.(3) From underside of steering wheel, remove
speed control switch mounting screw (Fig. 4).(4) Remove switch from steering wheel and unplug
electrical connector.
INSTALLATION(1) Plug electrical connector into switch.(2) Position switch to steering wheel.(3) Install switch mounting screw and tighten to
1.5 N·m (14 in. lbs.) torque.(4) Install airbag module. Refer to Group 8M, Pas-
sive Restraint Systems for procedures.
Fig. 3 Servo Cable Clip Remove/Install—Typical
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TJ SPEED CONTROL SYSTEM 8H - 5
REMOVAL AND INSTALLATION (Continued)
(5) Connect negative battery cable to battery.
TOP LAMP SWITCHRefer to Stop Lamp Switch in Group 5, Brakes for
emoval/installation and adjustment procedures.
ERVO CABLE
EMOVAL(1) Disconnect negative battery cable at battery.(2) Using finger pressure only, remove cable con-
ector by pushing connector off the throttle bodyellcrank pin (Fig. 5). DO NOT try to pull cableonnector off perpendicular to the bellcrankin. Connector will be broken.(3) Two squeeze tabs are located on sides of speed
ontrol cable at cable locking plate (Fig. 6). Squeezehe tabs together and push cable out of cable lockinglate.(4) Unclip cable from cable guide at valve cover
Fig. 6).(5) Disconnect servo cable at servo. Refer to Speedontrol Servo—Removal/Installation.
NSTALLATION(1) Attach end of cable to speed control servo.efer to Speed Control Servo Removal/Installation.(2) Install cable into cable locking plate (snaps in).(3) Install cable connector at throttle body
ellcrank pin (snaps on).(4) Clip cable to cable guide at valve cover.(5) Connect negative battery cable to battery.(6) Before starting engine, operate accelerator
edal to check for any binding.
Fig. 4 Speed Control Switch Remove/Install
Fig. 5 Servo Cable to Bellcrank—Remove/Install
Fig. 6 Squeeze Tabs at Cable Locking Plate
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8H - 6 SPEED CONTROL SYSTEM TJ
REMOVAL AND INSTALLATION (Continued)
ACUUM RESERVOIRThe vacuum reservoir is located under the vehicle
attery tray (Fig. 7).
Fig. 7 Vacuum Reservoir Removal/Installation
REMOVAL(1) Remove battery and battery tray. Refer to
Group 8A, Battery for procedure.(2) Disconnect vacuum supply line at reservoir
(Fig. 7).(3) Remove screw securing reservoir to inner
fender.(4) Remove reservoir from vehicle.
INSTALLATION(1) Position reservoir to vehicle and install mount-
ing screw.(2) Tighten screw to 1.2 N·m (10 in. lbs.) torque.(3) Connect vacuum line to reservoir.(4) Install battery and battery tray. Refer to Group
ESCRIPTIONA turn signal system is standard factory-installed
afety equipment on this model. The turn signal sys-em uses ignition switched battery current, and willperate only when the ignition switch is in the On orccessory positions. The turn signal system includes
he following components:• Combination flasher• Front side marker lamps• Turn signal cancelling cam• Turn signal indicator lamps• Turn signal lamps• Turn signal switch.Refer to Lamp in the proper section of Group 8L -
amps for more information on the exterior turn sig-al lamps. Refer to Instrument Cluster in theroper section of Group 8E - Instrument Panel Sys-ems for more information on the turn signal indica-or lamps. Following are general descriptions of theajor components in the turn signal system. For
omplete circuit diagrams, refer to Turn Signals inhe Contents of Group 8W - Wiring Diagrams.
PERATIONWith the ignition switch in the On or Accessory
osition, and the turn signal (multi-function) switchontrol stalk moved up (right turn) or down (lefturn), the turn signal system is activated. When theurn signal system is activated, the circuitry of theurn signal switch and the combination flasher willause the selected (right or left) turn signal indicatoramp, front park/turn signal lamp, front side markeramp and rear tail/stop/turn signal lamp to flash on
and off. If the exterior lamps are turned off, the frontpark/turn signal lamp and the front side markerlamp will flash in unison. If the exterior lamps areturned on, the front park/turn signal lamp and thefront side marker lamp will flash alternately.
See the owner’s manual in the vehicle glove box formore information on the features, use and operationof the turn signal system.
HAZARD WARNING SYSTEM
DESCRIPTIONA hazard warning system is standard factory-in-
stalled safety equipment on this model. Unlike theturn signal system, the hazard warning system usesa non-switched source of battery current so that thesystem will operate regardless of the ignition switchposition. The hazard warning system includes the fol-lowing components:
• Combination flasher• Front side marker lamps• Hazard warning switch• Turn signal indicator lamps• Turn signal lamps.Refer to Lamp in the proper section of Group 8L -
Lamps for more information on the exterior turn sig-nal lamps. Refer to Instrument Cluster in theproper section of Group 8E - Instrument Panel Sys-tems for more information on the turn signal indica-tor lamps. Following are general descriptions of themajor components in the hazard warning system. Forcomplete circuit diagrams, refer to Turn Signals inthe Contents of Group 8W - Wiring Diagrams.
OPERATIONWith the hazard warning switch in the On posi-
tion, the hazard warning system is activated. When
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8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
he hazard warning system is activated, the circuitryf the hazard warning switch and the combinationlasher will cause both the right side and the left sideurn signal indicator lamps, front park/turn signalamps, front side marker lamps and rear tail/stop/urn signal lamps to flash on and off. If the exterioramps are turned off, the front park/turn signalamps and the front side marker lamps will flash innison. If the exterior lamps are turned on, the frontark/turn signal lamps and the front side markeramps will flash alternately.
See the owner’s manual in the vehicle glove box forore information on the features, use and operation
f the hazard warning system.
URN SIGNAL SWITCH AND HAZARDARNING SWITCH
ESCRIPTIONThe turn signal and hazard warning switches are
ntegral to the multi-function switch unit, which isecured to the left side of the steering column (Fig.). The only visible parts of the multi-function switchre the control stalk that extends from the left sidef the steering column, and the hazard warningwitch button that protrudes from the top of theteering column. The multi-function switch controltalk has international control symbols on it, whichdentify its functions. The hazard warning switchutton is identified with a double triangle, which ishe international control symbol for hazard warning.he remainder of the multi-function switch is con-ealed beneath the steering column shrouds.The multi-function switch also contains circuitry
or the following functions:• Headlamp beam selection• Headlamp optical horn
Fig. 1 Multi-Function Switch
The information contained in this group addressesonly the multi-function switch turn signal and haz-ard warning functions. For information relative tothe other systems that are controlled by and circuitsthat are integral to the multi-function switch, see thegroup in this service manual that covers that system.However, the turn signal and hazard warningswitches cannot be repaired. If these switches or anyother circuit or component of the multi-functionswitch unit is faulty or damaged, the entire multi-function switch unit must be replaced.
OPERATION
TURN SIGNAL SWITCHThe multi-function switch control stalk that
extends from the left side of the steering column justbelow the steering wheel is moved up or down toactivate the turn signal switch. When the controlstalk is moved in the upward direction, the rightturn signal switch circuitry is activated; and, whenthe control stalk is moved in the downward direction,the left turn signal switch circuitry is activated. Theturn signal switch has a detent position in eachdirection that provides turn signals with automaticcancellation, and an intermediate momentary posi-tion in each direction that provides turn signals onlyuntil the multi-function switch control stalk isreleased.
When the turn signal switch is in a detent posi-tion, it is turned off by one of two turn signal cancel-ling cam lobes that are integral to the rotor of theclockspring mechanism. Turning the steering wheelcauses the turn signal cancelling cam lobes to contacta cancel actuator in the multi-function switch, andthe turn signal switch automatically returns to theoff position.
HAZARD WARNING SWITCHThe hazard warning switch is controlled by the
hazard warning switch button. Slide the switch but-ton to the left to turn the switch on and activate thehazard warning system, and slide the button to theright again to turn the switch and the hazard warn-ing system off.
TURN SIGNAL CANCELLING CAM
DESCRIPTIONThe turn signal cancelling cam is concealed within
the steering column below the steering wheel. Theturn signal cancelling cam consists of two lobes thatare integral to the lower surface of the clockspringrotor. The clockspring mechanism provides turn sig-nal cancellation as well as a constant electrical con-nection between the horn switch, driver side airbag
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TJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3
DESCRIPTION AND OPERATION (Continued)
odule and speed control switches on the steeringheel and the instrument panel wire harness on the
teering column. The housing of the clockspring isecured to the steering column and remains station-ry. The rotor of the clockspring, including the turnignal cancelling cam lobes rotate with the steeringheel.The turn signal cancelling cam is integral to the
lockspring and cannot be repaired. If faulty or dam-ged, the entire clockspring assembly must beeplaced. Refer to Clockspring in the Removal andnstallation section of Group 8M - Passive Restraintystems for the clockspring service procedures.
PERATIONThe turn signal cancelling cam has two lobesolded into the lower surface of the clockspring
otor. When the turn signals are activated by movinghe multi-function switch control stalk to a detentosition, a turn signal cancel actuator is extendedrom the inside surface of the multi-function switchousing toward the clockspring rotor. When theteering wheel is rotated during the turn, one of thewo turn signal cancelling cam lobes will contact theurn signal cancel actuator, releasing the multi-func-ion switch control stalk from its detent and cancel-ing the turn signal event.
OMBINATION FLASHER
ESCRIPTIONThe combination flasher is a smart relay that func-
ions as both the turn signal system and the hazardarning system flasher. The combination flasher con-
ains active electronic Integrated Circuitry (IC) ele-ents. This flasher is designed to handle the current
low requirements of the factory-installed lighting. Ifupplemental lighting is added to the turn signalamp circuits, such as when towing a trailer withights, the combination flasher will automatically tryo compensate to keep the flash rate the same.
While the combination flasher has a Internationaltandards Organization (ISO)-type relay terminalonfiguration or footprint, the internal circuitry isuch different. The combination flasher does not use
tandard ISO-relay inputs or provide ISO-relay typeutputs or functions. The combination flasher shouldever be substituted for an ISO-relay or replacedith an ISO-relay, or else component and vehicleamage may occur.Because of the active electronic elements within
he combination flasher, it cannot be tested with con-entional automotive electrical test equipment. If theombination flasher is believed to be faulty, test theurn signal system and hazard warning system cir-uits as described in this group. Then replace the
combination flasher with a known good unit to con-firm system operation.
The combination flasher has five blade-type termi-nals intended for the following inputs and outputs:fused B(+), fused ignition switch output, ground, turnsignal circuit, and hazard warning circuit. Constantbattery voltage and ground are supplied to theflasher so that it can perform the hazard warningfunction, and ignition switched battery voltage issupplied for the turn signal function. Refer to TurnSignals in the Contents of Group 8W - Wiring Dia-grams for complete circuit diagrams.
The combination flasher is located in a bracketsecured with a screw to the underside of the uppersteering column support bracket, to the right of thesteering column under the instrument panel. Thecombination flasher cannot be repaired or adjustedand, if faulty or damaged, it must be replaced.
OPERATIONThe IC within the combination flasher (Fig. 2) con-
tains the logic that controls the flasher operation andthe flash rate. Pin 6 of the IC receives a sense volt-age from the hazard warning circuit of the multi-function switch. When the hazard warning switch isturned on, the 9hazard on sense9 voltage will becomelow due to the circuit being grounded through theturn signal bulbs. This low voltage sense signals theIC to energize the flash control Positive-Negative-Positive (PNP) transistor at a pre-calibrated flashrate or frequency. Each time the PNP transistor ener-gizes the hazard warning circuit, the pin 6 9hazardon sense9 voltage will become high and the IC signalsthe PNP transistor to de-energize the circuit. Thiscycling will continue until the hazard warning switchis turned off.
Fig. 2 Combination Flasher - Typical
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8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
Likewise, pin 8 of the IC receives a sense voltagerom the turn signal circuits of the multi-functionwitch. When the left or right turn signal switch isurned on, the 9turn signal on sense9 voltage willecome low due to the circuit being groundedhrough the turn signal bulbs. This low voltage senseignals the IC to energize the flash control PNP tran-istor at a pre-calibrated flash rate or frequency.ach time the PNP transistor energizes the turn sig-al circuit, the pin 8 9turn signal on sense9 voltageill become high and the IC signals the PNP transis-
or to de-energize the circuit. This cycling will con-inue until the right or left turn signal switch isurned off.
A special design feature of the combination flasherllows it to 9sense9 that a turn signal circuit or bulbs not operating, and provide the driver an indicationf the condition by flashing the remaining bulbs inhe affected circuit at a higher rate (120 flashes-per-inute or higher). Conventional flashers either con-
inue flashing at their typical rate (heavy-duty type),r discontinue flashing the affected circuit entirelystandard-duty type). During turn signal operation,he combination flasher IC compares normal batteryoltage input on pin 2 with the shunt resistor voltagenput on pin 7. If the IC 9senses9 that the voltage dif-erence between pin 2 and pin 7 is different than there-calibrated value of the IC, it will increase theate at which it signals the PNP transistor to ener-ize the pin 1 output. Thus, the inoperative half (leftr right side) of the turn signal circuit will flashaster.
IAGNOSIS AND TESTING
URN SIGNAL AND HAZARD WARNINGYSTEMSWhen diagnosing the turn signal or hazard warn-
ng circuits, remember that high generator outputan burn out bulbs rapidly and repeatedly. If this is aroblem on the vehicle being diagnosed, refer toharging System in the Diagnosis and Testing sec-
ion of Group 8C - Charging System for further diag-osis of a possible generator overcharging condition.If the problem being diagnosed is related to a fail-
re of the turn signals to automatically cancel follow-ng completion of a turn, inspect the multi-functionwitch for a faulty or damaged cancel actuator andnspect the turn signal cancelling cam lobes on thelockspring mechanism for damage or impropernstallation. For complete circuit diagrams, refer tourn Signals in the Contents of Group 8W - Wiringiagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Turn the ignition switch to the On position.Actuate the turn signal switch or the hazard warningswitch. Observe the turn signal indicator lamp(s) inthe instrument cluster. If the flash rate is very high,check for a turn signal bulb that is not lit or is verydimly lit. Repair the circuits to that lamp or replacethe faulty bulb, as required. If the turn signal indi-cator(s) fail to light, go to Step 2.
(2) Turn the ignition switch to the Off position.Check the turn signal fuse in the fuseblock moduleand/or the hazard warning fuse in the Power Distri-bution Center (PDC). If OK, go to Step 3. If not OK,repair the shorted circuit or component as requiredand replace the faulty fuse(s).
(3) Check for battery voltage at the hazard warn-ing fuse in the PDC. If OK, go to Step 4. If not OK,repair the open fused B(+) circuit to the battery asrequired.
(4) Turn the ignition switch to the On position.Check for battery voltage at the turn signal fuse inthe fuseblock module. If OK, go to Step 5. If not OK,repair the open fused ignition switch output (accesso-ry/run) circuit to the ignition switch as required.
(5) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Remove the combination flasher from its wire har-ness connector and replace it with a known goodunit. Connect the battery negative cable. Test theoperation of the turn signal and hazard warning sys-tems. If OK, discard the faulty combination flasher.If not OK, remove the test flasher and go to Step 6.
(6) Turn the ignition switch to the On position.Check for battery voltage at the combo flasher inputcircuit cavity in the combination flasher wire harnessconnector. If OK, go to Step 7. If not OK, go to Step9.
(7) Turn the ignition switch to the Off position.Place the hazard warning switch in the On position.Check for battery voltage again at the combo flasherinput circuit cavity in the combination flasher wireharness connector. If OK, go to Step 8. If not OK, goto Step 9.
(8) Disconnect and isolate the battery negativecable. Check for continuity between the ground cir-cuit cavity of the combination flasher wire harnessconnector and a good ground. There should be conti-
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TJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5
DIAGNOSIS AND TESTING (Continued)
uity. If OK, go to Step 9. If not OK, repair the openround circuit to ground as required.(9) Disconnect the instrument panel wire harness
onnector from the multi-function switch connectoreceptacle. Check for continuity between the combolasher input circuit cavities in the combinationlasher wire harness connector and in the instrumentanel wire harness connector for the multi-functionwitch. There should be continuity. If OK, go to Step0. If not OK, repair the open combo flasher inputircuit as required.(10) Check for continuity between the combo
lasher output circuit cavities in the combinationlasher wire harness connector and in the instrumentanel wire harness connector for the multi-functionwitch. There should be continuity. If OK, refer tourn Signal Switch and Hazard Warning Switch
n the Diagnosis and Testing section of this group. Ifot OK, repair the open combo flasher output circuits required.
URN SIGNAL SWITCH AND HAZARDARNING SWITCHThe turn signal switch and the hazard warning
witch are integral to the multi-function switch.efer to Turn Signal and Hazard Warning Sys-
ems in the Diagnosis and Testing section of thisroup before testing the multi-function switch. Foromplete circuit diagrams, refer to Turn Signals inhe Contents of Group 8W - Wiring Diagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable. Disconnect the instrument panel wire harnessonnector from the multi-function switch connectoreceptacle.(2) Using an ohmmeter, perform the switch conti-
uity checks at the connector receptacle terminals ashown in the Multi-Function Switch Continuity chartFig. 3).
(3) If the turn signal switch or hazard warningwitch fails any of the continuity checks, replace theaulty multi-function switch assembly as required. Ifhe switch circuits are OK, repair the lighting cir-uits as required.
REMOVAL AND INSTALLATION
COMBINATION FLASHER
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL(1) Disconnect and isolate the battery negative
cable.(2) Remove the knee blocker from the instrument
panel. Refer to Knee Blocker in the Removal andInstallation section of Group 8E - Instrument PanelSystems for the procedures.
NOTE: The combination flasher and flasher bracketare serviced only as a unit.
(3) Reach through the inboard side of the instru-ment panel steering column opening to access andremove the screw that secures the combinationflasher bracket to the upper steering column mount-ing bracket to the right of the steering column (Fig.4).
Fig. 3 Multi-Function Switch Continuity
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8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(4) Lower the combination flasher and bracket farnough to access the wire harness connector.(5) Remove the combination flasher from the wire
arness connector.(6) Remove the combination flasher and bracket
rom under the instrument panel as a unit.
NSTALLATION(1) Position the combination flasher and bracket
nder the instrument panel as a unit.(2) Align the combination flasher terminals with
he terminal cavities in the wire harness connector.(3) Push in firmly on the combination flasher until
he terminals are fully seated in the terminal cavitiesn the wire harness connector.
(4) Position the combination flasher and bracket tohe upper steering column mounting bracket to theight of the steering column under the instrumentanel.(5) Install and tighten the screw that secures the
ombination flasher and bracket to the upper steer-ng column mounting bracket. Tighten the screw to 4·m (35 in. lbs.).(6) Install the knee blocker onto the instrument
anel. Refer to Knee Blocker in the Removal andnstallation section of Group 8E - Instrument Panelystems for the procedures.(7) Reconnect the battery negative cable.
Fig. 4 Combination Flasher Remove/Install
TURN SIGNAL SWITCH AND HAZARDWARNING SWITCH
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL(1) Disconnect and isolate the battery negative
cable.(2) Remove the knee blocker from the instrument
panel. Refer to Knee Blocker in the Removal andInstallation section of Group 8E - Instrument PanelSystems for the procedures.
(3) Remove the three screws that secure the lowersteering column shroud to the upper shroud (Fig. 5).
(4) If the vehicle is equipped with a standard non-tilt steering column, loosen the two upper steeringcolumn mounting nuts. If the vehicle is equippedwith the optional tilt steering column, move the tiltsteering column to the fully lowered position.
Fig. 5 Steering Column Shrouds Remove/Install
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TJ TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7
REMOVAL AND INSTALLATION (Continued)
(5) Remove both the upper and lower shrouds fromhe steering column.
(6) Remove the two screws that secure the multi-unction switch water shield and bracket to the top ofhe steering column (Fig. 6).
(7) Remove the one screw located below the multi-unction switch control stalk that secures the multi-unction switch water shield and bracket to theteering column (Fig. 7).
(8) Gently pull the lower mounting tab of theulti-function switch water shield bracket away from
he steering column far enough to clear the screwoss below the multi-function switch control stalk.(9) Lift the water shield and bracket with theulti-function switch off of the left side of the steer-
ng column far enough to access the two multi-func-ion switch wire harness connectors. If the vehicle isquipped with the optional tilt steering column, lift-ng gently upward on the tilt release lever will pro-ide additional clearance to ease multi-functionwitch removal.
Fig. 6 Water Shield Upper Screws Remove/Install
Fig. 7 Water Shield Lower Screw Remove/Install
(10) Disconnect the two instrument panel wireharness connectors from the multi-function switchconnector receptacles.
(11) Remove the multi-function switch and watershield from the steering column as a unit.
(12) Gently and carefully remove the water shieldfrom the switch by pulling it over the hazard warn-ing switch button and the multi-function switch con-trol stalk.
INSTALLATION(1) Gently and carefully install the water shield
onto the switch by pulling it over the hazard warningswitch button and the multi-function switch controlstalk.
(2) Position the multi-function switch and watershield near its mounts on the steering column as aunit.
(3) Reconnect the two instrument panel wire har-ness connectors to the multi-function switch connec-tor receptacles.
(4) Position the multi-function switch onto itsmounts on the left side of the steering column. If thevehicle is equipped with the optional tilt steering col-umn, lifting gently upward on the tilt release leverwill provide additional clearance to ease multi-func-tion switch installation.
(5) Position the lower mounting tab of the multi-function switch water shield bracket to the steeringcolumn screw boss below the multi-function switchcontrol stalk.
(6) Install and tighten the one screw located belowthe multi-function switch control stalk that securesthe multi-function switch water shield and bracket tothe steering column. Tighten the screw to 1.1 N·m(10 in. lbs.).
(7) Install and tighten the two screws that securethe multi-function switch water shield and bracket tothe top of the steering column. Tighten the screws to2.2 N·m (20 in. lbs.).
(8) Position both the upper and lower shrouds ontothe steering column.
(9) Install and tighten the three screws that securethe lower steering column shroud to the uppershroud. Tighten the screws to 2 N·m (18 in. lbs.).
(10) If the vehicle is so equipped, tighten the twonuts that secure the non-tilt steering column uppermounting bracket to the dash panel steering columnsupport bracket studs. Tighten the nuts to 22 N·m(200 in. lbs.).
(11) Install the knee blocker onto the instrumentpanel. Refer to Knee Blocker in the Removal andInstallation section of Group 8E - Instrument PanelSystems for the procedures.
NTRODUCTIONFollowing are general descriptions of the major
omponents in the wiper and washer systems. Refero 8W-53 - Wipers in Group 8W - Wiring Diagramsor complete circuit descriptions and diagrams.
ESCRIPTION AND OPERATION
INDSHIELD WIPER SYSTEMA two-speed windshield wiper system is standard
quipment on this model. An intermittent windshieldiper system is optional. The standard system lets
he driver select from two wiper speeds, low or high.he intermittent wiper system adds an intermittentipe delay feature.On models equipped with the intermittent wiper
ystem, the intermittent wipe mode delay times areriver adjustable from about one second to about fif-een seconds. The intermittent wipe mode is providedy delay logic and relay control circuitry containedithin the intermittent wiper/washer switch. The
ntermittent wipe relay is also contained within thewitch.The windshield wipers will operate only when the
gnition switch is in the Accessory or On positions. Ause located in the fuseblock module protects the cir-uitry of either windshield wiper system. Refer to thewner’s manual for more information on the wind-hield wiper system controls and operation.
WINDSHIELD WASHER SYSTEMAn electrically operated windshield washer system
is standard equipment. A washer reservoir in theengine compartment holds the washer fluid, which ispressurized by a pump when the windshield washerswitch lever is actuated. The windshield washerpump feeds the pressurized washer fluid through thewasher system plumbing to the windshield washernozzles.
If the vehicle is equipped with the two-speed wipersystem and the wipers are not already turned onwhen the washers are activated, the wiper switchwill be turned on to the low speed position automat-ically. The wipers must be turned off manually fol-lowing a washer switch activation. If the vehicle isequipped with the intermittent wipe system and thewipers are not turned on when the washers are acti-vated, the wipers will be automatically cycled for oneor two wipes, then be turned off.
The washers will operate only when the ignitionswitch is in the Accessory or On positions. A fuselocated in the fuseblock module protects the circuitryof the washer system. Refer to the owner’s manualfor more information on the windshield washer sys-tem controls and operation.
REAR WIPER AND WASHER SYSTEMA rear wiper and washer system is standard equip-
ment on models equipped with the optional hardtop.The rear wiper system provides the following operat-ing modes:
• Continuous fixed-cycle wipe.• A rear washer mode.
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8K - 2 WIPER AND WASHER SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
• A park mode that operates the wiper motor untilhe blade reaches its park position when the reariper switch is placed in the Off position.A single switch in the instrument panel accessory
witch bezel controls both the rear wiper and washerunctions. The rear washer system shares the reser-oir of the windshield washer system, but has itswn dedicated washer pump and plumbing.The rear wiper and washer systems will operate
nly when the ignition switch is in the On position. Ause in the fuseblock module protects the circuitry ofoth the rear wiper and washer systems.Refer to the owner’s manual for more information
n the rear wiper and washer system controls andperation.
IPER ARM AND BLADEAll models have two 33.02-centimeter (13-inch)indshield wiper blades with non-replaceable rubberlements (squeegees). The rear wiper uses a single5.72-centimeter (18-inch) wiper blade with a non-re-laceable rubber element (squeegee).Caution should be exercised to protect the rubber
queegees from any petroleum-based cleaners or con-aminants, which will rapidly deteriorate the rubber.f the squeegees are damaged, worn, or contami-ated, the entire wiper blade assembly must beeplaced.Wiper squeegees exposed to the elements for a long
ime tend to lose their wiping effectiveness. Periodicleaning of the squeegees is suggested to removeeposits of salt and road film. The wiper blades,rms, and windshield or rear liftglass should beleaned with a sponge or cloth and windshieldasher fluid, a mild detergent, or a non-abrasive
leaner. If the squeegees continue to streak or smear,he wiper blades should be replaced.
The blades are mounted to spring-loaded wiperrms. The spring tension of the wiper arms controlshe pressure applied to the blades on the glass. Theindshield wiper arms are secured by an integral
atch to the two wiper pivots on the cowl plenum cov-r/grille panel at the base of the windshield. The reariper arm is secured by an integral latch directly to
he rear wiper motor output shaft on the liftglass.The wiper arms and blades cannot be adjusted or
epaired. If faulty or damaged, they must beeplaced.
IPER LINKAGE AND PIVOTThe wiper linkage and pivot module is securedith screws to the cowl plenum panel beneath the
owl plenum cover/grille panel. The wiper motor isecured with screws to the center of the linkage andivot module bracket. The wiper pivots are securedo the ends of the module bracket.
The driver side wiper pivot crank arm and thewiper motor crank arm each have ball studs on theirends. The passenger side crank arm has two ballstuds. A drive link is connected from the motor crankarm ball stud to one ball stud on the passenger sidepivot crank arm. A connecting link is connected fromthe other ball stud on the passenger side pivot crankarm to the driver side pivot crank arm ball stud.
Both the drive link and the connector link have aplastic socket-type bushing on each end. Each of thesocket-type bushings are snap-fit over their respec-tive ball studs.
The wiper linkage, pivots, bushings, motor, crankarm, and mounting bracket are only serviced as acomplete unit. If any part of this assembly except themotor is faulty or damaged, the entire unit must bereplaced. The wiper motor is also available as a sep-arate service item.
WIPER MOTOR
FRONTThe two-speed permanent magnet wiper motor has
an integral transmission and park switch. The motoralso contains an internal automatic resetting circuitbreaker to protect the motor from overloads. Themotor is secured to the wiper linkage and pivot mod-ule bracket with three screws and is protected by arubber boot. The wiper motor output shaft passesthrough a hole in the module bracket, where a nutsecures the wiper motor crank arm to the motor out-put shaft.
Wiper speed is controlled by current flow to theproper set of brushes. The wiper motor completes itswipe cycle when the windshield wiper switch stalk ismoved to the Off position, and parks the blades inthe lowest portion of the wipe pattern.
The windshield wiper motor cannot be repaired. Iffaulty or damaged, the entire wiper motor and bootassembly must be replaced. The wiper linkage andpivots module, which includes the wiper motor, isalso available for service.
REARThe rear wiper motor is secured on the inside of
the liftglass with a slotted bracket that fits onto agrommet under the right liftglass hinge mountingnut. The motor output shaft passes through the lift-glass, where a rubber gasket and a plastic bezel andnut unit seal and secure the output shaft to the out-side of the liftglass. The rear wiper arm is secureddirectly to the motor output shaft.
The rear wiper motor unit contains an internalpark switch. The motor also contains an automaticresetting thermal switch for overload protection.
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DESCRIPTION AND OPERATION (Continued)
The rear wiper motor cannot be repaired. If faultyr damaged, the entire rear wiper motor assemblyust be replaced.
IPER SWITCH AND WASHER SWITCH
RONTThe windshield wiper and washer switches areounted on the right side of the steering column
Fig. 1). The switch stalk is moved up or down toelect the wiper switch mode, and pulled towards theteering wheel to activate the washer system. Modelsith the intermittent wiper system also have a knobn the end of the switch stalk, which is rotated toelect the desired delay interval. The windshieldiper and washer switch contains circuitry for the
ollowing functions:• Windshield wipers• Intermittent wiper delay relay control and logic
if the vehicle is so equipped)• Intermittent wipe relay (if the vehicle is so
quipped)• Windshield washers.The windshield wiper and washer switch cannot be
epaired. If any function of the switch is faulty, or ifhe switch is damaged, the entire switch unit muste replaced.
EARThe single two-function rear wiper and washer
witch is installed in the instrument panel accessorywitch bezel, which is located near the bottom of thenstrument panel center bezel area, next to the asheceiver. The rear wiper and washer switch controlshe rear wiper and washer functions.
The toggle-type switch features a detent in the Onosition, and a momentary Wash position. The reariper and washer switch also has an integral illumi-ation lamp with a serviceable bulb. The switch knob
Fig. 1 Windshield Wiper Switch and Washer Switch
is pushed down to its detent to activate the rearwiper system, and down again to the momentaryposition to activate the rear washer system. Both therear wiper and rear washer motors will operate con-tinuously for as long as the switch is held in themomentary Wash position.
The rear wiper and washer switch cannot berepaired and, if faulty or damaged, the entire switchunit must be replaced.
WASHER RESERVOIRA single washer fluid reservoir is used for both the
front and rear washer systems. The washer fluid res-ervoir is secured to the inner fender shield, over theleft front wheel house in the engine compartment.
Each washer pump and motor unit has a barbednipple, which is installed through a rubber grommetseal inserted in a hole near the bottom of the reser-voir. The washer pumps are retained by an interfer-ence fit between the barbed nipple and the grommetseal, which is a light press fit.
The washer reservoir has a snap-fit filler cap witha rubber gasket. The cap hinges on and is secured toa molded-in hook formation on the reservoir behindthe filler neck.
The washer reservoir and filler cap are each avail-able for service.
WASHER PUMPThe washer pumps and motors are mounted near
the bottom of the washer reservoir. A barbed nippleon the pump housing passes through a rubber grom-met seal installed in a hole near the bottom of thereservoir. The washer pump is retained by an inter-ference fit between the barbed pump nipple and thegrommet seal, which is a light press fit.
A permanently lubricated and sealed motor is cou-pled to a rotor-type pump. Washer fluid is gravity-fedfrom the reservoir to the pump. When the motor isenergized, the pump pressurizes the washer fluidand forces it through the plumbing to the nozzles.
The washer pump and motor unit cannot berepaired. If faulty, the entire washer pump andmotor unit must be replaced.
WASHER NOZZLE AND PLUMBING
FRONTPressurized washer fluid is fed through a single
hose, attached to a barbed nipple on the front washerpump. The hose is routed to a tee fitting located nearthe rear inner hood panel reinforcement. Hoses fromthe tee fitting are routed to the two nozzles.
A check valve is located in the washer supply linenear each of the two front nozzles, which preventswasher fluid drain-back or siphoning from occurring.
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8K - 4 WIPER AND WASHER SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
he nozzles are snapped into openings in the hoodanel below the windshieldThe two washer nozzles each emit two streams ofasher fluid into the wipe pattern (Fig. 2). If the aimf the washer fluid streams is unacceptable, eachtream can be adjusted using a pin inserted in theozzle orifice to rotate the nozzle ball.
The nozzles, check valves and hose fittings cannote repaired and, if faulty or damaged, they must beeplaced.
EARPressurized washer fluid is fed through a single
ose, attached to a barbed nipple on the rear washerump. The hose is routed from the front of the vehi-le to the liftglass with the left body wire harness. Athe left rear corner of the hardtop, the hose connectso a check valve, which prevents washer fluid drain-ack or siphoning from occurring.There is also a washer hose cap attached to the
ose below the check valve (Fig. 3). When the hard-op is removed from the vehicle, the body half of theasher hose must be disconnected from the checkalve. The washer hose cap is used to plug the bodyalf of the washer hose after it is disconnected fromhe check valve.
Fig. 2 Windshield Washer Nozzles
Fig. 3 Rear Washer Hose Cap
From the check valve, another single hose is routedthrough the rear liftglass opening reinforcements ofthe hardtop to the rear wiper motor cover. Behindthe rear wiper motor cover, the hose attaches to therear washer nozzle nipple.
The fluidic rear washer nozzle and a seal areinstalled from the outside through a hole in the lift-glass near the rear wiper motor output shaft. Thenozzle is secured on the inside of the glass by a plas-tic hex nut.
The rear washer nozzle cannot be adjusted. Thenozzle, check valve, and hose fittings cannot berepaired and, if faulty or damaged, they must bereplaced.
DIAGNOSIS AND TESTING
WIPER SYSTEM
FRONTFor circuit descriptions and diagrams, refer to
8W-53 - Wipers in Group 8W - Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Check the fuse in the fuseblock module. If OK,go to Step 2. If not OK, repair the shorted circuit orcomponent as required and replace the faulty fuse.
(2) Disconnect and isolate the battery negativecable. Unplug the windshield wiper switch wire har-ness connector. Connect the battery negative cable.Turn the ignition switch to the On position. Checkfor battery voltage at the fused ignition switch out-put (run/acc) circuit cavity of the wiper switch wireharness connector. If OK, go to Step 3. If not OK,repair the open circuit to the fuseblock module asrequired.
(3) If the vehicle is equipped with the optionalintermittent wiper system and the problem beingdiagnosed involves only the pulse wipe, wipe-after-wash, or intermittent wipe modes, go to Step 4. Ifnot, go to Step 5.
(4) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Check for continuity between the ground circuit cav-ity of the wiper switch wire harness connector and agood ground. There should be continuity. If OK,
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TJ WIPER AND WASHER SYSTEMS 8K - 5
DIAGNOSIS AND TESTING (Continued)
eplace the faulty switch. If not OK, repair the openircuit to ground as required.(5) Turn the ignition switch to the Off position.isconnect and isolate the battery negative cable.emove the windshield wiper and washer switch andheck the switch continuity. See Wiper Switch andasher Switch in the Diagnosis and Testing section
f this group for the procedures. If OK, go to Step 6.f not OK, replace the faulty switch.
(6) Unplug the windshield wiper motor wire har-ess connector. Check for continuity between theround circuit cavity in the body half of the wiperotor wire harness connector and a good ground.here should be continuity. If OK, go to Step 7. If notK, repair the open circuit to ground as required.(7) Connect the battery negative cable. Turn the
gnition switch to the On position. Check for batteryoltage at the fused ignition switch output (run/acc)ircuit cavity in the body half of the wiper motor wirearness connector. If OK, go to Step 8. If not OK,epair the open circuit to the fuseblock module asequired.(8) Turn the ignition switch to the Off position.isconnect and isolate the battery negative cable.ith the windshield wiper and washer switch wire
arness connector still unplugged, check the cavitiesor each of the following circuits in the body half ofhe wiper motor wire harness connector for continu-ty to ground. In each case, there should be no conti-uity. If OK, go to Step 9. If not OK, repair the shortircuit as required.• Wiper park switch sense• Wiper switch low speed output• Wiper switch high speed output.(9) Check for continuity between the cavities in
he body half of the wiper motor wire harness con-ector and the cavities in the windshield wiper andasher switch wire harness connector for each of the
ollowing circuits. In each case, there should be con-inuity. If OK, replace the faulty wiper motor. If notK, repair the open circuit as required.• Wiper park switch sense• Wiper switch low speed output• Wiper switch high speed output.
EARFor circuit descriptions and diagrams, refer to
W-53 - Wipers in Group 8W - Wiring Diagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Check the fuse in the fuseblock module. If OK,go to Step 2. If not OK, repair the shorted circuit orcomponent as required and replace the faulty fuse.
(2) Disconnect and isolate the battery negativecable. Remove the accessory switch bezel and unplugthe wire harness connector from the rear wiper andwasher switch. Connect the battery negative cable.Turn the ignition switch to the On position. Checkfor battery voltage at the rear washer switch outputcircuit cavity of the rear wiper and washer switchwire harness connector. If OK, go to Step 3. If notOK, repair the open circuit to the fuseblock moduleas required.
(3) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Check for continuity between the ground circuit cav-ity of the rear wiper and washer switch wire harnessconnector and a good ground. There should be conti-nuity. If OK, go to Step 4. If not OK, repair the opencircuit to ground as required.
(4) Test the rear wiper and washer switch continu-ity. See Wiper Switch and Washer Switch in theDiagnosis and Testing section of this group for theprocedures. If OK, go to Step 5. If not OK, replacethe faulty switch.
(5) Remove the rear wiper motor cover and unplugthe rear wiper motor wire harness connector. Con-nect the battery negative cable. Turn the ignitionswitch to the On position. Check for battery voltageat the fused ignition switch output (run) circuit cav-ity of the rear wiper motor wire harness connector. IfOK, go to Step 6. If not OK, repair the open circuit tothe fuseblock module as required.
(6) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Check for continuity between the ground circuit cav-ity of the rear wiper motor wire harness connectorand a good ground. There should be continuity. IfOK, go to Step 7. If not OK, repair the open circuit toground as required.
(7) Check for continuity between the rear wipermotor control circuit cavity of the rear wiper motorwire harness connector and a good ground. Thereshould be no continuity. If OK, go to Step 8. If notOK, repair the short circuit as required.
(8) Check for continuity between the rear wipermotor control circuit cavities of the rear wiper motorwire harness connector and the rear wiper andwasher switch wire harness connector. There shouldbe continuity. If OK, replace the faulty rear wipermotor. If not OK, repair the open circuit as required.
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8K - 6 WIPER AND WASHER SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
ASHER SYSTEM
RONTThe diagnosis found here addresses an inoperative
ront washer pump. If the washer pump operates,ut no washer fluid is emitted from the washer noz-les, be certain to check the fluid level in the reser-oir. Check for ice or other foreign material in theeservoir, and for pinched, disconnected, broken, orncorrectly routed washer system plumbing. For cir-uit descriptions and diagrams, refer to 8W-53 - Wip-rs in Group 8W - Wiring Diagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Turn the ignition switch to the On position.urn the wiper switch to the Low or High speed posi-ion. Check whether the wipers operate. If OK, go totep 2. If not OK, see the Wiper System diagnosis inhis group.
(2) Turn the ignition switch to the Off position.isconnect and isolate the battery negative cable.nplug the front washer pump wire harness connec-
or. Check for continuity between the ground circuitavity of the front washer pump wire harness connec-or and a good ground. There should be continuity. IfK, go to Step 3. If not OK, repair the open circuit toround as required.(3) Connect the battery negative cable. Turn the
gnition switch to the On position. Check for batteryoltage at the front washer switch output circuit cav-ty of the front washer pump wire harness connectorhile actuating the washer switch. If OK, replace the
aulty washer pump. If not OK, go to Step 4.(4) Turn the ignition switch to the Off position.isconnect and isolate the battery negative cable.nplug the windshield wiper/washer switch wirearness connector. Check for continuity between theront washer switch output circuit cavity of the frontasher pump wire harness connector and a goodround. There should be no continuity. If OK, go totep 5 If not OK, repair the short circuit as required.(5) Check for continuity between the front washer
witch output circuit cavities of the front washerump wire harness connector and the wiper/washerwitch wire harness connector. There should be con-inuity. If OK, replace the faulty switch. If not OK,epair the open circuit as required.
REARThe diagnosis found here addresses an inoperative
rear washer pump. If the washer pump operates, butno washer fluid is emitted from the washer nozzle, becertain to check the fluid level in the reservoir. Checkfor ice or other foreign material in the reservoir, andfor pinched, disconnected, broken, or incorrectlyrouted washer system plumbing. For circuit descrip-tions and diagrams, refer to 8W-53 - Wipers in Group8W - Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Turn the ignition switch to the On position.Place the rear wiper/washer switch in the Wipe posi-tion. Check whether the rear wiper is operating. IfOK, go to Step 2. If not OK, see the Wiper Systemdiagnosis in this group.
(2) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Unplug the rear washer pump wire harness connec-tor. Check for continuity between the ground circuitcavity of the rear washer pump wire harness connec-tor and a good ground. There should be continuity. IfOK, go to Step 3. If not OK, repair the open circuit toground as required.
(3) Connect the battery negative cable. Turn theignition switch to the On position. Check for batteryvoltage at the rear washer motor control circuit cav-ity of the rear washer pump wire harness connectorwhile the rear washer switch is actuated. If OK,replace the faulty pump. If not OK, go to Step 4.
(4) Turn the ignition switch to the Off position.Disconnect and isolate the battery negative cable.Unplug the rear wiper/washer switch wire harnessconnector. Check for continuity between the rearwasher motor control circuit cavity of the rearwasher pump wire harness connector and a goodground. There should be no continuity. If OK, go toStep 5. If not OK, repair the short circuit asrequired.
(5) Check for continuity between the rear washermotor control circuit cavities of the rear washerpump wire harness connector and the rear wiper/washer switch wire harness connector. There shouldbe continuity. If OK, replace the faulty switch. If notOK, repair the open circuit as required.
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TJ WIPER AND WASHER SYSTEMS 8K - 7
DIAGNOSIS AND TESTING (Continued)
IPER SWITCH AND WASHER SWITCH
RONTPerform the diagnosis for the front wiper system
nd/or washer system as described in this groupefore testing the front wiper and washer switch. Forircuit descriptions and diagrams, see 8W-53 - Wip-rs in Group 8W - Wiring Diagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable.(2) Remove the front wiper and washer switch
rom the steering column and unplug the wire har-ess connector from the switch.(3) Using an ohmmeter, perform the switch conti-
uity checks at the switch terminals as shown in theindshield Wiper Switch and Washer Switch Conti-
uity chart (Fig. 4).
(4) If the switch fails any of the continuity checks,eplace the faulty switch. If the switch is OK, repairhe wiper system and/or washer system wire harnessircuits as required.
Fig. 4 Windshield Wiper Switch and Washer SwitchContinuity
REARPerform the diagnosis for the rear wiper system
and/or washer system as described in this groupbefore testing the rear wiper and washer switch. Forcircuit descriptions and diagrams, see 8W-53 - Wip-ers in Group 8W - Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Remove the accessory switch bezel from theinstrument panel and unplug the rear wiper andwasher switch wire harness connector.
(2) Using an ohmmeter, check the rear wiper andwasher switch continuity at the switch terminals asshown in the Rear Wiper Switch and Washer SwitchContinuity chart (Fig. 5).
(3) If the switch fails any of the continuity checks,replace the faulty switch. If the switch is OK, repairthe rear wiper system and/or washer system wireharness circuits as required.
Fig. 5 Rear Wiper Switch and Washer SwitchContinuity
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8K - 8 WIPER AND WASHER SYSTEMS TJ
EMOVAL AND INSTALLATION
IPER BLADE
RONT
OTE: The notched retainer end of the wiper ele-ent should always be oriented towards the end of
he wiper blade that is nearest to the wiper pivot.
(1) Lift the wiper arm to raise the wiper blade andlement off of the windshield glass.(2) To remove the wiper blade from the wiper arm,
ush the release tab under the arm tip and slide thelade away from the tip towards the pivot end of therm (Fig. 6).
(3) To install the wiper blade on the wiper arm,lide the blade retainer into the U-shaped formationn the tip of the wiper arm until the release tabnaps into its locked position. Be certain that theotched retainer for the wiper element is orientedowards the end of the wiper blade that is nearest tohe wiper pivot.
EAR
OTE: The notched retainer end of the wiper ele-ent should always be oriented towards the end of
he wiper blade that is nearest to the wiper pivot.
(1) Lift the rear wiper arm to raise the wiper bladend element off of the rear liftglass.(2) To remove the wiper blade from the wiper arm,
ush the release tab under the arm tip and slide thelade away from the tip towards the rear wiperotor output shaft end of the arm (Fig. 6).(3) To install the wiper blade on the wiper arm,
lide the blade retainer into the U-shaped formationn the tip of the wiper arm until the release tabnaps into its locked position. Be certain that theotched retainer for the wiper element is orientedowards the end of the wiper blade that is nearest tohe rear wiper motor output shaft.
Fig. 6 Wiper Blade Remove/Install - Typical
WIPER ARM
CAUTION: The use of a screwdriver or other pryingtool to remove a wiper arm may distort it. This dis-tortion could allow the arm to come off of the pivotshaft, regardless of how carefully it is installed.
FRONT(1) Lift the wiper arm to permit the latch to be
pulled out to its holding position, then release thearm (Fig. 7). The arm will remain off the windshieldwith the latch in this position.
(2) Remove the arm from the pivot using a rockingmotion.
(3) Install the arm and blade with the wiper motorin the Park position. See the Front Wiper ArmInstallation illustration (Fig. 8).
(4) Mount the arms on the pivot shafts so that thetip of the wiper blade is on the upper edge of thelower windshield blackout area, + 15 mm/ – 0 mm (+0.59 in./ – 0 in.).
(5) Lift the wiper arm away from the windshieldslightly to relieve the spring tension on the latch.
Fig. 7 Wiper Arm Remove/Install
Fig. 8 Front Wiper Arm Installation
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TJ WIPER AND WASHER SYSTEMS 8K - 9
REMOVAL AND INSTALLATION (Continued)
ush the latch into the locked position and slowlyelease the arm until the wiper blade rests on theindshield.(6) Operate the wipers with the windshield glasset, then turn the wiper switch to the Off position.heck for the correct wiper arm positioning andeadjust if required.
EAR(1) Lift the wiper arm to permit the latch to be
ulled out to its holding position, then release therm (Fig. 7). The arm will remain off the liftglassith the latch in this position.(2) Remove the wiper arm from the motor output
haft using a rocking motion.(3) Install the rear wiper arm with the wiperotor in the Park position. Place the rear wiper
lade on the liftglass so that it is parallel to or tippedown from the upper edge of the liftglass a maximumf 80 mm (3.14 in.) (Fig. 9).
(4) Lift the wiper arm away from the liftglasslightly to relieve the spring tension on the latch.ush the latch into the locked position and slowlyelease the arm until the wiper blade rests on theiftglass.
(5) Operate the wiper with the liftglass wet, thenurn the wiper switch to the Off position. Check forhe correct wiper arm positioning and readjust ifequired.
IPER LINKAGE AND PIVOTThe wiper linkage and pivots can only be removed
rom or installed in the vehicle as a unit with theiper motor. See Wiper Motor in this group for the
ervice procedures.
IPER MOTOR
RONT(1) Disconnect and isolate the battery negative
able.
Fig. 9 Rear Wiper Arm Installation
(2) Remove the wiper arms from the wiper pivots.See Wiper Arm in this group for the procedures.
(3) Remove the one screw that secures the centerof the cowl plenum cover/grille panel to the cowl ple-num panel.
(4) Remove the four screws that secure the cowlplenum cover/grille panel to the cowl panel near thebase of the windshield.
(5) Open and support the hood(6) Pull each end of the cowl to hood seal away
from the metal flange where the dash panel and cowlplenum panel meet far enough to access the onescrew that secures each outboard end of the cowl ple-num cover/grille panel to the cowl plenum panel (Fig.10).
(7) Remove the one screw that secures each out-board end of the cowl plenum cover/grille panel tothe cowl plenum panel.
(8) Carefully remove the cowl plenum cover/grillepanel from the vehicle, so as not to damage the paintaround the pivot openings of the panel.
(9) Reach into the cowl plenum and unplug thewiper motor wire harness connector.
(10) Remove the three screws that secure thewiper module mounting bracket to the cowl plenumpanel (Fig. 11).
(11) Remove the wiper module from the cowl ple-num as a unit.
(12) Release the retainer that secures the wipermotor wire harness connector to the wiper modulebracket.
(13) Turn the wiper module over and remove theut that secures the wiper linkage crank arm to theiper motor output shaft.(14) Remove the three screws that secure theiper motor to the wiper module mounting bracket.(15) Remove the wiper motor from the wiper mod-
le bracket.(16) Reverse the removal procedures to install.
ighten the mounting hardware as follows:• Wiper motor screws - 6 N·m (53 in. lbs.)• Crank arm nut - 11.5 N·m (101 in. lbs.)• Wiper module bracket screws - 7.9 N·m (70 in.
EAR(1) Disconnect and isolate the battery negative
able.(2) From the outside of the liftglass, remove the
ear wiper arm from the rear wiper motor outputhaft. See Wiper Arm in this group for the proce-ures.(3) From the outside of the liftglass, remove the
ear wiper motor output shaft nut and bezel unitFig. 12).
(4) From the outside of the liftglass, remove theear wiper motor output shaft rubber gasket.(5) From the inside of the liftglass, remove the
hree screws that secure the rear wiper motor covero the motor.
(6) Unplug the rear wiper motor wire harness con-ector.
Fig. 11 Wiper Module Assembly Remove/Install
(7) Loosen, but do not remove, the right liftglasshinge nut.
(8) From the inside of the liftglass, gently pull therear wiper motor away from the liftglass until theoutput shaft clears the hole in the liftglass.
(9) Move the motor towards the right side of thevehicle until the slotted hole in the motor mountingbracket clears the grommet under the right liftglasshinge nut.
(10) Remove the rear wiper motor from the vehi-cle.
(11) Reverse the removal procedures to install.Tighten the mounting hardware as follows:
• Liftglass hinge nut - 6 N·m (53 in. lbs.)• Wiper motor cover screws - 1.1 N·m (10 in. lbs.).
WIPER SWITCH AND WASHER SWITCH
FRONT
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Disconnect and isolate the battery negativecable.
(2) Remove the knee blocker from the instrumentpanel. See Knee Blocker in Group 8E - InstrumentPanel Systems for the procedures.
(3) Remove the three screws that secure the lowersteering column shroud to the upper shroud (Fig. 13).
Fig. 12 Rear Wiper and Washer System
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TJ WIPER AND WASHER SYSTEMS 8K - 11
REMOVAL AND INSTALLATION (Continued)
(4) If the vehicle is equipped with a standard non-ilt steering column, loosen the two upper steeringolumn mounting nuts. If the vehicle is equippedith the optional tilt steering column, move the tilt
teering column to the fully lowered position.(5) Remove both the upper and lower shrouds from
he steering column.(6) Remove the two screws that secure the switchater shield and bracket to the top of the steering
olumn (Fig. 14).
Fig. 13 Steering Column Shrouds Remove/Install
Fig. 14 Water Shield Upper Screws Remove/Install
(7) Remove the one screw located below the multi-function switch lever that secures the switch watershield and bracket to the steering column (Fig. 15).
(8) Gently pull the lower mounting tab of theswitch water shield bracket away from the steeringcolumn far enough to clear the screw boss below themulti-function switch lever.
(9) Lift the water shield and bracket with themulti-function switch off of the left side of the steer-ing column as a unit and move it out of the way. Ifthe vehicle is equipped with the optional tilt steeringcolumn, lifting gently upward on the tilt release leverwill provide additional clearance to ease multi-func-tion switch removal.
(10) Gently pull the windshield wiper and washerswitch up and away from the right side of the steer-ing column far enough to access the wire harnessconnector.
(11) Unplug the wire harness connector from thewindshield wiper and washer switch.
(12) Remove the windshield wiper and washerswitch from the steering column.
(13) Reverse the removal procedures to install.Tighten the upper switch mounting screws to 2.2N·m (20 in. lbs.). Tighten the lower switch watershield and bracket screw to 1.1 N·m (10 in. lbs.).Tighten the non-tilt steering column mounting nutsto 22 N·m (200 in. lbs.) and the steering columnshroud mounting screws to 2 N·m (18 in. lbs.).
Fig. 15 Water Shield Lower Screw Remove/Install
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8K - 12 WIPER AND WASHER SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
EAR
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable.(2) Remove the center bezel from the instrument
anel. See Instrument Panel Center Bezel in GroupE - Instrument Panel Systems for the procedures.(3) Remove the four screws that secure the acces-
ory switch bezel to the instrument panel (Fig. 16).
(4) Pull the accessory switch bezel out from thenstrument panel far enough to access the wire har-ess connectors.(5) Unplug the wire harness connectors from the
ear of the accessory switches and the cigar lighter/ower outlet.(6) Remove the accessory switch bezel from the
nstrument panel.(7) With a small thin-bladed screwdriver, gently
ry the snap clips at the top and bottom of the reariper and washer switch receptacle on the back of
he accessory switch bezel and pull the switch out ofhe bezel.
(8) Reverse the removal procedures to install. Beertain that both of the switch snap clip retainers inhe receptacle on the back of the accessory switch
Fig. 16 Accessory Switch Bezel Remove/Install
bezel are fully engaged. Tighten the mounting screwsto 2.2 N·m (20 in. lbs.).
WASHER SYSTEM
WASHER RESERVOIR(1) Disconnect and isolate the battery negative
cable.(2) Remove the three screws that secure the
washer reservoir to the inner fender (Fig. 17).
(3) Lift the reservoir far enough to access thewasher pump(s).
(4) Remove the washer supply hose(s) from thewasher pump(s) and drain the washer fluid from thereservoir into a clean container for reuse.
(5) Unplug the wire harness connector(s) from thewasher pump(s).
(6) Remove the washer reservoir from the vehicle.(7) Reverse the removal procedures to install.
Tighten the reservoir mounting screws to 4 N·m (35in. lbs.).
WASHER PUMP(1) Disconnect and isolate the battery negative
cable.(2) Remove the washer supply hose(s) from the
barbed outlet nipple of the washer pump(s) and drainthe washer fluid from the reservoir into a clean con-tainer for reuse.
(3) Unplug the wire harness connector(s) from thewasher pump(s).
(4) Using a trim stick or another suitable wide
Fig. 17 Washer Reservoir Remove/Install
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TJ WIPER AND WASHER SYSTEMS 8K - 13
REMOVAL AND INSTALLATION (Continued)
he washer pump out of the rubber grommet seal inhe reservoir. Care must be taken not to damage theeservoir.(5) Remove the rubber grommet seal from the res-
rvoir and discard.(6) Reverse the removal procedures to install.lways use a new rubber grommet seal on the reser-oir.
ASHER NOZZLE
RONT(1) Open and support the hood.(2) From under the rear of the hood, disconnect
he washer supply hose from the barbed nipple of theasher nozzle (Fig. 18).
(3) From under the rear of the hood, gentlyqueeze the nozzle retainers and push the nozzle outhrough the top of the hood panel.
(4) Reverse the removal procedures to install. Seeasher Nozzles and Plumbing in this group for the
ozzle adjustment procedures.
EAR(1) Disconnect and isolate the battery negative
able.(2) From the inside of the liftglass, remove the
hree screws that secure the rear wiper motor covero the motor (Fig. 19).
(3) Remove the rear wiper motor cover.(4) Disconnect the washer supply hose from the
arbed rear washer nozzle nipple.(5) While holding the nozzle securely from the out-
ide of the liftglass, remove the plastic nut that
Fig. 18 Front Washer Nozzles Remove/Install
secures the threaded nozzle nipple from the inside ofthe liftglass.
(6) Push the nozzle and seal out through the lift-glass from the inside.
(7) Reverse the removal procedures to install.Tighten the washer nozzle nut to 0.9 N·m (8 in. lbs.).
CHECK VALVEA check valve is located under the hood in the
washer supply line near each of the front washernozzles. Models with the optional rear washer systemalso have a check valve in the washer supply line inthe left rear pillar of the hardtop, near where thehardtop joins the vehicle body.
(1) Disconnect the washer supply hoses from thebarbed nipples on each end of the front or rearwasher system check valve.
(2) Remove the check valve from the vehicle.(3) When reinstalling the check valve, be certain
the valve is properly oriented within the system flow(Fig. 20).
(4) Reverse the remaining removal procedures tocomplete the installation.
ENERAL INFORMATIONEach vehicle is equipped with various lamp assem-
lies. A good ground is necessary for proper lightingperation. Grounding is provided by the lamp sockethen it comes in contact with the metal body, or
hrough a separate ground wire.When changing lamp bulbs check the socket for
orrosion. If corrosion is present, clean it with a wirerush and coat the inside of the socket lightly withopar Multi-Purpose Grease or equivalent.
AFETY PRECAUTIONS
ARNING: EYE PROTECTION SHOULD BE USEDHEN SERVICING GLASS COMPONENTS. PER-ONAL INJURY CAN RESULT.
AUTION: Do not touch the glass of halogen bulbsith fingers or other possibly oily surface, reducedulb life will result.Do not use bulbs with higher candle power than
this group. Damage to lamp and/or Daytime Run-ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-ing greater amperage value than indicated on thefuse panel or in the Owners Manual.
When it is necessary to remove components to ser-vice another, it should not be necessary to applyexcessive force or bend a component to remove it.Before damaging a trim component, verify hiddenfasteners or captured edges are not holding the com-ponent in place.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURESWhen a vehicle experiences problems with the
headlamp system, verify the condition of the batteryconnections, fuses, charging system, headlamp bulbs,wire connectors, relay, high beam dimmer switch andheadlamp switch. Refer to Group 8W, Wiring Dia-grams for component locations and circuit informa-tion.
H
8L - 2 LAMPS TJ
DIAGNOSIS AND TESTING (Continued)
EADLAMP
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIMWITH ENGINE IDLING
1. Loose or corroded battery cables. 1. Clean and secure battery cable clampsand posts.
OR IGNITION TURNEDOFF
2. Loose or worn generator drivebelt.
2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer toGroup 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge, refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-groundlocations, refer to Group 8W.
7. Both headlamp bulbs defective. 7. Replace both headlamp bulbs.
HEADLAMP BULBS BURNOUT
1. Charging system output too high. 1. Test and repair charging system, refer toGroup 8A.
FREQUENTLY 2. Loose or corroded terminals orsplices in circuit.
2. Inspect and repair all connectors andsplices, refer to Group 8W.
HEADLAMPS ARE DIMWITH ENGINE RUNNING
1. Charging system output too low. 1. Test and repair charging system, refer toGroup 8A.
ABOVE IDLE* 2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-groundlocations, refer to Group 8W.
3. High resistance in headlampcircuit.
3. Test amperage draw of headlamp circuit.
4. Both headlamp bulbs defective. 4. Replace both headlamp bulbs.
HEADLAMPS FLASHRANDOMLY
1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-groundlocations, refer to Group 8W.
2. High resistance in headlampcircuit.
2. Test amperage draw of headlamp circuit.Should not exceed 30 amps.
3. Faulty headlamps switch circuitbreaker.
3. Replace headlamp switch.
4. Loose or corroded terminals orsplices in circuit.
4. Inspect and repair all connectors andsplices, refer to Group 8W.
HEADLAMPS DO NOTILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit, refer toGroup 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Group 8W.
1. Secure connector on DRLmodule.2. Disengage parking brake.3. Check voltage on pin 3 ofmodule, refer to Group 8W.4. Check L3 circuit, refer to Group8W.5. Replace DRL module.
EADLAMP ALIGNMENTHeadlamps can be aligned using the screen method
rovided in this section. Alignment Tool C-4466-A orquivalent can also be used. Refer to instructionsrovided with the tool for proper procedures.
ERVICE PROCEDURES
AMP ALIGNMENT SCREEN PREPARATION(1) Position vehicle on a level surface perpendicu-
ar to a flat wall 7.62 meters (25 ft) away from frontf headlamp lens (Fig. 1).(2) If necessary, tape a line on the floor 7.62eters (25 ft) away from and parallel to the wall.(3) Measure from the floor up 1.27 meters (5 ft)
vehicle. Sight along the centerline of the vehicle(from rear of vehicle forward) to verify accuracy ofthe line placement.
(4) Rock vehicle side-to-side three times to allowsuspension to stabilize.
(5) Jounce front suspension three times by pushingdownward on front bumper and releasing.
(6) Measure the distance from the center of head-lamp lens to the floor. Transfer measurement to thealignment screen (with tape). Use this line forup/down adjustment reference.
(7) Measure distance from the centerline of thevehicle to the center of each headlamp being aligned.Transfer measurements to screen (with tape) to eachside of vehicle centerline. Use these lines for left/right adjustment reference.
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8L - 6 LAMPS TJ
SERVICE PROCEDURES (Continued)
EHICLE PREPARATION FOR HEADLAMPLIGNMENT(1) Verify headlamp dimmer switch and high beam
ndicator operation.(2) Correct defective components that could hinder
roper headlamp alignment.(3) Verify proper tire inflation.(4) Clean headlamp lenses.(5) Verify that luggage area is not heavily loaded.(6) Fuel tank should be FULL. Add 2.94 kg (6.5
bs.) of weight over the fuel tank for each estimatedallon of missing fuel.
EADLAMP ADJUSTMENT(1) Place headlamps on LOW beam.(2) Cover front of the headlamp that is not being
djusted.(3) Turn the upper, outboard (up/down) adjustment
crew (Fig. 2) until the headlamp beam pattern oncreen/wall is similar to the pattern depicted in (Fig.).
OTE: When using a headlamp aiming screen:
• Adjust the headlamps so that the beam horizon-al position is at 0.
Fig. 1 Headlamp Align
• Adjust the beam vertical position is 25 mm (1in) downward from the lamp horizontal centerline.
(4) Rotate the lower, inboard (left/right) adjust-ment screw (Fig. 2) until the headlamp beam patternon the aiming screen/wall similar to the pattern in(Fig. 1).
(5) Cover front of the headlamp that has beenadjusted and adjust the other headlamp beam asinstructed above.
t Screen—Typical
Fig. 2 Headlamp Adjustment Screws
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TJ LAMPS 8L - 7
SERVICE PROCEDURES (Continued)
OG LAMP ADJUSTMENTPrepare an alignment screen. A properly aligned
og lamp will project a pattern on the alignmentcreen 100 mm (4 in.) below the fog lamp centerlinend straight ahead (Fig. 3).(1) Loosen the nut attaching the fog lamp to theounting bracket (Fig. 4).(2) Move the fog lamp to adjust beam height.
Fig. 3 Fog Lamp A
Fig. 4 Fog Lamp Adjustment
(3) Tighten the nut attaching the fog lamp to themounting bracket.
EADLAMP BULBThe headlamp is a sealed unit. Refer to the Head-
amp Removal/Installation procedure located in theamp Service section of this group.
OG LAMP BULB
EMOVAL(1) Remove the screws that attach the reflector to
he lamp housing.(2) Separate the reflector from the lamp housing.(3) Squeeze the bulb retainer together to disengage
t from the reflector.(4) Remove the bulb/element from the reflector
Fig. 1).(5) Disconnect the electrical connector.
NSTALLATION
AUTION: Do not touch the bulb glass with fingersr other oily surfaces. Reduced bulb life will result.(1) Connect the electrical connector.
Fig. 1 Fog Lamp Bulb
(2) Position the bulb/element in the reflector.(3) Engage the bulb retainer.(4) Position the reflector in the lamp housing.(5) Install the screws that attach the reflector to
the lamp housing.
FRONT PARK/TURN SIGNAL LAMP BULB
REMOVAL(1) Remove the park/turn signal lamp bulb socket
via the underside of the fender.(2) Rotate the bulb socket one-third turn counter-
clockwise and separate it from the lamp housing.(3) Pull the bulb straight out of the socket.
INSTALLATION(1) Install the bulb in the socket.(2) Install the bulb and socket in the lamp hous-
ing.
SIDE MARKER LAMP BULB
REMOVAL(1) Remove side marker bulb socket via the under-
side of the fender. Rotate it one-third turn counter-clockwise and separate it from the side marker lamphousing.
(2) Remove the bulb from the socket by pulling itstraight outward.
INSTALLATION(1) Install a replacement bulb in the socket.(2) Install the bulb and socket in the side marker
lamp housing.
TAIL/TURN SIGNAL/BACK-UP LAMP BULB
REMOVAL(1) Remove the screws attaching the lens to the
tail lamp housing (Fig. 2).(2) Separate the lens from the tail lamp housing.
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REMOVAL AND INSTALLATION (Continued)
(3) Push the bulb inward and rotate counter-clock-ise.(4) Remove the bulb from the lamp socket.
NSTALLATION(1) Install a replacement bulb in the lamp socket.(2) Position the lens on the lamp housing.(3) Install the screws. Tighten the screws securely.
ACK-UP LAMP BULBThe back-up lamp bulb is located with-in the tail
amp. Refer to the Tail Lamp Bulb Removal/Installa-ion procedure.
ENTER HIGH MOUNTED STOP LAMPCHMSL) BULB
EMOVAL(1) Remove the screws attaching the CHMSL lens
o the CHMSL (Fig. 3).(2) Rotate the bulb socket one third turn counter-
lockwise and separate from lamp housing.(3) Pull the bulb straight out of the socket.
NSTALLATION(1) Install the bulb.(2) Position the lens on the CHMSL and install the
crews.
NDERHOOD LAMP BULB
EMOVAL(1) Insert a small flat blade in the access slot
etween the lamp base and lamp lens.(2) Pry the lamp lens upward and remove the
amp lens (Fig. 4).(3) Depress the bulb terminal inward (Fig. 5) to
elease the bulb.
Fig. 2 Lens Removal
INSTALLATION(1) Engage the replacement bulb wire loop to the
terminal closest to the lamp base wire connector.
Fig. 3 CHMSL Bulb
Fig. 4 Underhood Lamp Lens
Fig. 5 Underhood Lamp Bulb
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8L - 10 LAMPS TJ
REMOVAL AND INSTALLATION (Continued)
(2) Depress the opposite terminal inward andngage the remaining bulb wire loop.(3) Position the lamp lens on the lamp base and
ress into place.
OME LAMP
OUND BAR DOME LAMP BULB REMOVAL(1) Insert a small flat blade between the lamp
ousing and lamp lens. Carefully pry lamp lens toisengage lens retaining tabs.(2) Separate lens from lamp housing.(3) Grasp bulb and pull from lamp.
OUND BAR DOME LAMP BULB INSTALLATION(1) Position bulb in lamp socket and press into
lace.(2) Position lamp lens on lamp housing and press
nto place.
ARGO AREA DOME LAMP BULB REMOVAL(1) Remove the dome/cargo lamp lens by squeezing
t at the lens at the top and bottom (Fig. 6). This willeparate the lens retaining tabs from the lamp hous-ng shoulders.
(2) Remove the lens from the lamp housing.(3) Pull the bulb straight out to remove from the
bulb holder.
CARGO AREA DOME LAMP BULB INSTALLATION(1) Insert the replacement bulb in the bulb holder.(2) Position lens at the lamp housing and press
into the housing until the retainer tabs are seated.
Fig. 6 Cargo Area Dome Lamp
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LAMP SERVICE
INDEX
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EMOVAL AND INSTALLATIONCENTER HIGH MOUNTED STOP LAMP
EMOVAL(1) Remove the screws that attach the headlamp
ezel (Fig. 1).(2) Remove the screws that attach the headlamp
etaining ring (Fig. 2).(3) Disconnect the headlamp wire harness connec-
or and remove the bulb from the bucket (Fig. 3).
NSTALLATION(1) Connect the wire harness connector and posi-
ion the bulb in the bucket.(2) Position retaining ring on the headlamp bulb
nd install screws.(3) Install the headlamp bezel. Tighten the screws
ecurely.
OG LAMP
EMOVAL(1) Disconnect the fog lamp wire harness connec-
or.
Fig. 1 Headlamp Bezel
(2) Remove the nut attaching the fog lamp to thefront bumper.
(3) Separate the fog lamp from the bumper.
INSTALLATION(1) Position the fog lamp on the bumper.(2) Install the nut attaching the fog lamp to the
front bumper.
Fig. 2 Headlamp Retaining Ring
Fig. 3 Headlamp Connector
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REMOVAL AND INSTALLATION (Continued)
(3) Connect the fog lamp wire harness connector.
RONT PARK/TURN SIGNAL LAMP
EMOVAL(1) Remove the park/turn signal lamp housing
crews (Fig. 4).(2) Separate the park/turn signal lamp housing
rom the fender.(3) Rotate bulb socket one third turn counter-clock-ise and separate bulb socket from lamp.
NSTALLATION(1) Install the bulb socket in the lamp housing.(2) Position the park/turn signal lamp housing in
he fender.(3) Install the park/turn signal lamp housing
crews.
IDE MARKER LAMP
EMOVAL(1) From underside of the fender, remove nut
ttaching marker lamp to fender.(2) Separate lamp from fender.(3) Rotate bulb socket one-third turn counter-clock-ise and separate socket from lamp housing.
NSTALLATION(1) Position bulb socket in lamp housing and
otate bulb socket one-third turn clockwise.(2) Position lamp in fender.(3) Install nut attaching marker lamp to fender.
Fig. 4 Park/Turn Signal Lamp
TAIL/STOP/TURN SIGNAL/BACK-UP LAMP
REMOVAL(1) From the underside of the vehicle, remove the
push-in fastener attaching the bottom rear edge ofthe rear wheelhouse splash shield to the body.
(2) Pull the rear of the wheelhouse splash shieldaway from the body and reach upward to disengagethe tail lamp electrical connector.
(3) Remove the screws attaching the lens to thetail lamp housing.
(4) Remove the bolts attaching the tail lamp hous-ing to the body (Fig. 5).
(5) Separate the lamp housing from the body.
INSTALLATION(1) Engage the electrical connector.(2) Install the push-in fastener attaching the bot-
tom rear edge of the rear wheelhouse splash shield tothe body.
(3) Position the lamp housing on the body.(4) Install the bolts attaching the tail lamp hous-
ing to the body.(5) Install the screws attaching the lens to the tail
(2) Separate lens from lamp.(3) Remove the screws attaching the lamp to the
sound bar (Fig. 8).(4) Disengage lamp electrical connector.
SOUND BAR DOME LAMP INSTALLATION(1) Engage lamp electrical connector.(2) Position lamp in sound bar.(3) Install the screws attaching the lamp to the
sound bar.(4) Position lamp lens on lamp housing and press
into place.
CARGO AREA DOME LAMP REMOVALVehicles equipped with a hardtop have a dome
lamp located above the rear window lift glass.(1) Remove the dome/cargo lamp lens by squeezing
it at the top and bottom. This will separate the lensretaining tabs from the lamp housing shoulders.
(2) Remove the lens from the lamp housing.(3) Remove the bulb.(4) Remove the screws that attach the lamp to the
hardtop.(5) Separate the lamp from the hardtop.
Fig. 7 Underhood Lamp
8L - 14 LAMPS TJ
REMOVAL AND INSTALLATION (Continued)
(6) Disconnect the lamp wire connector.
Fig. 8 Sound Bar Dome Lamp
CARGO AREA DOME LAMP INSTALLATION(1) Connect the lamp wire connector.(2) Position the lamp in the hardtop.(3) Install the screws that attach the lamp to the
hardtop.(4) Install the bulb.(5) Position the lens on the lamp housing and
press into place.
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LAMP SYSTEMS
INDEX
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ENERAL INFORMATION DAYTIME RUNNING LIGHTS (CANADA ONLY) . . 15
(2) Install the screws.
EMOVAL AND INSTALLATION
DAYTIME RUNNING LAMP (DRL) MODULE . . . . 15
ENERAL INFORMATION
AYTIME RUNNING LIGHTS (CANADA ONLY)The Daytime Running Lights (Headlamps) System
s installed on vehicles manufactured for sale in Can-da only. The headlamps are illuminated when thegnition switch is turned to the ON position. TheRL module receives a vehicle-moving signal from
he vehicle speed sensor. This provides a constanteadlamps-on condition as long as the vehicle isoving. The lamps are illuminated at less than 50
ercent of normal intensity.
EMOVAL AND INSTALLATION
AYTIME RUNNING LAMP (DRL) MODULE
EMOVAL(1) Disconnect the wire harness connector from theodule.(2) Remove the screws that attach the module to
he cowl (Fig. 1).(3) Separate the module from the vehicle.
NSTALLATION(1) Position the DRL module on the cowl.
(3) Connect the wire harness connector to the mod-ule.
CAUTION: Do not use bulbs that have a higher can-dle power than the bulb listed in the Bulb Applica-tion Table. Damage to lamp can result.
Service procedures for most of the lamps in theinstrument panel, Instrument cluster and switchesare located in Group 8E, Instrument Panel andGauges. Some components have lamps that can onlybe serviced by an Authorized Service Center (ASC)after the component is removed from the vehicle.
The following Bulb Application Table lists the lamptitle on the left side of the column and trade numberor part number on the right.
ENERAL INFORMATIONEach vehicle is equipped with varies lamp assem-
lies. A good ground is necessary for proper lightingperation. Grounding is provided by the lamp sockethen it comes in contact with the metal body, or
hrough a separate ground wire.When changing lamp bulbs check the sockets for
orrosion. If corrosion is present, clean it with a wirerush and coat the inside of the socket lightly withopar Multi-Purpose Grease or equivalent.
AFETY PRECAUTIONS
ARNING: EYE PROTECTION SHOULD BE USEDHEN SERVICING GLASS COMPONENTS. PER-ONAL INJURY CAN RESULT.
AUTION: Do not touch the glass of halogen bulbsith fingers or other possibly oily surfaces,
Do not use bulbs with higher candle power thanindicated in the Bulb Application Table at the end ofthis group. Damage to lamp can result.
Do not use fuses, circuit breakers or relays hav-ing greater amperage value than indicated on thefuse panel or in the Owners Manual.
When it necessary to remove components to serviceanother, it should not be necessary to apply excessiveforce or bend a component to remove it. Before dam-aging a trim component, verify hidden fasteners orcaptured edges are not holding the component inplace.
HEADLAMP LEVELING MOTORThis vehicle is equipped with a remote headlamp
leveling system. This system allows the driver toadjust the vertical headlamp aim from the interior ofthe vehicle to compensate for passenger or cargoload. A headlamp leveling switch is located in theinstrument panel and controls the headlamp levelingmotor found on the back of the head lamp assembly.
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IAGNOSIS AND TESTING
IAGNOSTIC PROCEDURESWhen a vehicle experiences problems with the head-
amp system, verify the condition of the battery connec-
ions, charging system, headlamp bulbs, wireonnectors, relay, high beam dimmer switch and head-amp switch. Refer to Group 8W, Wiring Diagrams, foromponent locations and circuit information.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS AREDIM WITH ENGINEIDLING ORIGNITION TURNEDOFF
1. Loose or corroded battery cables. 1. Clean and secure battery cable clampsand posts.
2. Loose or worn alternator drive belt. 2. Adjust or replace alternator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer toGroup 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer toGroup 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-groundlocations. Refer to Group 8W.
HEADLAMP BULBSBURN OUTFREQUENTLY
1. Charging system output too high. 1. Test and repair charging system. Refer toGroup 8A.
2. Loose or corroded terminals or splices incircuit.
2. Inspect and repair all connectors andsplices. Refer to Group 8W.
HEADLAMPS AREDIM WITH ENGINERUNNING ABOVEIDLE
1. Charging system output too low. 1. Test and repair charging system. Refer toGroup 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-groundlocations. Refer to Group 8W.
3. High resistance in headlamp circuit. 3. Test amperage draw of headlamp circuit.
HEADLAMPSFLASH RANDOMLY
1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-groundlocations, refer to Group 8W.
2. High resistance in headlamp circuit. 2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or splices incircuit.
3. Inspect and repair all connectors andsplices. Refer to Group 8W.
HEADLAMPS DONOT ILLUMINATE
1. No voltage to headlamps. 1. Repair open headlamp circuit. Refer toGroup 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground. Refer to Group8W.
EMOVAL(1) Remove the headlamp bezel attaching screws
Fig. 1).(2) Remove the headlamp assembly retaining ring
ttaching screws (Fig. 2).(3) Disconnect the headlamp assembly electrical
onnectors and remove the headlamp assembly fromhe bucket.
nstallation(1) Perform the removal procedure in reverse order.
EADLAMP LEVELING MOTOR
EMOVAL(1) Remove the headlamp bezel attaching screws
nd bezel (Fig. 3).(2) Disconnect the headlamp and headlamp level-
ng motor electrical connectors.(3) Remove the headlamp housing attaching
crews (Fig. 4).(4) Rotate leveling motor one quarter turn counter-
lockwise.
Fig. 1 Headlamp Bezel
(5) Pull the leveling motor from the headlamphousing.
(6) Separate the leveling motor from the headlamphousing (Fig. 5).
NOTE: The headlamp leveling motor arm issnapped into the headlamp housing very securely.Use a firm, steady pull to disengage motor armfrom the headlamp housing.
Fig. 2 Headlamp Retaining Ring
Fig. 3 Headlamp Bezel
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REMOVAL AND INSTALLATION (Continued)
NSTALLATION(1) Perform the removal procedure in reverse
rder.
AIL LAMP
EMOVAL(1) Remove the tail lamp lense attaching screws
nd lense (Fig. 6).
Fig. 4 Headlamp Housing
Fig. 5 Headlamp Leveling Motor
(2) Remove the tail lamp housing attaching bolts(Fig. 7).
(3) Separate the lamp housing from the body.(4) Disconnect the tail lamp electrical connector
and remove tail lamp housing.
INSTALLATION(1) Perform the removal procedure in reverse
order.
Fig. 6 Tail Lamp Lense
Fig. 7 Tail Lamp Housing
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8L - 10 LAMPS TJ
REMOVAL AND INSTALLATION (Continued)
ENTER HIGH MOUNTED STOP LAMPCHMSL)
EMOVAL
OTE: It may be necessary to remove the spareire.
(1) Remove the CHMSL housing to CHMSLracket attaching screws.(2) Disconnect the CHMSL wire harness from the
etaining clips.(3) Remove the cover from the CHMSL contact
uttons.(4) Carefully pull the wire harness terminal ends
rom the contact buttons (Fig. 8).(5) Route wire harness through tailgate and sepa-
ate CHMSL from vehicle.
NSTALLATION(1) Perform the removal procedure in reverse
rder.
EAR FOG LAMP
EMOVAL(1) Remove the rear fog lamp attaching screw (Fig.
).(2) Disconnect the rear fog lamp electrical connec-
or.
NSTALLATION(1) Perform the removal procedure in reverse
ENERAL INFORMATION(1) The following bulb Application tables lists the
amp title on the left side of the column and tradeumber on the right.
AUTION: Do not use bulbs that have a higher can-le power the bulb listed in the Bulb Applicationable. Damage to lamp can result. Do not touchalogen bulbs with fingers or other oily surfaces.ulb life will be reduced.
INTERIOR LAMPSService procedures for most of the lamps in the
instrument panel, Instrument cluster and switchesare located in Group 8E, Instrument panel andGauges. Some components have lamps than can onlybe serviced by an Authorized Service Center (ASC)after the component is removed from the vehicle.Contact a local dealer for location of nearest ASC.
ESCRIPTIONA dual front airbag system is standard factory-in-
talled safety equipment on this model. The primaryassenger restraints in this vehicle are the standardquipment factory-installed seat belts, which requirective use by the vehicle occupants. The airbag sys-em is a supplemental passive restraint that wasesigned and is intended to enhance the protectionor the front seat occupants of the vehicle only whensed in conjunction with the seat belts. See the own-r’s manual in the vehicle glove box for more infor-ation on the features, use and operation of all of
he factory-installed passenger restraints, includinghe airbag system.
The dual front airbag system consists of the follow-ng components:
• Airbag Control Module (ACM)• Airbag indicator lamp• Clockspring• Driver and passenger side airbag modules
including the airbag inflators)• Driver and passenger side knee blockers• Passenger side airbag on/off switch• Wire harness and connections.This group provides complete service information
or the ACM, both airbag modules, the clockspring,nd the passenger side airbag on/off switch. Com-
plete service information for the other airbag systemcomponents can be located as follows:
• Refer to Instrument Cluster in the proper sec-tion of Group 8E - Instrument Panel Systems forcomplete service information for the airbag indicatorlamp.
• Refer to Knee Blocker in the Removal andInstallation section of Group 8E - Instrument PanelSystems for complete service information on thedriver side knee blocker.
• Refer to Glove Box in the Removal and Instal-lation section of Group 8E - Instrument Panel Sys-tems for complete service information on thepassenger side knee blocker.
• Refer to Airbag System in the Contents ofGroup 8W - Wiring Diagrams for complete serviceinformation and circuit diagrams for the airbag sys-tem wiring components.
See the proper Diagnostic Procedures manual totest or diagnose a problem with any component ofthe airbag system.
OPERATIONThe airbag system electrical circuits are continu-
ously monitored and controlled by a microprocessorand software contained within the Airbag ControlModule (ACM). The ACM also contains an impactsensor and a safing sensor, which are monitored bythe ACM to determine when an impact occurs that issevere enough to require airbag system protection.When a frontal impact is severe enough, the ACM
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8M - 2 PASSIVE RESTRAINT SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
ignals the inflator units of both airbag modules toeploy the airbags.An airbag indicator lamp in the instrument cluster
ights for about seven seconds as a bulb test, eachime the ignition switch is turned to the On or Startositions. Following the bulb test, the airbag indica-or lamp is turned on or off by the ACM to indicatehe status of the airbag system. If the airbag indica-or lamp comes on at any time other than during theulb test, it indicates that there is a problem in theirbag system circuits. Such a problem may causehe airbags not to deploy when required, or to deployhen not required.The driver side airbag module includes an inflat-
ble airbag and an inflator unit behind a trim covern the hub area of the steering wheel. The passengeride airbag module includes a second inflatable air-ag and an inflator unit behind an airbag door in thenstrument panel above the glove box.
During a frontal vehicle impact, the knee blockersork in concert with properly adjusted seat belts to
estrain the driver and front seat passenger in theroper position for an airbag deployment. The kneelockers also work to absorb and distribute the crashnergy from the driver and front seat passenger tohe structure of the instrument panel. The driveride knee blocker is a stamped metal reinforcementocated behind the instrument panel steering columnpening cover. The passenger side knee blocker isntegral to the glove box door.
Following are general descriptions of the majoromponents in the airbag system.
ARNING:• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
LEX ELECTROMECHANICAL UNIT. BEFORETTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-AG SYSTEM OR RELATED STEERING WHEEL,TEERING COLUMN, OR INSTRUMENT PANELOMPONENTS YOU MUST FIRST DISCONNECTND ISOLATE THE BATTERY NEGATIVE (GROUND)ABLE. THEN WAIT TWO MINUTES FOR THE SYS-EM CAPACITOR TO DISCHARGE BEFORE FUR-HER SYSTEM SERVICE. THIS IS THE ONLY SUREAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
O DO THIS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.• THE DRIVER SIDE AIRBAG MODULE INFLATOR
SSEMBLY CONTAINS SODIUM AZIDE AND POTAS-IUM NITRATE. THESE MATERIALS ARE POISON-US AND EXTREMELY FLAMMABLE. CONTACTITH ACID, WATER, OR HEAVY METALS MAY PRO-UCE HARMFUL AND IRRITATING GASES (SODIUMYDROXIDE IS FORMED IN THE PRESENCE OFOISTURE) OR COMBUSTIBLE COMPOUNDS. THEASSENGER AIRBAG MODULE CONTAINS ARGON
GAS PRESSURIZED TO OVER 2500 PSI. DO NOTATTEMPT TO DISMANTLE AN AIRBAG MODULE ORTAMPER WITH ITS INFLATOR. DO NOT PUNCTURE,INCINERATE, OR BRING INTO CONTACT WITHELECTRICITY. DO NOT STORE AT TEMPERATURESEXCEEDING 93° C (200° F).
• REPLACE AIRBAG SYSTEM COMPONENTSONLY WITH PARTS SPECIFIED IN THE CHRYSLERMOPAR PARTS CATALOG. SUBSTITUTE PARTSMAY APPEAR INTERCHANGEABLE, BUT INTERNALDIFFERENCES MAY RESULT IN INFERIOR OCCU-PANT PROTECTION.
• THE FASTENERS, SCREWS, AND BOLTS ORIG-INALLY USED FOR THE AIRBAG SYSTEM COMPO-NENTS HAVE SPECIAL COATINGS AND ARESPECIFICALLY DESIGNED FOR THE AIRBAG SYS-TEM. THEY MUST NEVER BE REPLACED WITH ANYSUBSTITUTES. ANY TIME A NEW FASTENER ISNEEDED, REPLACE IT WITH THE CORRECT FAS-TENERS PROVIDED IN THE SERVICE PACKAGE ORSPECIFIED IN THE CHRYSLER MOPAR PARTS CAT-ALOG.
• WHEN A STEERING COLUMN HAS AN AIRBAGMODULE ATTACHED, NEVER PLACE THE COLUMNON THE FLOOR OR ANY OTHER SURFACE WITHTHE STEERING WHEEL OR AIRBAG MODULE FACEDOWN.
DRIVER SIDE AIRBAG MODULE
DESCRIPTIONThe driver side airbag module protective trim cover
is the most visible part of the driver side airbag sys-tem. The driver side airbag module is mounteddirectly to the steering wheel. Located under the air-bag module trim cover are the horn switch, thefolded airbag cushion, and the airbag cushion sup-porting components. The resistive membrane-typehorn switch is secured with heat stakes to the insidesurface of the airbag module trim cover, between thetrim cover and the folded airbag cushion.
The driver side airbag module cannot be repaired,and must be replaced if deployed or in any way dam-aged. The driver side airbag module trim cover andthe horn switch are available as a unit for servicereplacement.
OPERATIONThe driver side airbag module includes a stamped
metal housing to which the cushion and an inflatorunit are attached and sealed. The conventional pyro-technic-type inflator assembly is mounted to studs onthe back of the airbag module housing. The inflatorseals the hole in the airbag cushion so it can dis-charge the gas it produces directly into the cushion
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TJ PASSIVE RESTRAINT SYSTEMS 8M - 3
DESCRIPTION AND OPERATION (Continued)
hen supplied with the proper electrical signal. Fol-owing an airbag deployment, the airbag cushionuickly deflates by venting this gas towards thenstrument panel through the porous fabric materialsed on the steering wheel side of the airbag cushion.The protective trim cover is fitted to the front of
he airbag module and forms a decorative cover inhe center of the steering wheel. The inside of therim cover has locking blocks molded into it thatngage a lip on the airbag module metal housing.wo stamped metal retainers then fit over the infla-or mounting studs on the back of the airbag moduleousing and are engaged in slots on the inside of theover, securely locking the trim cover into place. Therim cover will split at predetermined breakout lines,hen fold back out of the way along with the hornwitch upon airbag deployment.
ASSENGER SIDE AIRBAG MODULE
ESCRIPTIONThe passenger side airbag door on the instrument
anel above the glove box is the most visible part ofhe passenger side airbag system. Located under theirbag door are the passenger side airbag cushionnd the airbag cushion supporting components.The passenger side airbag module includes a
tamped metal housing within which the cushion andnflator are mounted and sealed. The airbag housingas three stamped metal mounting brackets spotelded to it. The mounting brackets at the top andt the lower rear of the airbag module secure theodule to the instrument panel armature. The
tamped metal mounting bracket at the lower frontf the housing secures the passenger side airbagodule to two studs on the dash panel, behind the
love box. A plastic end bracket encloses the inboardnd of the housing and retains the wire harness con-ector for the inflator.Following a passenger side airbag deployment, the
assenger side airbag module, the passenger side air-ag door and the instrument panel assembly must beeplaced. The passenger side airbag module cannote repaired, and must be replaced if deployed or inny way damaged. The passenger side airbag door isvailable as a separate service item.
PERATIONThe hybrid-type inflator assembly includes a small
anister of highly compressed argon gas. The inflatoreals the hole in the airbag cushion so it can dis-harge the gas it produces directly into the cushionhen supplied with the proper electrical signal. Fol-
owing an airbag deployment, the airbag cushionuickly deflates by venting this gas through the
porous fabric material used on each end panel of theairbag cushion.
The molded plastic passenger side airbag door issecured to the instrument panel at the upper andlower flanges with screws. A stamped metal bracketlocated on the back side of the airbag door is securedto the instrument panel armature with one screw oneach end, and serves as the hinge for the door uponan airbag deployment. The airbag door has predeter-mined breakout lines concealed beneath its decora-tive cover. Upon airbag deployment, the airbag doorwill split at the breakout lines and the door will foldback over the top of the instrument panel, out of theway.
PASSENGER SIDE AIRBAG ON/OFF SWITCH
DESCRIPTIONA passenger side airbag on/off switch, which is
located on the forward end of the floor console (bothfull and mini versions), allows the passenger side air-bag system to be disabled when certain childrestraint devices are being used in the right frontseating position. The passenger side airbag on/offswitch is equipped with a key actuator so that theswitch position can only be changed using an ignitionkey. When the ignition switch is in the On positionand the passenger side airbag system is disabled, aLight-Emitting Diode (LED) illuminates an Off indi-cator lamp on the face plate of the switch.
The passenger side airbag on/off switch cannot beadjusted or repaired and, if faulty or damaged, theswitch assembly must be replaced. The switch bezelis available for service replacement.
OPERATIONTo actuate the passenger side airbag on/off switch,
insert the ignition key in the switch key actuator.The switch key actuator is then rotated with theignition key to its clockwise stop (the key actuatorslot will be aligned with the Off indicator lamp) todisable the passenger side airbag system. When theswitch key actuator is rotated with the ignition keyto its counterclockwise stop (the key actuator slotwill be in a vertical position), the Off indicator lampwill be extinguished and the passenger side airbagsystem will be enabled.
WARNING: THE KEY MUST ALWAYS BE REMOVEDFROM THE PASSENGER SIDE AIRBAG ON/OFFSWITCH KEY ACTUATOR AFTER THE SWITCH HASBEEN USED. NEVER LEAVE A KEY IN THE SWITCHKEY ACTUATOR. FAILURE TO OBSERVE THISWARNING COULD RESULT IN ACCIDENTAL,INCOMPLETE OR IMPROPER AIRBAG DEPLOY-MENT AND POSSIBLE OCCUPANT INJURIES.
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8M - 4 PASSIVE RESTRAINT SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
IRBAG CONTROL MODULE
ESCRIPTIONThe Airbag Control Module (ACM) is secured with
crews to a mounting bracket that is secured withour screws onto the floor panel transmission tunnelelow the instrument panel and forward of the centerloor console in the passenger compartment of theehicle. The ACM contains an electronic microproces-or, an electronic impact sensor, an electromechanicalafing sensor, and an energy storage capacitor.The ACM is serviced as a unit with the mounting
racket. The ACM cannot be repaired or adjustednd, if damaged or faulty, the ACM and mountingracket unit must be replaced.
PERATIONThe microprocessor in the ACM contains the airbag
ystem logic. The airbag system logic includesn-Board Diagnostics (OBD), and the ability to com-unicate with the instrument cluster circuitry over
he Chrysler Collision Detection (CCD) data bus toontrol the airbag indicator lamp. The microprocessorontinuously monitors all of the airbag system elec-rical circuits to determine the system readiness. Ifhe ACM detects a monitored system fault, it sendsessages to the instrument cluster over the CCD
ata bus to turn on the airbag indicator lamp. Refero Instrument Cluster in the proper section ofroup 8E - Instrument Panel Systems for more infor-ation on the airbag indicator lamp.One electronic impact sensor is used in this airbag
ystem. The impact sensor is an accelerometer thatenses the rate of vehicle deceleration, which pro-ides verification of the direction and severity of anmpact. The impact sensor is calibrated for the spe-ific vehicle, and is only serviced as a unit with theCM. A pre-programmed decision algorithm in theCM microprocessor determines when the decelera-
ion rate as signaled by the impact sensor indicatesn impact that is severe enough to require airbagystem protection. When the programmed conditionsre met, the ACM sends an electrical signal to deployhe airbags.
In addition to the electronic impact sensor, there isn electromechanical sensor within the ACM called aafing sensor. The safing sensor is a normally openeries switch located in the airbag deployment circuitf the ACM. This sensor detects impact energy of aesser magnitude than the electronic impact sensor,nd must be closed in order for the airbags to deploy.The ACM also contains an energy-storage capaci-
or. This capacitor stores enough electrical energy toeploy the airbags for up to one second following aattery disconnect or failure during an impact. Theurpose of the capacitor is to provide airbag system
protection in a severe secondary impact, if the initialimpact has damaged or disconnected the battery, butwas not severe enough to deploy the airbags.
CLOCKSPRING
DESCRIPTIONThe clockspring assembly is secured with two inte-
gral plastic latches onto the steering column lockhousing near the top of the steering column behindthe steering wheel. The clockspring is used to main-tain a continuous electrical circuit between the fixedclockspring wire harness on the steering column andseveral electrical components that rotate with thesteering wheel. The rotating components include thedriver side airbag module, the horn switch and, if thevehicle is so equipped, the vehicle speed controlswitches.
The clockspring cannot be repaired. If the clock-spring is faulty, damaged, or if the driver side airbaghas been deployed, the clockspring must be replaced.
OPERATIONThe clockspring assembly consists of a plastic case
which contains a flat, ribbon-like, electrically conduc-tive tape that winds and unwinds like a clockspringwith the steering wheel rotation. The electrically con-ductive tape consists of several fine gauge copperwire leads sandwiched between two narrow strips ofplastic film.
Like the clockspring in a timepiece, the clockspringtape has travel limits and can be damaged by beingwound too tightly. To prevent this from occurring, theclockspring is centered when it is installed on thesteering column. Centering the clockspring indexesthe clockspring tape to other steering components sothat it can operate within its designed travel limits.However, if the clockspring is removed for service orif the steering column is disconnected from the steer-ing gear allowing the clockspring tape to change posi-tion relative to the other steering components, itmust be re-centered following completion of the ser-vice or it may be damaged. Refer to ClockspringCentering in the Adjustments section of this groupfor the proper centering procedures.
Service replacement clocksprings are shipped pre-centered and with a locking pin installed. This lock-ing pin should not be removed until the clockspringhas been installed on the steering column. If thelocking pin is removed before the clockspring isinstalled on a steering column, the clockspring cen-tering procedure must be performed.
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TJ PASSIVE RESTRAINT SYSTEMS 8M - 5
IAGNOSIS AND TESTING
IRBAG SYSTEMA DRB scan tool is required for diagnosis of the
irbag system. See the proper Diagnostic Proceduresanual for more information.(1) Connect the DRB scan tool to the 16-way data
ink wire harness connector. The connector is locatedn the driver side lower edge of the instrumentanel, outboard of the steering column (Fig. 1).
(2) Turn the ignition switch to the On position. Exithe vehicle with the DRB. Be certain that the DRB con-ains the latest version of the proper DRB software.
(3) Using the DRB, read and record the activeiagnostic Trouble Code (DTC) data.(4) Read and record any stored DTC data.(5) See the proper Diagnostic Procedures manual if
ny DTC is found in Step 3 or Step 4.(6) After completing the necessary repairs, try to
rase the stored DTC data. If any problems remain,he stored DTC data will not erase. See the properiagnostic Procedures manual for the procedures toiagnose any stored DTC that will not erase.(7) With the ignition switch still in the On posi-
ion, check to be certain that nobody is in the vehicle.(8) From outside of the vehicle (away from the air-
ags in case of an accidental deployment) turn thegnition switch to the Off position for about ten sec-nds, and then back to the On position. Observe theirbag indicator lamp in the instrument cluster. Ithould light for six to eight seconds, and then go out.his indicates that the airbag system is functioningormally.
Fig. 1 16-Way Data Link Connector - Typical
NOTE: If the airbag indicator lamp fails to light, orlights and stays on, there is an airbag system mal-function. See the proper Diagnostic Proceduresmanual to diagnose the problem.
SERVICE PROCEDURES
AIRBAG SYSTEM
NON-DEPLOYEDAt no time should any source of electricity be per-
mitted near the inflator on the back of an airbagmodule. When carrying a non-deployed airbag mod-ule, the trim cover or airbag side of the moduleshould be pointed away from the body to minimizeinjury in the event of an accidental deployment. Ifthe module is placed on a bench or any other surface,the trim cover or airbag side of the module should beface up to minimize movement in the event of anaccidental deployment.
In addition, the airbag system should be disarmedwhenever any steering wheel, steering column, orinstrument panel components require diagnosis orservice. Failure to observe this warning could resultin accidental airbag deployment and possible per-sonal injury. Refer to Group 8E - InstrumentPanel Systems for additional service procedures onthe instrument panel components. Refer to Group19 - Steering for additional service procedures onthe steering wheel and steering column components.
DISPOSAL OF NON-DEPLOYED AIRBAG MODULESAll damaged or faulty and non-deployed driver side
or passenger side airbag modules which are replacedon vehicles are to be returned. If an airbag moduleassembly is faulty or damaged and non-deployed,refer to the parts return list in the current ChryslerCorporation Warranty Policies and Procedures man-ual for the proper handling and disposal procedures.
DEPLOYEDAny vehicle which is to be returned to use after an
airbag deployment, must have both airbag modules,the instrument panel assembly, the passenger sideairbag module door and the clockspring replaced.These components will be damaged or weakened as aresult of an airbag deployment, which may or maynot be obvious during a visual inspection, and arenot intended for reuse.
Other vehicle components should be closelyinspected, but are to be replaced only as required bythe extent of the visible damage incurred.
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8M - 6 PASSIVE RESTRAINT SYSTEMS TJ
SERVICE PROCEDURES (Continued)
TORAGEAn airbag module must be stored in its original,
pecial container until used for service. Also, it muste stored in a clean, dry environment; away fromources of extreme heat, sparks, and high electricalnergy. Always place or store an airbag module on aurface with its trim cover or airbag side facing up,o minimize movement in case of an accidentaleployment.
LEANUP PROCEDUREFollowing an airbag system deployment, the vehi-
le interior will contain a powdery residue. This res-due consists primarily of harmless particulatey-products of the small pyrotechnic charge used tonitiate the airbag deployment propellant. However,his residue will also contain traces of sodiumydroxide powder, a chemical by-product of the pro-ellant material that is used to generate the nitrogenas that inflates the airbag. Since sodium hydroxideowder can irritate the skin, eyes, nose, or throat, beure to wear safety glasses, rubber gloves, and aong-sleeved shirt during cleanup (Fig. 2).
ARNING: IF YOU EXPERIENCE SKIN IRRITATIONURING CLEANUP, RUN COOL WATER OVER THEFFECTED AREA. ALSO, IF YOU EXPERIENCE
RRITATION OF THE NOSE OR THROAT, EXIT THEEHICLE FOR FRESH AIR UNTIL THE IRRITATIONEASES. IF IRRITATION CONTINUES, SEE A PHYSI-IAN.
Fig. 2 Wear Safety Glasses and Rubber Gloves -Typical
Begin the cleanup by removing the airbag modulesfrom the vehicle. Refer to Driver Side Airbag Mod-ule and Passenger Side Airbag Module in theRemoval and Installation section of this group for theprocedures.
Use a vacuum cleaner to remove any residual pow-der from the vehicle interior. Clean from outside thevehicle and work your way inside, so that you avoidkneeling or sitting on a non-cleaned area.
Be sure to vacuum the heater and air conditioningoutlets as well (Fig. 3). Run the heater and air con-ditioner blower on the lowest speed setting and vac-uum any powder expelled from the outlets. You mayneed to vacuum the interior of the vehicle a secondtime to recover all of the powder.
Place the deployed airbag modules in your vehicu-lar scrap pile.
REMOVAL AND INSTALLATION
DRIVER SIDE AIRBAG MODULEThe following procedure is for replacement of a
faulty or damaged driver side airbag module. If thedriver side airbag has been deployed, the clockspringmust also be replaced. Refer to Clockspring in theRemoval and Installation section of this group for theadditional service procedures for the clockspring.
Fig. 3 Vacuum Heater and A/C Outlets - Typical
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TJ PASSIVE RESTRAINT SYSTEMS 8M - 7
REMOVAL AND INSTALLATION (Continued)
ARNING:• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
LEX ELECTROMECHANICAL UNIT. BEFORETTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-AG SYSTEM OR RELATED STEERING WHEEL,TEERING COLUMN, OR INSTRUMENT PANELOMPONENTS YOU MUST FIRST DISCONNECTND ISOLATE THE BATTERY NEGATIVE (GROUND)ABLE. THEN WAIT TWO MINUTES FOR THE SYS-EM CAPACITOR TO DISCHARGE BEFORE FUR-HER SYSTEM SERVICE. THIS IS THE ONLY SUREAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
O DO THIS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.• WHEN REMOVING A DEPLOYED AIRBAG MOD-
LE, RUBBER GLOVES, EYE PROTECTION, AND AONG-SLEEVED SHIRT SHOULD BE WORN. THEREAY BE DEPOSITS ON THE AIRBAG MODULE ANDTHER INTERIOR SURFACES. IN LARGE DOSES,HESE DEPOSITS MAY CAUSE IRRITATION TO THEKIN AND EYES.
EMOVAL(1) Disconnect and isolate the battery negative
able. If either of the airbags has not been deployed,ait two minutes for the system capacitor to dis-
harge before further service.(2) From the underside of the steering wheel,
emove the two screws that secure the driver sideirbag module to the steering wheel (Fig. 4).
(3) Pull the airbag module away from the steeringheel far enough to access the two wire harness con-ectors on the back of the airbag module.(4) Disconnect the clockspring horn switch wire
arness connector from the horn switch feed wireonnector, which is located on the back of the airbagodule.
Fig. 4 Driver Side Airbag Module Remove/Install
(5) The clockspring airbag wire harness connectoris a tight snap-fit into the airbag module connectorreceptacle, which is located on the airbag inflator onthe back of the airbag module. Firmly grasp and pullor gently pry on the clockspring airbag wire harnessconnector to disconnect it from the airbag module.Do not pull on the clockspring wire harness todisengage the connector from the airbag mod-ule connector receptacle.
(6) Remove the driver side airbag module from thesteering wheel.
(7) If the driver side airbag has been deployed, theclockspring must be replaced. Refer to Clockspringin the Removal and Installation section of this groupfor the clockspring service procedures.
INSTALLATION
WARNING:• USE EXTREME CARE TO PREVENT ANY FOR-
EIGN MATERIAL FROM ENTERING THE DRIVERSIDE AIRBAG MODULE, OR BECOMINGENTRAPPED BETWEEN THE AIRBAG CUSHIONAND THE DRIVER SIDE AIRBAG TRIM COVER.FAILURE TO OBSERVE THIS WARNING COULDRESULT IN OCCUPANT INJURIES UPON AIRBAGDEPLOYMENT.
• THE DRIVER SIDE AIRBAG MODULE TRIMCOVER MUST NEVER BE PAINTED. REPLACEMENTTRIM COVERS ARE SERVICED IN THE ORIGINALCOLORS. PAINT MAY CHANGE THE WAY IN WHICHTHE MATERIAL OF THE TRIM COVER RESPONDSTO AN AIRBAG DEPLOYMENT. FAILURE TOOBSERVE THIS WARNING COULD RESULT INOCCUPANT INJURIES UPON AIRBAG DEPLOY-MENT.
(1) When installing the driver side airbag module,reconnect the clockspring airbag wire harness con-nector to the airbag module connector receptacle bypressing straight in on the connector. You can be cer-tain that the connector is fully engaged by listeningcarefully for a distinct audible click as the connectorsnaps into place.
(2) Reconnect the clockspring horn switch wireharness connector to the horn switch feed wire con-nector, which is located on the back of the airbagmodule.
(3) Carefully position the driver side airbag mod-ule in the steering wheel. Be certain that the clock-spring wire harnesses in the steering wheel hub areaare not pinched between the airbag module and thesteering wheel.
(4) From the underside of the steering wheel,install and tighten the two driver side airbag modulemounting screws. Tighten the screws to 10.2 N·m (90in. lbs.).
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8M - 8 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(5) Do not reconnect the battery negative cable athis time. Refer to Airbag System in the Diagnosisnd Testing section of this group for the proper pro-edures.
RIVER SIDE AIRBAG MODULE TRIM COVERThe horn switch is integral to the driver side air-
ag module trim cover. If either component is faultyr damaged, the entire driver side airbag modulerim cover and horn switch unit must be replaced.
ARNING:• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
LEX ELECTROMECHANICAL UNIT. BEFORETTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-AG SYSTEM OR RELATED STEERING WHEEL,TEERING COLUMN, OR INSTRUMENT PANELOMPONENTS YOU MUST FIRST DISCONNECTND ISOLATE THE BATTERY NEGATIVE (GROUND)ABLE. THEN WAIT TWO MINUTES FOR THE SYS-EM CAPACITOR TO DISCHARGE BEFORE FUR-HER SYSTEM SERVICE. THIS IS THE ONLY SUREAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
O DO THIS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.• THE HORN SWITCH IS INTEGRAL TO THE AIR-
AG MODULE TRIM COVER. SERVICE OF THISOMPONENT SHOULD BE PERFORMED ONLY BYHRYSLER-TRAINED AND AUTHORIZED DEALERERVICE TECHNICIANS. FAILURE TO TAKE THEROPER PRECAUTIONS OR TO FOLLOW THEROPER PROCEDURES COULD RESULT IN ACCI-ENTAL, INCOMPLETE, OR IMPROPER AIRBAGEPLOYMENT AND POSSIBLE OCCUPANT INJU-IES.
EMOVAL(1) Disconnect and isolate the battery negative
able. If either of the airbags has not been deployed,ait two minutes for the system capacitor to dis-
harge before further service.(2) Remove the driver side airbag module from the
teering wheel. Refer to Driver Side Airbag Mod-le in the Removal and Installation section of thisroup for the procedures.(3) Remove the plastic horn switch feed wire
etainer(s) from the stud(s) on the back of the driveride airbag housing (Fig. 5) or (Fig. 6).
(4) Remove the four nuts that secure the upperand lower trim cover retainers to the studs on theback of the driver side airbag housing (Fig. 7) or (Fig.8).
(5) Remove the upper and lower trim cover retain-ers from the airbag housing studs.
(6) Remove the horn switch ground wire eyeletfrom the upper airbag housing stud.
(7) Disengage the four trim cover locking blocksfrom the lip around the outside edge of the driverside airbag housing and remove the housing from thecover (Fig. 9) or (Fig. 10).
Fig. 5 Horn Switch Feed Wire Remove/Install - w/oSpeed Control
Fig. 6 Horn Switch Feed Wire Remove/Install -w/Speed Control
- w/o Speed Control
TJ PASSIVE RESTRAINT SYSTEMS 8M - 9
REMOVAL AND INSTALLATION (Continued)
Fig. 7 Driver Side Airbag Trim Cover RetainersRemove/Install - w/o Speed Control
Fig. 8 Driver Side Airbag Trim Cover RetainersRemove/Install - w/Speed Control
Fig. 9 Driver Side Airbag Trim Cover Remove/Install
Fig. 10 Driver Side Airbag Trim Cover Remove/Install - w/Speed Control
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8M - 10 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
NSTALLATION
ARNING:• USE EXTREME CARE TO PREVENT ANY FOR-
IGN MATERIAL FROM ENTERING THE DRIVERIDE AIRBAG MODULE, OR BECOMINGNTRAPPED BETWEEN THE AIRBAG CUSHIONND THE DRIVER SIDE AIRBAG TRIM COVER.AILURE TO OBSERVE THIS WARNING COULDESULT IN OCCUPANT INJURIES UPON AIRBAGEPLOYMENT.• THE DRIVER SIDE AIRBAG MODULE TRIM
OVER MUST NEVER BE PAINTED. REPLACEMENTRIM COVERS ARE SERVICED IN THE ORIGINALOLORS. PAINT MAY CHANGE THE WAY IN WHICHHE MATERIAL OF THE TRIM COVER RESPONDSO AN AIRBAG DEPLOYMENT. FAILURE TOBSERVE THIS WARNING COULD RESULT INCCUPANT INJURIES UPON AIRBAG DEPLOY-ENT.
(1) Carefully position the driver side airbag mod-le in the trim cover. Be certain that the horn switcheed and ground wires are not pinched between theirbag housing and the trim cover locking blocks.(2) Engage the upper and lower trim cover locking
locks with the lip of the driver side airbag housing,hen engage the locking blocks on each side of therim cover with the lip of the housing. Be certainhat each of the locking blocks is fully engaged onhe lip of the airbag housing (Fig. 11).
Fig. 11 Driver Side Airbag Trim Cover LockingBlocks Engaged
(4) Install the upper and lower airbag trim coverretainers over the airbag housing studs. Be certainthat the tabs on each retainer are engaged in theretainer slots of the upper and lower trim cover lock-ing blocks (Fig. 9) or (Fig. 10).
(5) Install and tighten the trim cover retainermounting nuts on the airbag housing studs. Tightenthe nuts to 10 N·m (90 in. lbs.).
(6) Install the driver side airbag module onto thesteering wheel. Refer to Driver Side Airbag Mod-ule in the Removal and Installation section of thisgroup for the procedures.
PASSENGER SIDE AIRBAG MODULEThe following procedure is for replacement of a
faulty or damaged passenger side airbag module. Ifthe passenger side airbag module has been deployed,the instrument panel assembly must be replaced.The instrument panel assembly includes the passen-ger side airbag module and the passenger side airbagdoor. Refer to Instrument Panel Assembly in theRemoval and Installation section of Group 8E -Instrument Panel Systems for the instrument panelassembly service procedures.
WARNING:• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFOREATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG SYSTEM OR RELATED STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANELCOMPONENTS YOU MUST FIRST DISCONNECTAND ISOLATE THE BATTERY NEGATIVE (GROUND)CABLE. THEN WAIT TWO MINUTES FOR THE SYS-TEM CAPACITOR TO DISCHARGE BEFORE FUR-THER SYSTEM SERVICE. THIS IS THE ONLY SUREWAY TO DISABLE THE AIRBAG SYSTEM. FAILURETO DO THIS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MOD-ULE, RUBBER GLOVES, EYE PROTECTION, AND ALONG-SLEEVED SHIRT SHOULD BE WORN. THEREMAY BE DEPOSITS ON THE AIRBAG MODULE ANDOTHER INTERIOR SURFACES. IN LARGE DOSES,THESE DEPOSITS MAY CAUSE IRRITATION TO THESKIN AND EYES.
REMOVAL(1) Disconnect and isolate the battery negative
cable. If either of the airbags has not been deployed,wait two minutes for the system capacitor to dis-charge before further service.
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TJ PASSIVE RESTRAINT SYSTEMS 8M - 11
REMOVAL AND INSTALLATION (Continued)
(2) Remove the instrument panel assembly fromhe passenger compartment of the vehicle. Refer tonstrument Panel Assembly in the Removal andnstallation section of Group 8E - Instrument Panelystems for the procedures.(3) Place the instrument panel on a suitable work
urface. Be certain to take the proper precautions torotect the instrument panel from any possible cos-etic damage.(4) Remove the three nuts that secure the passen-
er side airbag module to the studs on the instru-ent panel armature (Fig. 12).
(5) Remove the passenger side airbag module fromhe instrument panel.
NSTALLATION
ARNING: USE EXTREME CARE TO PREVENTNY FOREIGN MATERIAL FROM ENTERING THEASSENGER SIDE AIRBAG MODULE, OR BECOM-
NG ENTRAPPED BETWEEN THE AIRBAG CUSHIONND THE PASSENGER SIDE AIRBAG DOOR. FAIL-RE TO OBSERVE THIS WARNING COULD RESULT
N OCCUPANT INJURIES UPON AIRBAG DEPLOY-ENT.
(1) Carefully position the passenger side airbagodule in the instrument panel.(2) Install and tighten the three nuts that secure the
assenger side airbag module upper and lower mount-ng brackets to the studs on the instrument panel arma-ure. Tighten the nuts to 12 N·m (105 in. lbs.).
(3) Install the instrument panel assembly into theassenger compartment of the vehicle. Refer tonstrument Panel Assembly in the Removal andnstallation section of Group 8E - Instrument Panelystems for the procedures. When installing the
nstrument panel, be certain to reconnect the passen-er side airbag module wire harness to the cross-ody wire harness, and that the connector is fullyngaged and latched.(4) Do not reconnect the battery negative cable at
his time. Refer to Airbag System in the Diagnosisnd Testing section of this group for the proper pro-edures.
Fig. 12 Passenger Side Airbag Module Remove/Install
PASSENGER SIDE AIRBAG DOOR
WARNING:• THE AIRBAG SYSTEM IS A SENSITIVE, COM-
PLEX ELECTROMECHANICAL UNIT. BEFOREATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG SYSTEM OR RELATED STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANELCOMPONENTS YOU MUST FIRST DISCONNECTAND ISOLATE THE BATTERY NEGATIVE (GROUND)CABLE. THEN WAIT TWO MINUTES FOR THE SYS-TEM CAPACITOR TO DISCHARGE BEFORE FUR-THER SYSTEM SERVICE. THIS IS THE ONLY SUREWAY TO DISABLE THE AIRBAG SYSTEM. FAILURETO DO THIS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
• WHEN REMOVING A DEPLOYED AIRBAG MOD-ULE, RUBBER GLOVES, EYE PROTECTION, AND ALONG-SLEEVED SHIRT SHOULD BE WORN. THEREMAY BE DEPOSITS ON THE AIRBAG MODULE ANDOTHER INTERIOR SURFACES. IN LARGE DOSES,THESE DEPOSITS MAY CAUSE IRRITATION TO THESKIN AND EYES.
REMOVAL(1) Disconnect and isolate the battery negative
cable. If either of the airbags has not been deployed,wait two minutes for the system capacitor to dis-charge before further service.
(2) Remove the passenger side airbag module fromthe instrument panel. Refer to Passenger Side Air-bag Module in the Removal and Installation sectionof this group for the procedures.
(3) Remove the five screws that secure the passen-ger side airbag door upper flange to the top of theinstrument panel (Fig. 13).
Fig. 13 Passenger Side Airbag Door Upper ScrewsRemove/Install
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8M - 12 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
(4) Remove the grab handle bezel from the instru-ent panel. Refer to Instrument Panel Grab Han-le Bezel in the Removal and Installation section ofroup 8E - Instrument Panel Systems for the proce-ures.(5) Remove the five screws that secure the passen-
er side airbag door lower flange to the instrumentanel above the glove box opening.(6) Remove the two screws that secure the ends of
he passenger side airbag door bracket to the instru-ent panel armature (Fig. 14).
(7) Remove and discard the two passenger side air-ag door bracket J-nuts from the instrument panelrmature. These J-nuts must be replaced with newarts whenever the passenger side airbag doorracket screws are removed.(8) Remove the passenger side airbag door from
he instrument panel.
NSTALLATION
ARNING:• USE EXTREME CARE TO PREVENT ANY FOR-
IGN MATERIAL FROM ENTERING THE PASSEN-ER SIDE AIRBAG MODULE, OR BECOMINGNTRAPPED BETWEEN THE AIRBAG CUSHIONND THE PASSENGER SIDE AIRBAG DOOR. FAIL-RE TO OBSERVE THIS WARNING COULD RESULT
N OCCUPANT INJURIES UPON AIRBAG DEPLOY-ENT.• THE PASSENGER SIDE AIRBAG DOOR MUST
EVER BE PAINTED. REPLACEMENT AIRBAGOORS ARE SERVICED IN THE ORIGINAL COL-RS. PAINT MAY CHANGE THE WAY IN WHICH THEATERIAL OF THE AIRBAG DOOR RESPONDS TON AIRBAG DEPLOYMENT. FAILURE TO OBSERVEHIS WARNING COULD RESULT IN OCCUPANT
NJURIES UPON AIRBAG DEPLOYMENT.
(1) Install two new passenger airbag door bracket-nuts onto the instrument panel armature. These-nuts must be replaced with new parts whenever
Fig. 14 Passenger Side Airbag Door Remove/Install
the passenger side airbag door bracket screws areremoved.
(2) Position the passenger side airbag door to theinstrument panel and align the mounting holes ineach end of the airbag door bracket with the J-nutson the instrument panel armature.
(3) Install and tighten the two screws that securethe passenger side airbag door bracket to the instru-ment panel armature. Tighten the screws to 12 N·m(105 in. lbs.).
(4) Install and tighten the five screws that securethe passenger side airbag door lower flange to theinstrument panel above the glove box opening.Tighten the screws to 2.2 N·m (20 in. lbs.).
(5) Install the grab handle bezel onto the instru-ment panel. Refer to Instrument Panel Grab Han-dle Bezel in the Removal and Installation section ofGroup 8E - Instrument Panel Systems for the proce-dures.
(6) Install and tighten the five screws that securethe passenger side airbag door upper flange to thetop of the instrument panel. Tighten the screws to2.2 N·m (20 in. lbs.).
(7) Install the passenger side airbag module ontothe instrument panel. Refer to Passenger Side Air-bag Module in the Removal and Installation sectionof this group for the procedures.
PASSENGER SIDE AIRBAG ON/OFF SWITCH
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,COMPLEX ELECTROMECHANICAL UNIT. BEFOREATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG SYSTEM OR RELATED STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANELCOMPONENTS YOU MUST FIRST DISCONNECTAND ISOLATE THE BATTERY NEGATIVE (GROUND)CABLE. THEN WAIT TWO MINUTES FOR THE SYS-TEM CAPACITOR TO DISCHARGE BEFORE FUR-THER SYSTEM SERVICE. THIS IS THE ONLY SUREWAY TO DISABLE THE AIRBAG SYSTEM. FAILURETO DO THIS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL
PASSENGER SIDE AIRBAG ON/OFF SWITCH(1) Disconnect and isolate the battery negative
cable. If either of the airbags has not been deployed,wait two minutes for the system capacitor to dis-charge before further service.
(2) Remove the glove box from the instrumentpanel. Refer to Glove Box in the Removal andInstallation section of Group 8E - Instrument PanelSystems for the procedures.
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REMOVAL AND INSTALLATION (Continued)
(3) Reach through the glove box opening to accessnd disconnect the two passenger side airbag on/offwitch wire harness connectors from the instrumentanel wire harness. These connectors are retained onbracket located on the outboard glove box opening
einforcement (Fig. 15).
(4) Still reaching through the glove box opening,isengage the passenger side airbag on/off switchire harness from the retainer clip on the plenumracket that supports the heater-A/C housing justnboard of the fuseblock module.
(5) Remove the full floor console or mini-floor con-ole from the floor panel transmission tunnel. Refero Full Floor Console or Mini Floor Console inhe Removal and Installation section of Group 23 -ody for the procedures.(6) From the underside of the console, remove the
hree screws that secure the passenger side airbagn/off switch to the back of the switch bezel (Fig. 16).(7) Remove the passenger side airbag on/off switch
rom the switch bezel.
ASSENGER SIDE AIRBAG ON/OFF SWITCH BEZELThe passenger side airbag on/off switch can be ser-
iced without removing the switch bezel from theloor console. If the passenger side airbag on/offwitch bezel is removed from the floor console, itust be replaced. The latch tabs that secure the
ezel to the console will be damaged during theemoval process.(1) Disconnect and isolate the battery negative
able. If either of the airbags has not been deployed,ait two minutes for the system capacitor to dis-
harge before further service.
Fig. 15 Passenger Side Airbag On/Off Switch WireHarness Connectors
(2) Remove the passenger side airbag on/off switchfrom the bezel. Refer to Passenger Side AirbagOn/Off Switch in the Removal and Installation sec-tion of this group for the procedures.
(3) From the underside of the console, release thefour latch tabs that secure the passenger side airbagon/off switch bezel to the mounting hole in the frontof the full floor console or mini floor console.
(4) Remove the passenger side airbag on/off switchbezel from the top of the full floor console or minifloor console.
INSTALLATION
PASSENGER SIDE AIRBAG ON/OFF SWITCH(1) From the underside of the console, position the
passenger side airbag on/off switch to the back of theswitch bezel.
(2) Install and tighten the three screws that securethe passenger side airbag on/off switch to the switchbezel. Tighten the screws to 2.2 N·m (20 in. lbs.).
(3) Install the full floor console or mini floor con-sole onto the floor panel transmission tunnel. Referto Full Floor Console or Mini Floor Console inthe Removal and Installation section of Group 23 -Body for the procedures.
(4) Reach through the glove box opening to engagethe passenger side airbag on/off switch wire harnessin the retainer clip on the plenum bracket that sup-ports the heater-A/C housing just inboard of the fuse-block module.
(5) Still reaching through the glove box opening,access and reconnect the two passenger side airbagon/off switch wire harness connectors to the instru-ment panel wire harness. These connectors are
Fig. 16 Passenger Side Airbag On/Off SwitchRemove/Install
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8M - 14 PASSIVE RESTRAINT SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
etained on a bracket located on the outboard gloveox opening reinforcement. Be certain that both con-ectors are fully engaged and latched.(6) Install the glove box onto the instrument panel.efer to Glove Box in the Removal and Installationection of Group 8E - Instrument Panel Systems forhe procedures.
(7) Do not reconnect the battery negative cable athis time. Refer to Airbag System in the Diagnosisnd Testing section of this group for the proper pro-edures.
ASSENGER SIDE AIRBAG ON/OFF SWITCH BEZEL(1) Position the passenger side airbag on/off switch
ezel to the mounting hole at the front of the fullloor console or mini floor console.
(2) Press down firmly and evenly on the passengeride airbag on/off switch bezel until each of the fouratch tabs on the bezel is fully engaged with the
ounting hole of the full floor console or mini flooronsole.(3) Install the passenger side airbag on/off switch
nto the bezel. Refer to Passenger Side Airbagn/Off Switch in the Removal and Installation sec-
ion of this group for the procedures.(4) Do not reconnect the battery negative cable at
his time. Refer to Airbag System in the Diagnosisnd Testing section of this group for the proper pro-edures.
IRBAG CONTROL MODULE
ARNING:• THE AIRBAG CONTROL MODULE CONTAINS
HE IMPACT SENSOR, WHICH ENABLES THE SYS-EM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT-
NG TO DIAGNOSE OR SERVICE ANY AIRBAGYSTEM OR RELATED STEERING WHEEL, STEER-
NG COLUMN, OR INSTRUMENT PANEL COMPO-ENTS YOU MUST FIRST DISCONNECT AND
SOLATE THE BATTERY NEGATIVE (GROUND)ABLE. THEN WAIT TWO MINUTES FOR THE SYS-EM CAPACITOR TO DISCHARGE BEFORE FUR-HER SYSTEM SERVICE. THIS IS THE ONLY SUREAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
O DO THIS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.• NEVER STRIKE OR KICK THE AIRBAG CON-
ROL MODULE, AS IT CAN DAMAGE THE IMPACTENSOR OR AFFECT ITS CALIBRATION. IF AN AIR-AG CONTROL MODULE IS ACCIDENTALLYROPPED DURING SERVICE, THE MODULE MUSTE SCRAPPED AND REPLACED WITH A NEW UNIT.AILURE TO OBSERVE THIS WARNING COULDESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER AIRBAG DEPLOYMENT AND POSSIBLEOCCUPANT INJURIES.
REMOVAL(1) Disconnect and isolate the battery negative
cable. If either of the airbags has not been deployed,wait two minutes for the system capacitor to dis-charge before further service.
(2) Pull back the carpet from the floor panel trans-mission tunnel area under the heater-A/C housingfloor duct and forward of the full floor console ormini floor console.
(3) If the vehicle is equipped with the optionalAnti-lock Brake System (ABS), remove the accelera-tion switch and mounting bracket from the floorpanel transmission tunnel (Fig. 17). Refer to Accel-eration Switch in the Removal and Installation sec-tion of Group 5 - Brakes for the procedures.
NOTE: Always remove and replace the airbag con-trol module and its mounting bracket as a unit.Replacement modules include a replacementmounting bracket. Do not transfer the module toanother mounting bracket.
(4) Remove the four screws that secure the AirbagControl Module (ACM) mounting bracket to the floorpanel transmission tunnel (Fig. 18).
(5) Slide the ACM and mounting bracket out fromunder the heater-A/C housing floor duct far enoughto access the ACM wire harness connector.
(6) Disconnect the cross-body wire harness connec-tor from the ACM. To disconnect the cross-body wireharness connector from the ACM (Fig. 19):
(a) Pull the two white locks out about 3 millime-ters (0.125 in.) from each side of the connector.
(b) Squeeze the two connector latch tabsbetween the thumb and forefinger and pull theconnector straight away from the ACM connectorreceptacle.
Fig. 17 Acceleration Switch Remove/Install
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TJ PASSIVE RESTRAINT SYSTEMS 8M - 15
REMOVAL AND INSTALLATION (Continued)
(7) Remove the ACM and mounting bracket fromhe floor panel transmission tunnel as a unit.
Fig. 18 Airbag Control Module Remove/Install
Fig. 19 Airbag Control Module Connector Removal
INSTALLATION(1) Reconnect the cross-body wire harness connec-
tor to the ACM connector receptacle. Be certain thatthe connector latches are fully engaged and that thewhite connector locks are pushed in.
(2) Carefully position the ACM and mountingbracket unit to the floor panel transmission tunnel.When the ACM is correctly positioned the arrow onthe ACM label will be pointed forward in the vehicle.
(3) Install and tighten the four screws that securethe ACM mounting bracket to the floor panel trans-mission tunnel. Tighten the screws to 10.7 N·m (95in. lbs.).
(4) If the vehicle is equipped with the optionalABS brakes, install the acceleration switch andmounting bracket onto the floor panel transmissiontunnel. Refer to Acceleration Switch in theRemoval and Installation section of Group 5 - Brakesfor the procedures.
(5) Do not reconnect the battery negative cable atthis time. Refer to Airbag System in the Diagnosisand Testing section of this group for the proper pro-cedures.
CLOCKSPRINGThe clockspring cannot be repaired. It must be
replaced if faulty or damaged, or if the driver sideairbag has been deployed.
WARNING: THE AIRBAG SYSTEM IS A SENSITIVE,COMPLEX ELECTROMECHANICAL UNIT. BEFOREATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-BAG SYSTEM OR RELATED STEERING WHEEL,STEERING COLUMN, OR INSTRUMENT PANELCOMPONENTS YOU MUST FIRST DISCONNECTAND ISOLATE THE BATTERY NEGATIVE (GROUND)CABLE. THEN WAIT TWO MINUTES FOR THE SYS-TEM CAPACITOR TO DISCHARGE BEFORE FUR-THER SYSTEM SERVICE. THIS IS THE ONLY SUREWAY TO DISABLE THE AIRBAG SYSTEM. FAILURETO DO THIS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
REMOVAL
NOTE: Before starting this procedure, be certain toturn the steering wheel until the front wheels are inthe straight-ahead position.
(1) Place the front wheels in the straight-aheadposition.
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REMOVAL AND INSTALLATION (Continued)
(2) Remove the driver side airbag module from theteering wheel. Refer to Driver Side Airbag Mod-le in the Removal and Installation section of thisroup for the procedures.(3) If the vehicle is so equipped, disconnect the
pper clockspring wire harness connector from theteering wheel wire harness for the vehicle speedontrol switches located within the hub cavity of theteering wheel.(4) Remove the nut that secures the steering wheel
rmature to the steering column upper shaft, whichs located within the hub cavity of the steering wheel.
(5) Pull the steering wheel off of the steering col-mn upper shaft spline using a steering wheel pullerSpecial Tool C-3428-B).
(6) Remove the steering column opening coverrom the instrument panel. Refer to Steering Col-mn Opening Cover in the Removal and Installa-
ion section of Group 8E - Instrument Panel Systemsor the procedures.
(7) If the vehicle is so equipped, move the tiltteering column to the fully raised position.(8) Remove the three screws that secure the lower
teering column shroud to the upper shroud (Fig. 20).
(9) If the vehicle is equipped with a standard non-ilt steering column, loosen the two upper steeringolumn mounting nuts. If the vehicle is equippedith the optional tilt steering column, move the tilt
teering column to the fully lowered position.
Fig. 20 Steering Column Shrouds Remove/Install
(10) Remove both the upper and lower shroudsfrom the steering column.
(11) Disconnect the two instrument panel wireharness connectors from the lower clockspring con-nector receptacles (Fig. 21).
(12) The multi-function switch water shieldbracket on the top of the steering column has a smallaccess window which allows access to the upperclockspring latch with a small screwdriver (Fig. 22).Gently pry both plastic latches of the clockspringassembly to release them from the steering columnupper housing.
NOTE: If the clockspring plastic latches are broken,be certain to remove the broken pieces from thesteering column upper housing.
(13) Remove the clockspring from the steering col-umn. The clockspring cannot be repaired. It must bereplaced if faulty or damaged, or if the driver sideairbag has been deployed.
Fig. 21 Clockspring Remove/Install
Fig. 22 Upper Clockspring Latch Access Window
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REMOVAL AND INSTALLATION (Continued)
(14) If the removed clockspring is to be reused,ock the clockspring rotor to the clockspring case to
aintain clockspring centering until it is reinstalledn the steering column. This can be done by insertingstiff wire through the small index hole located at
bout the 11 o’clock position in the centered clock-pring rotor and case. Refer to Clockspring Center-ng in the Adjustments section of this group for anllustration of the clockspring index hole. Bend theire over after it has been inserted through the
ndex hole to prevent it from falling out.
NSTALLATIONIf the clockspring is not properly centered in rela-
ion to the steering wheel, steering shaft and steer-ng gear, it may be damaged. Refer to Clockspringentering in the Adjustments section of this groupefore installing or reinstalling a clockspring.Service replacement clocksprings are shipped pre-
entered and with a locking pin installed. This lock-ng pin should not be removed until the clockspringas been installed on the steering column. If the
ocking pin is removed before the clockspring isnstalled on a steering column, the clockspring cen-ering procedure must be performed.
OTE: Before starting this procedure, be certainhat the front wheels are still in the straight-aheadosition.
(1) If the removed clockspring is being reused,emove the wire from the index hole that is lockinghe clockspring rotor to the clockspring case to main-ain clockspring centering.
(2) Be certain that the turn signal switch controltalk is in the neutral position, then carefully slidehe centered clockspring down over the steering col-mn upper shaft until the clockspring latches engagehe steering column upper housing.
(3) If a new clockspring has been installed, removehe locking pin that is securing the clockspring rotoro the clockspring case and maintaining clockspringentering.(4) Reconnect the two instrument panel wire har-
ess connectors to the lower clockspring connectoreceptacles. Be certain that the connector latches areully engaged.
(5) Position both the upper and lower shrouds ontohe steering column.
(6) Install and tighten the three screws that securehe lower steering column shroud to the upperhroud. Tighten the screws to 2 N·m (18 in. lbs.).
(7) Install the steering column opening cover ontothe instrument panel. Refer to Steering ColumnOpening Cover in the Removal and Installation sec-tion of Group 8E - Instrument Panel Systems for theprocedures.
(8) Install the steering wheel onto the steering col-umn upper shaft. Be certain to index the flats on thehub of the steering wheel with the formations on theinside of the clockspring rotor. Pull the upper clock-spring wire harnesses through the lower hole in thesteering wheel armature.
(9) Install and tighten the steering wheel mount-ing nut. Tighten the nut to 61 N·m (45 ft. lbs.). Becertain not to pinch the wire harnesses between thesteering wheel and the nut.
(10) If the vehicle is so equipped, reconnect theupper clockspring wire harness connector to thesteering wheel wire harness for the vehicle speedcontrol switches.
(11) Install the driver side airbag module onto thesteering wheel. Refer to Driver Side Airbag Mod-ule in the Removal and Installation section of thisgroup for the procedures.
ADJUSTMENTS
CLOCKSPRING CENTERINGThe clockspring is designed to wind and unwind
when the steering wheel is rotated, but is onlydesigned to rotate the same number of turns (aboutfive complete rotations) as the steering wheel can beturned from stop to stop. Centering the clockspringindexes the clockspring tape to other steering compo-nents so that it can operate within its designedtravel limits. The rotor of a centered clockspring canbe rotated two and one-half turns in either directionfrom the centered position, without damaging theclockspring tape.
However, if the clockspring is removed for serviceor if the steering column is disconnected from thesteering gear, the clockspring tape can change posi-tion relative to the other steering components. Theclockspring must then be re-centered following com-pletion of the service or the clockspring tape may bedamaged.
Service replacement clocksprings are shipped pre-centered and with a locking pin installed. This lock-ing pin should not be removed until the clockspringhas been installed on the steering column. If thelocking pin is removed before the clockspring isinstalled on a steering column, the clockspring cen-tering procedure must be performed.
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ADJUSTMENTS (Continued)
ARNING: THE AIRBAG SYSTEM IS A SENSITIVE,OMPLEX ELECTROMECHANICAL UNIT. BEFORETTEMPTING TO DIAGNOSE OR SERVICE ANY AIR-AG SYSTEM OR RELATED STEERING WHEEL,TEERING COLUMN, OR INSTRUMENT PANELOMPONENTS YOU MUST FIRST DISCONNECTND ISOLATE THE BATTERY NEGATIVE (GROUND)ABLE. THEN WAIT TWO MINUTES FOR THE SYS-EM CAPACITOR TO DISCHARGE BEFORE FUR-HER SYSTEM SERVICE. THIS IS THE ONLY SUREAY TO DISABLE THE AIRBAG SYSTEM. FAILURE
O DO THIS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
OTE: Before starting this procedure, be certain tourn the steering wheel until the front wheels are inhe straight-ahead position.
(1) Place the front wheels in the straight-aheadosition.(2) Remove the clockspring from the steering col-
mn. Refer to Clockspring in the Removal andnstallation section of this group for the procedures.
(3) Hold the clockspring case in one hand so that its oriented as it would be when it is installed on theteering column (Fig. 23).(4) Use your other hand to rotate the clockspring
otor clockwise to the end of its travel. Do not applyxcessive torque.(5) From the end of the clockwise travel, rotate the
otor about two and one-half turns counterclockwise,ntil the rotor flats are horizontal. If the upper clock-pring wire harnesses are not oriented towards theottom of the clockspring, rotate the rotor anotherne-half turn in the counterclockwise direction.(6) The clockspring is now centered. Lock the
lockspring rotor to the clockspring case to maintainlockspring centering until it is reinstalled on theteering column. This can be done by inserting a stiffire through the small index hole located at about
he 11 o’clock position in the centered clockspringotor and case. Bend the wire over after it has beennserted through the index hole to prevent it fromalling out.
(7) The front wheels should still be in the straight-ahead position. Install the clockspring onto the steer-ing column. Refer to Clockspring in the Removaland Installation section of this group for the proce-dures.
NTRODUCTIONAn electrically heated rear window defogger is
vailable as factory-installed equipment on modelsquipped with the hardtop option. The defogger willnly operate when the ignition switch is in the Onosition. When the defogger switch is in the On posi-ion, an electric heater grid on the rear window glasss energized. This grid produces heat to help clearhe rear window glass of ice, snow, or fog.
The defogger system is controlled by a switchocated in the accessory switch bezel, which is nearhe bottom of the instrument panel center bezel andext to the ash receiver. An amber indicator lamp inhe switch button will light to indicate when theefogger system is turned on. The instrument clusterircuitry, which contains the defogger system timerogic, monitors the state of the defogger switchhrough a hard-wired input. The instrument clusterircuitry controls the defogger system through aard-wired control output to the defogger relay.The defogger system will be automatically turned
ff after a programmed time interval of about teninutes. After the initial time interval has expired, if
he defogger switch is turned on again during theame ignition cycle, the defogger system will auto-atically turn off after about five minutes.The defogger system will automatically shut off if
he ignition switch is turned to the Off position, or itan be turned off manually by depressing the instru-ent panel switch. Refer to the owner’s manual forore information on the defogger system controls
nd operation.
Following are general descriptions of the majorcomponents in the defogger system. Refer to 8W-48 -Rear Window Defogger in Group 8W - Wiring Dia-grams for complete circuit descriptions and diagrams.
DESCRIPTION AND OPERATION
REAR GLASS HEATING GRIDThe heated rear window glass has two electrically
conductive vertical bus bars and a series of horizon-tal grid lines made of a silver-ceramic material,which is baked on and bonded to the inside surface ofthe glass. The grid lines and bus bars comprise aparallel electrical circuit.
When the rear window defogger switch is placed inthe On position, electrical current is directed to therear window grid lines through the bus bars. Thegrid lines heat the rear window to clear the surfaceof fog or snow. Protection for the heated grid circuitis provided by a fuse in the Power Distribution Cen-ter (PDC).
The grid lines and bus bars are highly resistant toabrasion. However, it is possible for an open circuitto occur in an individual grid line, resulting in nocurrent flow through the line.
The grid lines can be damaged or scraped off withsharp instruments. Care should be taken when clean-ing the glass or removing foreign materials, decals,or stickers from the glass. Normal glass cleaning sol-vents or hot water used with rags or toweling is rec-ommended.
A repair kit is available to repair the grid lines andbus bars, or to reinstall the heated glass pigtailwires.
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DESCRIPTION AND OPERATION (Continued)
EFOGGER SWITCHThe rear window defogger switch is installed in the
nstrument panel accessory switch bezel, which isocated near the bottom of the instrument panel cen-er bezel area, next to the ash receiver. The momen-ary-type switch provides a hard-wired ground signalo the instrument cluster each time it is depressed.he instrument cluster rear window defogger timernd logic circuitry responds by energizing or de-ener-izing the rear window defogger relay.Energizing the rear window defogger relay pro-
ides electrical current to the rear window defoggerrid. An amber indicator lamp in the defogger switch,hich lights to indicate when the defogger system is
urned On, is also powered by the defogger relay out-ut.The defogger switch illumination lamp and indica-
or lamp bulbs are serviceable. The defogger switchannot be repaired and, if faulty or damaged, it muste replaced.
NSTRUMENT CLUSTERThe instrument cluster is an electromechanical
nit that contains integrated circuitry and internalrogramming to perform a variety of functions. Thenstrument cluster circuitry monitors hard-wiredwitch inputs, as well as message inputs receivedrom other vehicle electronic control modules on thehrysler Collision Detection (CCD) data bus network.The instrument cluster uses these many inputs
long with its internal programming and integralimer and logic circuitry to perform the functions ofhe rear window defogger timer on this model. Thenstrument cluster circuitry also has a self-diagnosticapability. Refer to Instrument Cluster in Group 8E -nstrument Panel Systems for more information onhis feature.
However, there are no diagnostics available for theear window defogger timer and logic circuitry.herefore, the diagnosis for this system consists ofonfirming the presence of a rear window defoggerwitch input signal at the instrument cluster connec-or, and the resulting rear window defogger relayontrol output signal at the defogger relay. For diag-osis of the CCD data bus and the data bus message
nputs, a DRB scan tool and the proper Diagnosticrocedures manual are recommended.Refer to Instrument Cluster in Group 8E - Instru-ent Panel Systems for the service procedures for
he instrument cluster. The rear window defoggerimer and logic circuitry cannot be adjusted orepaired and, if faulty or damaged, the instrumentluster assembly must be replaced.
DEFOGGER RELAYThe rear window defogger relay is a International
Standards Organization (ISO)-type relay. The rearwindow defogger relay is a electromechanical devicethat switches fused battery current to the rear glassheating grid and the indicator lamp of the defoggerswitch, when the instrument cluster rear windowdefogger timer and logic circuitry grounds the relaycoil. See Defogger Relay in the Diagnosis and Testingsection of this group for more information.
The rear window defogger relay is located in thePower Distribution Center (PDC) in the engine com-partment. Refer to the PDC label for relay identifica-tion and location.
The rear window defogger relay cannot be repairedand, if faulty or damaged, it must be replaced.
DIAGNOSIS AND TESTING
DEFOGGER SYSTEMFor circuit descriptions and diagrams, refer to
8W-48 - Rear Window Defogger in Group 8W - Wir-ing Diagrams. The operation of the electricallyheated rear window defogger system can be con-firmed in one of the following manners:
1. Turn the ignition switch to the On position.While monitoring the instrument panel voltmeter, setthe defogger switch in the On position. When thedefogger switch is turned On, a distinct voltmeterneedle deflection should be noted.
2. Turn the ignition switch to the On position. Setthe defogger switch in the On position. The rear win-dow defogger operation can be checked by feeling therear window glass. A distinct difference in tempera-ture between the grid lines and the adjacent clearglass can be detected within three to four minutes ofoperation.
3. Using a 12-volt DC voltmeter, contact the rearglass heating grid terminal A (right side) with thenegative lead, and terminal B (left side) with the pos-itive lead (Fig. 1). The voltmeter should read batteryvoltage.
The above checks will confirm system operation.Illumination of the defogger switch indicator lampmeans that there is electrical current available at theoutput of the defogger relay, but does not confirmthat the electrical current is reaching the rear glassheating grid lines.
If the defogger system does not operate, the prob-lem should be isolated in the following manner:
(1) Confirm that the ignition switch is in the Onposition.
(2) Ensure that the rear glass heating grid feedand ground wires are connected to the glass. Confirmthat the ground wire has continuity to ground.
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DIAGNOSIS AND TESTING (Continued)
(3) Check the fuses in the Power Distribution Cen-er (PDC) and in the fuseblock module. The fusesust be tight in their receptacles and all electrical
onnections must be secure.When the above steps have been completed and the
ear glass heating grid is still inoperative, one orore of the following is faulty:• Defogger switch• Defogger relay• Instrument cluster circuitry• Rear window grid lines (all grid lines would
ave to be broken or one of the feed wires discon-ected for the entire system to be inoperative).If setting the defogger switch to the On position
roduces a severe voltmeter deflection, check for ahort circuit between the defogger relay output andhe rear glass heating grid.
EAR GLASS HEATING GRIDFor circuit descriptions and diagrams, refer to
W-48 - Rear Window Defogger in Group 8W - Wir-ng Diagrams. To detect breaks in the grid lines, theollowing procedure is required:
(1) Turn the ignition switch to the On position. Sethe defogger switch in the On position. The indicatoramp should light. If OK, go to Step 2. If not OK, seehe Defogger Relay diagnosis in this group.
(2) Using a 12-volt DC voltmeter, contact the ver-ical bus bar on the right side of the vehicle with theegative lead. With the positive lead, contact the ver-ical bus bar on the left side of the vehicle. The volt-eter should read battery voltage. If OK, go to Step
. If not OK, repair the open circuit to the defoggerelay as required.(3) With the negative lead of the voltmeter, contactgood body ground point. The voltage reading should
ot change. If OK, go to Step 4. If not OK, repair theircuit to ground as required.(4) Connect the negative lead of the voltmeter to
he right side bus bar and touch each grid line at
Fig. 1 Rear Window Glass Grid Test
midpoint C with the positive lead. A reading ofapproximately six volts indicates a line is good. Areading of zero volts indicates a break in the gridline between midpoint C and the left side bus bar. Areading of ten to fourteen volts indicates a breakbetween midpoint C and the right side bus bar. Movethe positive lead on the grid line towards the breakand the voltage reading will change as soon as thebreak is crossed.
DEFOGGER SWITCHFor circuit descriptions and diagrams, refer to
8W-48 - Rear Window Defogger in Group 8W - Wir-ing Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Disconnect and isolate the battery negativecable. Remove the accessory switch bezel from theinstrument panel and unplug the defogger switchwire harness connector.
(2) Check for continuity between the ground cir-cuit cavity of the defogger switch wire harness con-nector and a good ground. There should becontinuity. If OK, go to Step 3. If not OK, repair theopen circuit as required.
(3) Check for continuity between the ground cir-cuit terminal and the rear window defogger switchsense circuit terminal on the back of the defoggerswitch housing (Fig. 2). There should be momentarycontinuity as the defogger switch button is depressed,and then no continuity. If OK, see the diagnosis forthe Instrument Cluster in this group. If not OK,replace the faulty switch.
DEFOGGER RELAY
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
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8N - 4 ELECTRICALLY HEATED SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
ELAY TESTThe defogger relay (Fig. 3) is located in the Poweristribution Center (PDC), in the engine compart-ent. Remove the defogger relay from the PDC to
erform the following tests:(1) A relay in the de-energized position should
ave continuity between terminals 87A and 30, ando continuity between terminals 87 and 30. If OK, goo Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-romagnet) should be 75 6 10 ohms. If OK, go totep 3. If not OK, replace the faulty relay.(3) Connect a battery to terminals 85 and 86.
here should now be continuity between terminals0 and 87, and no continuity between terminals 87And 30. If OK, see the Relay Circuit Test in thisroup. If not OK, replace the faulty relay.
ELAY CIRCUIT TEST(1) The relay common feed terminal cavity (30) is
onnected to battery voltage and should be hot at allimes. If OK, go to Step 2. If not OK, repair the openircuit to the PDC fuse as required.(2) The relay normally closed terminal (87A) is
onnected to terminal 30 in the de-energized position,ut is not used for this application. Go to Step 3.(3) The relay normally open terminal (87) is con-
ected to the common feed terminal (30) in the ener-ized position. This terminal supplies battery voltageo the rear glass heating grid and the defoggerwitch indicator lamp. There should be continuityetween the cavity for relay terminal 87 and the rearindow defogger relay output circuit cavities of the
Fig. 2 Defogger Switch Continuity
rear glass heating grid and defogger switch connec-tors at all times. If OK, go to Step 4. If not OK,repair the open circuit(s) as required.
(4) The coil battery terminal (86) is connected tothe electromagnet in the relay. This terminal is pro-vided with ground by the instrument cluster rearwindow defogger timer and logic circuitry to energizethe defogger relay. There should be continuity toground at the cavity for relay terminal 86 when thedefogger switch is turned On. However, with thedefogger relay removed, the defogger switch indicatorlamp will not light to show that the defogger systemis turned On. Be certain that you depress the defog-ger switch at least twice to confirm that the systemis turned on during this test. If OK, go to Step 5. Ifnot OK, repair the open circuit to the instrumentcluster as required.
(5) The coil ground terminal (85) is connected tothe electromagnet in the relay. It is connected tofused ignition switch output voltage and should behot when the ignition switch is in the On position.Check for battery voltage at the cavity for relay ter-minal 85 with the ignition switch in the On position.If OK, see the diagnosis for Instrument Cluster inthis group. If not OK, repair the open circuit to thefuse in the fuseblock module as required.
INSTRUMENT CLUSTERBefore performing this test, complete the Defogger
Switch and the Defogger Relay tests as described inthis group. For circuit descriptions and diagrams,refer to 8W-48 - Rear Window Defogger in Group 8W- Wiring Diagrams.
Fig. 3 Defogger Relay
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TJ ELECTRICALLY HEATED SYSTEMS 8N - 5
DIAGNOSIS AND TESTING (Continued)
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable. Remove the defogger relay from the Power Dis-ribution Center (PDC) and unplug the defoggerwitch wire harness connector.(2) Remove the instrument cluster from the instru-ent panel. Refer to Instrument Cluster in Group 8EInstrument Panel Systems for the procedures.(3) Check for continuity between the rear window
efogger switch sense circuit cavity of the rightnstrument cluster wire harness connector (connector) and a good ground. There should be no continuity.
f OK, go to Step 4. If not OK, repair the short circuits required.(4) Check for continuity between the rear window
efogger switch sense circuit cavities of the rightnstrument cluster wire harness connector (connector) and the defogger switch wire harness connector.here should be continuity. If OK, go to Step 5. If notK, repair the open circuit as required.(5) Check for continuity between the rear window
efogger relay control circuit cavity of the rightnstrument cluster wire harness connector (connector) and a good ground. There should be no continuity.
f OK, go to Step 6. If not OK, repair the short circuits required.(6) Check for continuity between the rear window
efogger relay control circuit cavities of the rightnstrument cluster wire harness connector (connector) and the defogger relay receptacle (the cavity for
SO relay terminal 86) in the PDC. There should beontinuity. If OK, replace the faulty instrument clus-er. If not OK, repair the open circuit as required.
ERVICE PROCEDURES
EAR GLASS HEATING GRID REPAIRRepair of the rear glass heating grid lines, bus
ars, terminals or pigtail wires can be accomplishedsing a Mopar Rear Window Defogger Repair KitPart Number 4267922) or equivalent.
ARNING: MATERIALS CONTAINED IN THEEPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.HE KIT CONTAINS EPOXY RESIN AND AMINEYPE HARDENER, WHICH ARE HARMFUL IF SWAL-OWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTEDAREAS WITH SOAP AND WATER. FOR CONTACTWITH THE EYES, FLUSH WITH PLENTY OF WATER.DO NOT TAKE INTERNALLY. IF TAKEN INTER-NALLY, INDUCE VOMITING AND CALL A PHYSICIANIMMEDIATELY. USE WITH ADEQUATE VENTILA-TION. DO NOT USE NEAR FIRE OR FLAME. CON-TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THEREACH OF CHILDREN.
(1) Mask the repair area so that the conductiveepoxy can be applied neatly. Extend the epoxy appli-cation onto the grid line or the bus bar on each sideof the break (Fig. 4).
(2) Follow the instructions in the repair kit forpreparing the damaged area.
(3) Remove the package separator clamp and mixthe two conductive epoxy components thoroughlywithin the packaging. Fold the package in half andcut the center corner to dispense the epoxy.
(4) For grid line repairs, mask the area to berepaired with masking tape or a template.
(5) Apply the epoxy through the slit in the mask-ing tape or template. Overlap both ends of the breakby at least 19 millimeters (0.75 inch).
(6) For a terminal or pigtail wire replacement,mask the adjacent areas so the epoxy can beextended onto the adjacent grid line as well as thebus bar. Apply a thin layer of epoxy to the areawhere the terminal or pigtail wire was fastened andonto the adjacent grid line.
(7) Apply a thin layer of conductive epoxy to theterminal or bare wire end of the pigtail and place itin the proper location on the bus bar. To prevent theterminal or pigtail wire from moving while the epoxyis curing, it must be wedged or clamped.
(8) Carefully remove the masking tape or tem-plate.
CAUTION: Do not allow the glass surface to exceed204° C (400° F) or the glass may fracture.
Fig. 4 Grid Line Repair - Typical
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8N - 6 ELECTRICALLY HEATED SYSTEMS TJ
SERVICE PROCEDURES (Continued)
(9) Allow the epoxy to cure 24 hours at room tem-erature, or use a heat gun with a 260° to 371° C500° to 700° F) range for fifteen minutes. Hold theeat gun approximately 25.4 centimeters (10 inches)rom the repair.
(10) After the conductive epoxy is properly cured,emove the wedge or clamp from the terminal or pig-ail wire. Do not attach the wire harness connectorsntil the curing process is complete.(11) Check the operation of the rear window defog-
er glass heating grid.
EMOVAL AND INSTALLATION
EFOGGER SWITCH
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable.(2) Remove the center bezel from the instrument
anel. See Instrument Panel Center Bezel in GroupE - Instrument Panel Systems for the procedures.(3) Remove the four screws that secure the acces-
ory switch bezel to the instrument panel (Fig. 5).
Fig. 5 Accessory Switch Bezel Remove/Install
(4) Pull the accessory switch bezel out from theinstrument panel far enough to access the wire har-ness connectors.
(5) Unplug the wire harness connectors from therear of the accessory switches and the cigar lighter/power outlet.
(6) Remove the accessory switch bezel from theinstrument panel.
(7) With a small thin-bladed screwdriver, gentlypry the snap clips at the top and bottom of the rearwindow defogger switch receptacle on the back of theaccessory switch bezel and pull the switch out of thebezel.
(8) Reverse the removal procedures to install. Becertain that both of the switch snap clip retainers inthe receptacle on the back of the accessory switchbezel are fully engaged. Tighten the mounting screwsto 2.2 N·m (20 in. lbs.).
DEFOGGER RELAY(1) Disconnect and isolate the battery negative
cable.(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 6).
(3) Refer to the label on the PDC for defoggerrelay identification and location.
(4) Unplug the defogger relay from the PDC.(5) Install the defogger relay by aligning the relay
terminals with the cavities in the PDC and pushingthe relay firmly into place.
(6) Install the PDC cover.(7) Connect the battery negative cable.(8) Test the relay operation.
ESCRIPTIONThis group covers the various standard and
ptional power distribution components used on thisodel. Refer to Group 8W - Wiring Diagrams for
omplete circuit diagrams of the various power distri-ution components.The power distribution system for this vehicle is
esigned to provide safe, reliable, and centralized dis-ribution of the electrical current required to operatell of the many standard and optional factory-in-talled electrical and electronic powertrain, chassis,afety, comfort and convenience systems. At the sameime, these systems were designed to provide conve-ient to access centralized locations for conductingiagnosis of faulty circuits, and for sourcing the addi-ional current requirements of many aftermarketehicle accessory and convenience items.These power distribution systems also incorporate
arious types of circuit control and protection fea-ures, including:
• Fuses• Maxi fuse-type fusible links• Relays.The power distribution system for this vehicle con-
ists of the following components:• Power Distribution Center (PDC)• Fuseblock ModuleFollowing are general descriptions of the major
omponents in the power distribution system. See thewner’s manual in the vehicle glove box for morenformation on the features, use and operation of allf the power distribution system components.
OWER DISTRIBUTION CENTER
ESCRIPTIONAll of the electrical current distributed throughout
his vehicle is directed through the standard equip-ent Power Distribution Center (PDC) (Fig. 1). The
molded plastic PDC housing is located on the rightside of the engine compartment, just forward of thebattery. The PDC housing has a molded plastic coverthat includes two integral pivot hooks on the out-board side, and an integral latch on the inboard side.The PDC cover is easily removed for service accessand has a convenient adhesive-backed fuse and relaylayout label affixed to the inside surface of the coverto ensure proper component identification.
The PDC housing is secured to a stamped sheetmetal bracket in the engine compartment by mount-ing slots and tabs that are integral to the PDC hous-ing. The PDC mounting bracket is secured with threescrews to the right front inner fender shield abovethe right front wheel house. A separate cover that issecured by an integral bail strap to the rear of thePDC housing is unlatched and removed to access thebattery/generator cable connection stud. The PDC isintegral to the dash wire harness, which exits fromthe rearward end of the PDC housing.
The PDC houses up to fourteen blade-type maxifuses, which replace all in-line fusible links. The PDCalso houses up to six blade-type mini fuses, the ABSrelay, and up to nine International Standards Orga-nization (ISO) relays (three standard-type and six
Fig. 1 Power Distribution Center
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8O - 2 POWER DISTRIBUTION SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
icro-type). Internal connection of all of the PDC cir-uits is accomplished by an intricate combination ofard wiring and bus bars. Refer to Power Distribu-ion in the Contents of Group 8W - Wiring Diagramsor complete circuit diagrams.
The maxi fuses, mini fuses and relays are availableor service replacement. The PDC unit cannot beepaired and is only serviced as a unit with the dashire harness. If the PDC internal circuits or housingre faulty or damaged, the PDC and dash wire har-ess unit must be replaced.
USEBLOCK MODULE
ESCRIPTIONAn electrical module is mounted on the dash panel
n the passenger compartment of the vehicle. Theolded plastic fuseblock module housing has an inte-
ral mounting bracket that is secured with twocrews to a bracket welded on the dash panel justbove the heater and air conditioner housing. Thelove box is rolled down from the instrument panelor service access of the fuseblock module fuses (Fig.). An adhesive-backed fuse layout label is located onhe heater and air conditioner housing below theuseblock module to ensure proper fuse identification.
The fuseblock module serves to distribute electricalurrent to many of the accessory systems in the vehi-le. All of the current entering and leaving the fuse-lock module does so through the cross body wirearness. The fuseblock module houses up to twentylade-type mini fuses. Internal connection of all ofhe fuseblock module circuits is accomplished by anntricate combination of hard wiring and bus bars.efer to Fuse/Fuse Block in the Contents of GroupW - Wiring Diagrams for complete circuit diagrams.
Fig. 2 Fuseblock Module
The fuses used in the fuseblock module are avail-able for service replacement. The fuseblock module isintegral to the cross body wire harness. If any inter-nal circuit or if the fuseblock module housing isfaulty or damaged, the entire fuseblock module andcross body harness unit must be replaced.
REMOVAL AND INSTALLATION
POWER DISTRIBUTION CENTERThe Power Distribution Center (PDC) is serviced
as a unit with the dash wire harness. If any internalcircuit of the PDC or if the PDC housing is faulty ordamaged, the entire PDC and the dash wire harnessunit must be replaced.
REMOVAL(1) Disconnect and isolate the battery negative
cable.(2) Disconnect each of the dash wire harness con-
nectors. Refer to Connector Locations in the Con-tents of Group 8W - Wiring Diagrams for moreinformation on the locations of the affected connec-tors.
(3) Remove all of the fasteners that secure each ofthe dash wire harness ground eyelets to the vehiclebody and chassis components. Refer to ConnectorLocations in the Contents of Group 8W - WiringDiagrams for more information on the ground eyeletlocations.
(4) Disengage each of the retainers that secure thedash wire harness to the vehicle body and chassiscomponents. Refer to Connector Locations in the
ontents of Group 8W - Wiring Diagrams for morenformation on the retainer locations.
(5) Unlatch and remove the terminal stud coverrom the rearward end of the PDC (Fig. 3).
(6) Remove the nut that secures the eyelets of theattery positive cable take out and the engine wirearness take out to the stud on the PDC.(7) Remove the battery positive cable take out and
he engine wire harness take out eyelets from theDC stud.(8) Disengage the latches on the PDC mounting
racket from the tabs on the PDC housing, and pullhe PDC housing upward to disengage the mountinglots from the stanchions of the mounting bracketFig. 4).
(9) Remove the PDC and the dash wire harnessrom the engine compartment as a unit.
(10) Remove the three screws that secure the PDCounting bracket to the right front inner fender (Fig.
).(11) Remove the PDC mounting bracket from the
ight front inner fender.
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TJ POWER DISTRIBUTION SYSTEMS 8O - 3
REMOVAL AND INSTALLATION (Continued)
NSTALLATION
OTE: If the PDC is being replaced with a new unit,e certain to transfer each of the fuses and relays
rom the old PDC to the proper cavities of the newDC. Refer to Power Distribution in the Contents ofroup 8W - Wiring Diagrams for the proper PDC
avity assignments.
(1) Position the PDC mounting bracket onto theight front inner fender.
Fig. 3 Power Distribution Center Connections
Fig. 4 Power Distribution Center Remove/Install
(2) Install and tighten the three screws that securethe PDC mounting bracket to the right front innerfender. Tighten the screws to 3.9 N·m (35 in. lbs.).
(3) Position the PDC and the dash wire harnessunit in the engine compartment.
(4) Engage the mounting slots on the PDC housingwith the stanchions of the PDC mounting bracketand push the unit downward until the mountingbracket latches engage the mounting tabs on thePDC housing.
(5) Install the eyelets of the battery positive cabletake out and the engine wire harness take out ontothe PDC stud.
(6) Install and tighten the nut that secures theeyelet of the battery positive cable take out and theengine wire harness take out onto the PDC stud.Tighten the nut to 8.4 N·m (75 in. lbs.).
(7) Engage the tabs on the lower edge of the ter-minal stud cover in the slots on the back of the PDChousing, then engage the latch on the top of thecover with the latch tabs on the PDC housing.
(8) Engage each of the retainers that secure thedash wire harness to the vehicle body and chassiscomponents. Refer to Connector Locations in theContents of Group 8W - Wiring Diagrams for moreinformation on the retainer locations.
(9) Install all of the fasteners that secure each ofthe dash wire harness ground eyelets to the vehiclebody and chassis components. Refer to ConnectorLocations in the Contents of Group 8W - WiringDiagrams for more information on the ground eyeletlocations.
(10) Reconnect each of the dash wire harness con-nectors. Refer to Connector Locations in the Con-tents of Group 8W - Wiring Diagrams for more
Fig. 5 PDC Mounting Bracket Remove/Install
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8O - 4 POWER DISTRIBUTION SYSTEMS TJ
REMOVAL AND INSTALLATION (Continued)
nformation on the locations of the affected connec-ors.
(11) Reconnect the battery negative cable.
USEBLOCK MODULEThe fuseblock module is serviced as a unit with the
ross body wire harness. If any internal circuit of theuseblock module if the fuseblock module housing isaulty or damaged, the entire fuseblock module andhe cross body wire harness unit must be replaced.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
EMOVAL(1) Disconnect and isolate the battery negative
able.(2) Remove the instrument panel assembly from
he dash panel. Refer to Instrument Panel Assem-ly in the Removal and Installation section of GroupE - Instrument Panel Systems for the procedures.(3) Disconnect each of the cross body wire harness
onnectors. Refer to Connector Locations in theontents of Group 8W - Wiring Diagrams for more
nformation on the locations of the affected connec-ors.
(4) Remove all of the fasteners that secure each ofhe cross body wire harness ground eyelets to theehicle body and chassis components. Refer to Con-ector Locations in the Contents of Group 8W -iring Diagrams for more information on the ground
yelet locations.(5) Disengage each of the retainers that secure the
ross body wire harness to the vehicle body and chas-is components. Refer to Connector Locations inhe Contents of Group 8W - Wiring Diagrams forore information on the retainer locations.(6) Remove the two screws that secure the fuse-
lock module to the bracket on the dash panel (Fig.).(7) Remove the fuseblock module and the cross
ody wire harness from the dash panel as a unit.
INSTALLATION
NOTE: If the fuseblock module is being replacedwith a new unit, be certain to transfer each of thefuses from the old fuseblock module to the propercavities of the new fuseblock module. Refer toFuse/Fuse Block in the Contents of Group 8W - Wir-ing Diagrams for the proper fuseblock module cav-ity assignments.
(1) Position the fuseblock module and the crossbody wire harness onto the dash panel as a unit.
(2) Install and tighten the two screws that securethe fuseblock module to the bracket on the dashpanel. Tighten the screws to 3.3 N·m (30 in. lbs.).
(3) Engage each of the retainers that secure thecross body wire harness to the vehicle body and chas-sis components. Refer to Connector Locations inthe Contents of Group 8W - Wiring Diagrams formore information on the retainer locations.
(4) Install all of the fasteners that secure each ofthe cross body wire harness ground eyelets to thevehicle body and chassis components. Refer to Con-nector Locations in the Contents of Group 8W -Wiring Diagrams for more information on the groundeyelet locations.
(5) Reconnect each of the cross body wire harnessconnectors. Refer to Connector Locations in theContents of Group 8W - Wiring Diagrams for moreinformation on the locations of the affected connec-tors.
(6) Install the instrument panel assembly onto thedash panel. Refer to Instrument Panel Assemblyin the Removal and Installation section of Group 8E -Instrument Panel Systems for the procedures.
NTRODUCTIONThe Sentry Key Immobilizer System (SKIS) is
vailable factory-installed optional equipment for thisodel. Following are some general descriptions of the
eatures and components of the SKIS. Refer to theehicle owner’s manual for more information on these and operation of the SKIS. Refer to 8W-30 - Fuel/gnition System in Group 8W - Wiring Diagrams foromplete circuit descriptions and diagrams.
ENTRY KEY IMMOBILIZER SYSTEMThe Sentry Key Immobilizer System (SKIS) is
esigned to provide passive protection against unau-horized vehicle use by preventing the engine fromperating while the system is armed. The primaryomponents of this system are the Sentry Key Immo-ilizer Module (SKIM), the Sentry Key transponder,he SKIS indicator lamp, and the Powertrain Controlodule (PCM).The SKIM is installed on the steering column near
he ignition lock cylinder. The transponder is locatednder the molded rubber cap on the head of the igni-ion key. The SKIS indicator lamp is located in thenstrument cluster.
The SKIS includes two valid Sentry Key transpon-ers from the factory. If the customer wishes, addi-ional non-coded blank Sentry Keys are available.hese blank keys can be cut to match a valid ignitioney, but the engine will not start unless the key tran-ponder is also programmed to the vehicle. The SKISill recognize no more than eight valid Sentry Key
ransponders at any one time.The SKIS performs a self-test each time the igni-
ion switch is turned to the On position, and willtore Diagnostic Trouble Codes (DTCs) if a systemalfunction is detected. The SKIS can be diagnosed,
and any stored DTC can be retrieved using a DRBscan tool as described in the proper Diagnostic Pro-cedures manual.
tains a Radio Frequency (RF) transceiver and a cen-tral processing unit, which includes the Sentry KeyImmobilizer System (SKIS) program logic. The SKISprogramming enables the SKIM to program andretain in memory the codes of at least two, but nomore than eight electronically coded Sentry Keytransponders. The SKIS programming also enablesthe SKIM to communicate over the Chrysler CollisionDetection (CCD) data bus network with the Power-train Control Module (PCM), the instrument clusterand/or the DRB scan tool.
The SKIM transmits and receives RF signalsthrough a tuned antenna enclosed within a moldedplastic ring formation that is integral to the SKIMhousing. When the SKIM is properly installed on thesteering column, the antenna ring is oriented aroundthe circumference of the ignition lock cylinder hous-ing. This antenna ring must be located within eightmillimeters (0.31 inches) of the Sentry Key in orderto ensure proper RF communication between theSKIM and the Sentry Key transponder.
For added system security, each SKIM is pro-grammed with a unique “Secret Key” code and asecurity code. The SKIM keeps the “Secret Key” codein memory and sends the code over the CCD databus to the PCM, which also keeps this code in itsmemory. The SKIM also sends the “Secret Key” codeto each of the programmed Sentry Key transponders.The security code is used by the assembly plant to
access the SKIS for initialization, or by the dealer
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8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
echnician to access the system for service. TheKIM also stores in its memory the Vehicle Identifi-ation Number (VIN), which it learns through a CCData bus message from the PCM during initializa-ion.
The SKIM and the PCM both use software thatncludes a rolling code algorithm strategy, whichelps to reduce the possibility of unauthorized SKISisarming. The rolling code algorithm ensures secu-ity by preventing an override of the SKIS throughhe unauthorized substitution of the SKIM or theCM. However, the use of this strategy also meanshat replacement of either the SKIM or the PCMnits will require a system initialization procedure toestore system operation.When the ignition switch is turned to the On or
tart positions, the SKIM transmits an RF signal toxcite the Sentry Key transponder. The SKIM thenistens for a return RF signal from the transponderf the Sentry Key that is inserted in the ignition lockylinder. If the SKIM receives an RF signal withalid “Secret Key” and transponder identificationodes, the SKIM sends a “valid key” message to theCM over the CCD data bus. If the SKIM receivesn invalid RF signal or no response, it sends “invalidey” messages to the PCM. The PCM will enable orisable engine operation based upon the status of theKIM messages.The SKIM also sends messages to the instrument
luster over the CCD data bus network to control theKIS indicator lamp. The SKIM sends messages tohe instrument cluster to turn the lamp on for abouthree seconds when the ignition switch is turned tohe On position as a bulb test. After completion ofhe bulb test, the SKIM sends bus messages to keephe lamp off for a duration of about one second. Thenhe SKIM sends messages to turn the lamp on or offased upon the results of the SKIS self-tests. If theKIS indicator lamp comes on and stays on after theulb test, it indicates that the SKIM has detected aystem malfunction and/or that the SKIS has becomenoperative.
If the SKIM detects an invalid key when the igni-ion switch is turned to the On position, it sendsessages to the instrument cluster to flash the SKIS
ndicator lamp. The SKIM can also send messages tohe instrument cluster to flash the lamp and to gen-rate a single audible chime tone. These functionserve as an indication to the customer that the SKISas been placed in its “Customer Learn” program-ing mode. See Sentry Key Immobilizer System
ransponder Programming in this group for morenformation on the “Customer Learn” programming
ode.For diagnosis or initialization of the SKIM and the
CM, a DRB scan tool and the proper Diagnostic
Procedures manual are required. The SKIM cannotbe repaired and, if faulty or damaged, the unit mustbe replaced.
SENTRY KEY IMMOBILIZER TRANSPONDERThe Sentry Key Immobilizer System (SKIS) uses a
transponder that is integral to each of the two igni-tion keys that are supplied with the vehicle when itis shipped from the factory. The transponder chip isinsulated within a nylon mount inserted in the headof the key, and invisible beneath a molded rubber cap(Fig. 1).
Each Sentry Key transponder has a unique tran-sponder identification code programmed into it by themanufacturer. The Sentry Key Immobilizer Module(SKIM) has a unique “Secret Key” code programmedinto it by the manufacturer. When a Sentry Keytransponder is programmed into the memory of theSKIM, the SKIM learns the transponder identifica-tion code from the transponder, and the transponderlearns the “Secret Key” code from the SKIM. Each ofthese codes is stored within the transponder and inthe nonvolatile memory of the SKIM. Therefore,blank keys for the SKIS must be programmed by andinto the SKIM, in addition to being cut to match themechanical coding of the ignition lock cylinder. SeeSentry Key Immobilizer System Transponder Pro-gramming in this group for more information.
The Sentry Key transponder is within the range ofthe SKIM transceiver antenna ring when it isinserted in the ignition lock cylinder. When the igni-tion switch is turned to the Start or On positions, theSKIM transceiver issues a Radio Frequency (RF) sig-nal that excites the transponder chip. The transpon-der chip responds by issuing an RF signal containing
Fig. 1 Sentry Key Immobilizer Transponder
its transponder identification code and the “Secret
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DESCRIPTION AND OPERATION (Continued)
ey” code. The SKIM transceiver compares the tran-ponder codes with the codes stored in its memory toetermine whether a valid key is in the ignition lockylinder.The Sentry Key transponder cannot be repaired
nd, if faulty or damaged, it must be replaced.
ENTRY KEY IMMOBILIZER SYSTEMNDICATOR LAMP
The Sentry Key Immobilizer System (SKIS) indica-or lamp gives an indication when the SKIS is faultyr when the vehicle has been immobilized due to these of an invalid ignition key. The lamp is controlledy the instrument cluster circuitry based upon mes-ages received from the Sentry Key Immobilizerodule (SKIM) on the Chrysler Collision Detection
CCD) data bus.The SKIM sends messages to the instrument clus-
er to turn the lamp on for about three seconds whenhe ignition switch is turned to the On position as aulb test. After completion of the bulb test, the SKIMends bus messages to keep the lamp off for a dura-ion of about one second. Then the SKIM sends mes-ages to the instrument cluster circuitry to turn theamp on or off based upon the results of the SKISelf-tests. If the SKIS indicator lamp comes on andtays on after the bulb test, it indicates that theKIM has detected a system malfunction and/or thathe SKIS has become inoperative.
If the SKIM detects an invalid key when the igni-ion switch is turned to the On position, it sendsessages to the instrument cluster to flash the SKIS
ndicator lamp. The SKIM can also send messages tohe instrument cluster to flash the lamp and to gen-rate a single audible chime tone. These functionserve as an indication to the customer that the SKISas been placed in its “Customer Learn” program-ing mode. See Sentry Key Immobilizer System
ransponder Programming in this group for morenformation on the “Customer Learn” programming
ode.The SKIS indicator lamp uses a replaceable incan-
escent bulb and bulb holder on the instrument clus-er electronic circuit board. Refer to Group 8E -nstrument Panel Systems for diagnosis and servicef a faulty SKIS indicator lamp. If the SKIS indicatoramp comes on and stays on after the bulb test func-ion, diagnosis of the SKIS should be performed with
DRB scan tool and the proper Diagnostic Proce-ures manual.
DIAGNOSIS AND TESTING
SENTRY KEY IMMOBILIZER SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
NOTE: The following tests may not prove conclu-sive in the diagnosis of this system. The most reli-able, efficient, and accurate means to diagnose theSentry Key Immobilizer System involves the use ofa DRB scan tool. Refer to the proper DiagnosticProcedures manual for the procedures.
The Sentry Key Immobilizer System (SKIS) andthe Chrysler Collision Detection (CCD) data bus net-work should be diagnosed using a DRB scan tool.The DRB will allow confirmation that the CCD databus is functional, that the Sentry Key ImmobilizerModule (SKIM) is placing the proper messages on theCCD data bus, and that the Powertrain Control Mod-ule (PCM) and the instrument cluster are receivingthe CCD data bus messages. Refer to the properDiagnostic Procedures manual for the procedures.Refer to 8W-39 - Vehicle Theft Security System inGroup 8W - Wiring Diagrams for complete circuitdescriptions and diagrams.
(1) Check the fuses in the fuseblock module. If OK,go to Step 2. If not OK, repair the shorted circuit orcomponent as required and replace the faulty fuse.
(2) Disconnect and isolate the battery negative cable.nplug the wire harness connector at the SKIM. Check
or continuity between the ground circuit cavity of theKIM wire harness connector and a good ground. Therehould be continuity. If OK, go to Step 3. If not OK,epair the open circuit to ground as required.
(3) Connect the battery negative cable. Check forbattery voltage at the fused B(+) circuit cavity of theSKIM wire harness connector. If OK, go to Step 4. Ifnot OK, repair the open circuit to the fuse in thefuseblock module as required.
(4) Turn the ignition switch to the On position.Check for battery voltage at the fused ignition switchoutput (run/start) circuit cavity of the SKIM wireharness connector. If OK, use a DRB scan tool andthe proper Diagnostic Procedures manual to completethe diagnosis of the SKIS. If not OK, repair the opencircuit to the fuse in the fuseblock module asrequired.
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8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS TJ
ERVICE PROCEDURES
ENTRY KEY IMMOBILIZER SYSTEMRANSPONDER PROGRAMMINGTwo programmed Sentry Key transponders are
ncluded with the Sentry Key Immobilizer SystemSKIS) when it is shipped from the factory. The Sen-ry Key Immobilizer Module (SKIM) can be pro-rammed to recognize up to six additionalransponders, for a total of eight Sentry Keys. Theollowing “Customer Learn” programming procedureor the programming of additional transpondersequires access to at least two of the valid Sentryeys. If two valid Sentry Keys are not available, Sen-
ry Key programming will require the use of a DRBcan tool and the proper Diagnostic Procedures man-al.
USTOMER LEARN(1) Obtain the additional Sentry Key transponder
lank(s) that are to be programmed for the vehicle.ut the additional Sentry Key transponder blanks toatch the ignition lock cylinder mechanical key
odes.(2) Insert one of the two valid Sentry Key tran-
ponders into the ignition switch and turn the igni-ion switch to the On position.
(3) After the ignition switch has been in the Onosition for about three seconds, but no more thanifteen seconds later, cycle the ignition switch back tohe Off position. Replace the first valid Sentry Key inhe ignition lock cylinder with the second valid Sen-ry Key and turn the ignition switch back to the Onosition.(4) About ten seconds after the completion of Step
, the SKIS indicator lamp will start to flash and aingle audible chime tone will sound to indicate thathe system has entered the “Customer Learn” pro-ramming mode.(5) Within about fifty seconds of entering the “Cus-
omer Learn” programming mode, turn the ignitionwitch to the Off position, replace the valid Sentryey with a blank Sentry Key transponder, and turn
he ignition switch back to the On position.(6) About ten seconds after the completion of Step
, a single audible chime tone will sound and theKIS indicator lamp will stop flashing and stay onolid for about three seconds to indicate that thelank Sentry Key transponder has been successfullyrogrammed. The SKIS will immediately return toormal system operation following exit from theCustomer Learn” programming mode.
(7) Go back to Step 2 and repeat this process forach additional Sentry Key transponder blank to berogrammed.
If any of the above steps is not completed in theproper sequence, or within the allotted time, theSKIS will automatically exit the “Customer Learn”programming mode. The SKIS will also automaticallyexit the “Customer Learn” programming mode if itsees a non-blank Sentry Key transponder when itshould see a blank, if it has already programmedeight valid Sentry Keys, or if the ignition switch isturned to the Off position for more than about fiftyseconds.
REMOVAL AND INSTALLATION
SENTRY KEY IMMOBILIZER MODULE
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINTSYSTEMS BEFORE ATTEMPTING ANY STEERINGWHEEL, STEERING COLUMN, OR INSTRUMENTPANEL COMPONENT DIAGNOSIS OR SERVICE. FAIL-URE TO TAKE THE PROPER PRECAUTIONS COULDRESULT IN ACCIDENTAL AIRBAG DEPLOYMENT ANDPOSSIBLE PERSONAL INJURY.
(1) Disconnect and isolate the battery negative cable.(2) Remove the knee blocker from the instrument
panel. See Knee Blocker in Group 8E - InstrumentPanel Systems for the procedures.
(3) Remove the three screws that secure the lowersteering column shroud to the upper shroud (Fig. 2).
Fig. 2 Steering Column Shrouds Remove/Install
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TJ VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5
REMOVAL AND INSTALLATION (Continued)
(4) If the vehicle is equipped with a standard non-ilt steering column, loosen the two upper steeringolumn mounting nuts. If the vehicle is equippedith the optional tilt steering column, move the tilt
teering column to the fully lowered position.(5) Remove both the upper and lower shrouds from
he steering column.(6) Disengage the steering column wire harness
etainer from the tab on the top of the Sentry Keymmobilizer Module (SKIM) mounting bracket (Fig.).(7) Unplug the wire harness connector from the
KIM receptacle.(8) The SKIM mounting bracket features a clip for-ation that secures the SKIM to the inboard lower
lange of the steering column jacket. Pull downward
Fig. 3 Sentry Key Immobili
on the connector end of the SKIM mounting bracketto release this clip from the steering column jacket.
(9) Rotate the SKIM and its mounting bracketdownwards and then to the side away from the steer-ing column to slide the SKIM antenna ring fromaround the ignition switch lock cylinder housing.
(10) Remove the SKIM from the vehicle.(11) Reverse the removal procedures to install.
Tighten the non-tilt steering column mounting nutsto 22 N·m (200 in. lbs.) and the steering columnshroud mounting screws to 2 N·m (18 in. lbs.).
(12) If the SKIM is replaced with a new unit, aRB scan tool and the proper Diagnostic Proceduresanual MUST be used to initialize the new SKIM
nd to program at least two Sentry Key transponders.
REMOVAL AND INSTALLATIONCHIME WARNING SYSTEM SWITCHES . . . . . . . 4
ENERAL INFORMATION
NTRODUCTIONThis group covers the chime warning system,hich is standard factory-installed equipment on thisodel. The chime warning system provides an audi-
le warning to the driver under the following condi-ions:
• Check gauges lamp illumination• Driver side seat belt is not fastened with the
gnition switch in the On position• Head or park lamps are turned on with the igni-
ion switch Off and the driver side front door open• Key is in the ignition switch with the ignition
witch Off and the driver side front door open• Low fuel warning lamp illumination - less than
bout one-eighth tank of fuel remaining• The optional Sentry Key Immobilizer System
SKIS) is in the “customer programming” mode.Following are general descriptions of the major
omponents in the chime warning system. Refer toW-40 Instrument Cluster or 8W-44 - Interior Light-ng in Group 8W - Wiring Diagrams for complete cir-uit descriptions and diagrams.
ESCRIPTION AND OPERATION
NSTRUMENT CLUSTERThe instrument cluster is an electromechanical
nit that contains integrated circuitry and internalrogramming to perform a variety of functions. Thenstrument cluster circuitry monitors hard-wiredwitch inputs, as well as message inputs receivedrom other vehicle electronic modules on the Chryslerollision Detection (CCD) data bus network.The instrument cluster uses these many inputs
long with its internal programming and an integral
chime tone generator to perform the functions of thechime warning module on this model. The instru-ment cluster circuitry also has a self-diagnostic capa-bility. Refer to Group 8E - Instrument Panel Systemsfor more information on this feature.
Hard-wired chime warning system inputs to theinstrument cluster include the following:
• Driver door jamb switch• Driver seat belt switch• Headlamp switch• Key-in ignition switch.The only instrument cluster diagnosis found in this
group consists of confirming the viability of the hard-wired chime request inputs to the instrument clustercircuitry. For diagnosis of the CCD data bus and thedata bus message inputs, a DRB scan tool and theproper Diagnostic Procedures manual are recom-mended.
Refer to Group 8E - Instrument Panel Systems forthe instrument cluster service procedures. Theinstrument cluster chime warning circuitry andchime tone generator cannot be repaired and, iffaulty or damaged, the instrument cluster assemblymust be replaced.
DRIVER DOOR JAMB SWITCHThe driver door jamb switch is mounted to the
driver side door hinge pillar. The switch closes a pathto ground for the instrument cluster chime warningcircuitry through the key-in ignition switch and/orthe headlamp switch when the driver door is opened,and opens the ground path when the driver door isclosed.
The driver door jamb switch cannot be repairedand, if faulty or damaged, it must be replaced. Referto Group 8L - Lamps for the service procedures.
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8U - 2 CHIME/BUZZER WARNING SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
RIVER SEAT BELT SWITCHThe driver seat belt switch is integral to the driver
eat belt buckle-half assembly. The switch is nor-ally closed, providing a ground path to the instru-ent panel chime warning circuitry. When the tip-alf of the seat belt is inserted into the seat beltuckle, the switch opens the ground path.The driver seat belt switch cannot be repaired and,
f faulty or damaged, the entire driver seat belt buck-e-half unit must be replaced. Refer to Group 23 -ody for the service procedures.
EY-IN IGNITION SWITCHThe key-in ignition switch is integral to the igni-
ion switch, which is mounted on the left side of theteering column, opposite the ignition lock cylinder.t closes a path to ground for the instrument clusterhime warning circuitry when the ignition key isnserted in the ignition lock cylinder and the driveroor jamb switch is closed (driver door is open). Theey-in ignition switch opens the ground path whenhe key is removed from the ignition lock cylinder.
The key-in ignition switch cannot be repaired and,f faulty or damaged, the entire ignition switch muste replaced. Refer to Group 8D - Ignition Systems forhe service procedures.
EADLAMP SWITCHThe headlamp switch is located in the instrument
anel, outboard of the steering column. It closes aath to ground for the instrument cluster chimearning circuitry when the park or head lamps aren and the driver door jamb switch is closed (driveroor is open). The headlamp switch opens the groundath when the headlamp switch is turned off.The headlamp switch cannot be repaired and, if
aulty or damaged, it must be replaced. Refer toroup 8E - Instrument Panel Systems for the servicerocedures.
IAGNOSIS AND TESTING
RIVER DOOR JAMB SWITCHFor circuit descriptions and diagrams, refer to
W-40 - Instrument Cluster or 8W-44 - Interiorighting in Group 8W - Wiring Diagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Rotate the headlamp switch knob counterclock-wise to ensure that the dome lamps are not switchedoff. Open the driver door and note whether the inte-rior lamps light. They should light. If OK, see thediagnosis for the Key-In Ignition Switch or the Head-lamp Switch in this group. If not OK, go to Step 2.
(2) Disconnect and isolate the battery negativecable. Unplug the driver door jamb switch from itswire harness connector. Check for continuity betweenthe door jamb switch output circuit cavity of thedriver door jamb switch wire harness connector anda good ground. There should be continuity. If OK, goto Step 3. If not OK, repair the circuit to ground asrequired.
(3) Check for continuity between the door jambswitch output circuit terminal and the left front doorjamb switch sense terminal of the door jamb switch.There should be continuity with the switch plungerreleased, and no continuity with the switch plungerdepressed. If not OK, replace the faulty switch.
DRIVER SEAT BELT SWITCHFor circuit descriptions and diagrams, refer to
8W-40 - Instrument Cluster or 8W-44 - InteriorLighting in Group 8W - Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Disconnect and isolate the battery negativecable. Unplug the driver seat belt switch wire har-ness connector on the floor under the driver seatnear the seat belt buckle-half anchor. Check for con-tinuity between the seat belt switch sense circuit andthe ground circuit cavities of the seat belt half of thedriver seat belt switch wire harness connector. Thereshould be continuity with the seat belt unbuckled,and no continuity with the seat belt buckled. If OK,go to Step 2. If not OK, replace the faulty seat beltbuckle-half assembly.
(2) Check for continuity between the ground cir-cuit cavity in the body half of the driver seat beltswitch wire harness connector and a good ground.There should be continuity. If OK, see the Instru-ment Cluster diagnosis in this group. If not OK,repair the circuit to ground as required.
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TJ CHIME/BUZZER WARNING SYSTEMS 8U - 3
DIAGNOSIS AND TESTING (Continued)
EY-IN IGNITION SWITCHFor circuit descriptions and diagrams, refer to
W-40 - Instrument Cluster or 8W-44 - Interiorighting in Group 8W - Wiring Diagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable. Remove the steering column shrouds. Refer toroup 8D - Ignition Systems for the procedures.nplug the key-in ignition switch wire harness con-ector from the ignition switch.(2) Check for continuity between the key-in switch
ense circuit and the left front door jamb switchense circuit terminals of the key-in ignition switch.here should be continuity with the key in the igni-ion lock cylinder, and no continuity with the keyemoved from the ignition lock cylinder. If OK, go totep 3. If not OK, replace the faulty ignition switchssembly.(3) Check for continuity between the left front door
amb switch sense circuit cavity of the key-in ignitionwitch wire harness connector and a good ground.here should be continuity with the driver door open,nd no continuity with the driver door closed. If OK,ee the diagnosis for Instrument Cluster in thisroup. If not OK, repair the circuit to the driver dooramb switch as required.
EADLAMP SWITCHFor circuit descriptions and diagrams, refer to
W-40 - Instrument Cluster or 8W-44 - Interiorighting in Group 8W - Wiring Diagrams.
ARNING: ON VEHICLES EQUIPPED WITH AIR-AGS, REFER TO GROUP 8M - PASSIVEESTRAINT SYSTEMS BEFORE ATTEMPTING ANYTEERING WHEEL, STEERING COLUMN, OR
NSTRUMENT PANEL COMPONENT DIAGNOSIS ORERVICE. FAILURE TO TAKE THE PROPER PRE-AUTIONS COULD RESULT IN ACCIDENTAL AIR-AG DEPLOYMENT AND POSSIBLE PERSONAL
NJURY.
(1) Disconnect and isolate the battery negativeable. Remove the headlamp switch from the instru-ent panel. Refer to Group 8E - Instrument Panelystems for the procedures. Unplug the headlampwitch wire harness connectors. Check for continuity
between the left front door jamb switch sense circuitcavity of the headlamp switch wire harness connectorand a good ground. There should be no continuitywith the driver door closed, and continuity with thedriver door open. If OK, go to Step 2. If not OK,repair the circuit to the driver door jamb switch asrequired.
(2) Check for continuity between the key-in switchsense circuit terminal and the left front door jambswitch sense terminal of the headlamp switch. Thereshould be no continuity with the switch in the Offposition, and continuity with the switch in the parkor head lamps On position. If OK, see the diagnosisfor the Instrument Cluster in this group. If not OK,replace the faulty headlamp switch.
INSTRUMENT CLUSTERBefore performing this test, complete the testing of
the hard-wired chime warning system switches asdescribed in this group. For circuit descriptions anddiagrams, refer to 8W-40 - Instrument Cluster or8W-44 - Interior Lighting in Group 8W - Wiring Dia-grams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO GROUP 8M - PASSIVERESTRAINT SYSTEMS BEFORE ATTEMPTING ANYSTEERING WHEEL, STEERING COLUMN, ORINSTRUMENT PANEL COMPONENT DIAGNOSIS ORSERVICE. FAILURE TO TAKE THE PROPER PRE-CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONALINJURY.
(1) Disconnect and isolate the battery negativecable. Remove the instrument cluster from theinstrument panel. Refer to Group 8E - InstrumentPanel Systems for the procedures.
(2) Unplug the headlamp switch and the key-inignition switch wire harness connectors. Check forcontinuity between the key-in switch sense circuitcavity of the right instrument cluster wire harnessconnector (connector B) and a good ground. Thereshould be no continuity. If OK, go to Step 3. If notOK, repair the short circuit as required.
(3) Check for continuity between the key-in switchsense circuit cavities of the right instrument clusterwire harness connector (connector B) and the head-lamp switch wire harness connector. There should becontinuity. If OK, go to Step 4. If not OK, repair theopen circuit as required.
(4) Unplug the driver seat belt switch wire har-ness connector. Check for continuity between the seatbelt switch sense circuit cavity of the right instru-ment cluster wire harness connector (connector B)and a good ground. There should be no continuity. If
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8U - 4 CHIME/BUZZER WARNING SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
K, go to Step 5. If not OK, repair the short circuits required.(5) Check for continuity between the seat belt
witch sense circuit cavities of the right instrumentluster wire harness connector (connector B) and theriver seat belt switch wire harness connector. Therehould be continuity. If OK, test the instrument clus-er as described in Group 8E - Instrument Panel Sys-ems. If not OK, repair the open circuit as required.
EMOVAL AND INSTALLATION
HIME WARNING SYSTEM SWITCHESService procedures for the various hard-wired
witches used in the chime warning system can beound in the proper group as follows:
• Driver door jamb switch - refer to Group 8L -Lamps
• Driver seat belt switch - refer to Group 23 -Body
• Headlamp switch - refer to Group 8E - Instru-ment Panel Systems
• Key-in ignition switch - refer to Group 8D - Igni-tion Systems.
NTRODUCTIONChrysler wiring diagrams are designed to provide
nformation regarding the vehicles wiring content. Inrder to effectively use Chrysler wiring diagrams toiagnose and repair a Chrysler vehicle, it is impor-ant to understand all of their features and charac-eristics.
Diagrams are arranged such that the power (B+)ide of the circuit is placed near the top of the page,nd the ground (B-) side of the circuit is placed nearhe bottom of the page.
All switches, components, and modules are shownn the at rest position with the doors closed and the
Components are shown two ways. A solid linearound a component indicates that the component iscomplete. A dashed line around a component indi-cates that the component being shown is not com-plete. Incomplete components have a referencenumber to indicate the page where the component isshown complete.
It is important to realize that no attempt is madeon the diagrams to represent components and wiringas they appear on the vehicle. For example, a shortpiece of wire is treated the same as a long one. Inaddition, switches and other components are shownas simply as possible, with regard to function only.
8W - 01 - 2 8W - 01 GENERAL INFORMATION TJ
DESCRIPTION AND OPERATION (Continued)
The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 3
DESCRIPTION AND OPERATION (Continued)
The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING
DIAGRAM SECTION.
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8W - 01 - 4 8W - 01 GENERAL INFORMATION TJ
DESCRIPTION AND OPERATION (Continued)
IRCUIT INFORMATIONEach wire shown in the diagrams contains a codehich identifies the main circuit, part of the main
ircuit, gage of wire, and color (Fig. 1).
Fig. 1 Wire Code Identification
WIRE COLOR CODE CHART
COLOR CODE COLORSTANDARDTRACERCOLOR
BL BLUE WT
BK BLACK WT
BR BROWN WT
DB DARK BLUE WT
DG DARK GREEN WT
GY GRAY BK
LB LIGHT BLUE BK
LG LIGHT GREEN BK
OR ORANGE BK
PK PINK BK or WT
RD RED WT
TN TAN WT
VT VIOLET WT
WT WHITE BK
YL YELLOW BK
* WITH TRACER
CIRCUIT FUNCTIONSAll circuits in the diagrams use an alpha/numeric
code to identify the wire and its function. To identifywhich circuit code applies to a system, refer to theCircuit Identification Code Chart. This chart showsthe main circuits only and does not show the second-ary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT FUNCTION
A BATTERY FEED
B BRAKE CONTROLS
C CLIMATE CONTROLS
D DIAGNOSTIC CIRCUITS
E DIMMING ILLUMINATION CIRCUITS
F FUSED CIRCUITS
G MONITORING CIRCUITS (GAUGES)
H OPEN
I NOT USED
J OPEN
K POWERTRAIN CONTROL MODULE
L EXTERIOR LIGHTING
M INTERIOR LIGHTING
N NOT USED
O NOT USED
P POWER OPTION (BATTERY FEED)
Q POWER OPTIONS (IGNITION FEED)
R PASSIVE RESTRAINT
S SUSPENSION/STEERING
T TRANSMISSION/TRANSAXLE/TRANSFER CASE
U OPEN
V SPEED CONTROL, WIPER/WASHER
W OPEN
X AUDIO SYSTEMS
Y OPEN
Z GROUNDS
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TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 5
DESCRIPTION AND OPERATION (Continued)
ECTION IDENTIFICATIONThe wiring diagrams are grouped into individual
ections. If a component is most likely found in a par-icular group, it will be shown complete (all wires,onnectors, and pins) within that group. For exam-le, the Auto Shutdown Relay is most likely to beound in Group 30, so it is shown there complete. Itan, however, be shown partially in another group ift contains some associated wiring.
GROUP TOPIC
8W-01 thru 8W-09 General Information andDiagram Overview
8W-10 thru 8W-19 Main Sources of Power andVehicle Grounding
8W-20 thru 8W-29 Starting and Charging
SYMBOLSInternational symbols are used throughout the wir-
ing diagrams. These symbols are consistent withthose being used around the world
8W-30 thru 8W-39 Powertrain/DrivetrainSystems
8W-40 thru 8W-49 Body Electrical items and A/C
8W-50 thru 8W-59 Exterior Lighting, Wipers, andTrailer Tow
8W-60 thru 8W-69 Power Accessories
8W-70 Splice Information
8W-80 Connector Pin Outs
8W-90 Connector Locations(including grounds)
8W-95 Splice Locations
8W - 01 - 6 8W - 01 GENERAL INFORMATION TJ
DESCRIPTION AND OPERATION (Continued)
Wiring Diagram Symbols
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TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 7
DESCRIPTION AND OPERATION (Continued)
ERMINOLOGYThis a list of terms with there definitions used in
he wiring diagrams.
Built-Up-Export . . . . . . . . Vehicles Built For Sale InMarkets Other Than North America
Except-Built-Up-Export . . Vehicles Built For Sale InNorth America
AUTION: Not all connectors are serviced. Someonnectors are serviced only with a harness. A typ-cal example might be the Supplemental Restraintystem connectors. Always check parts availabilityefore attempting a repair.
DENTIFICATIONIn-line connectors are identified by a number, as
ollows:• In-line connectors located on the engine com-
artment harness are C100 series numbers.• Connectors located on the instrument panel
arness are C200 series numbers.• Connectors located on the body harness are300 series numbers.• Jumper harness connectors are C400 series
umbers.• Grounds and ground connectors are identi-
ied with a “G” and follow the same series number-ng as the in-line connector.
Component connectors are identified by the compo-ent name instead of a number (Fig. 2). Multipleonnectors on a component use a C1, C2, etc. identi-ier (Fig. 3).
illustrations. The illustrations contain the connectorname (or number)/ground number and componentidentification. Connector/ground location charts inSection 8W-90 reference the illustration number forcomponents and connectors.
Section 8W-80 shows each connector and the cir-cuits involved with that connector. The connectorsare identified using the name/number on the Dia-gram pages.
SPLICE LOCATIONSSplice Location charts in Section 8W-70 show the
entire splice, and provide references to other sectionsthe splice serves.
Section 8W-95 contains illustrations that show thegeneral location of the splices in each harness. Theillustrations show the splice by number, and providea written location.
NOTES, CAUTIONS, and WARNINGSThroughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,and Warnings.
NOTES are used to help describe how switches orcomponents operate to complete a particular circuit.They are also used to indicate different conditionsthat may appear on the vehicle. For example, anup-to and after condition.
CAUTIONS are used to indicate information thatcould prevent making an error that may damage thevehicle.
WARNINGS provide information to prevent per-sonal injury and vehicle damage. Below is a list ofgeneral warnings that should be followed any time avehicle is being serviced.
WARNING: USE SAFETY STANDS ANYTIME A PRO-CEDURE REQUIRES BEING UNDER A VEHICLE.
Fig. 3 Connector Identification
WAP
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WWF
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WNP
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8W - 01 - 8 8W - 01 GENERAL INFORMATION TJ
DESCRIPTION AND OPERATION (Continued)
ARNING: BE SURE THAT THE IGNITION SWITCHLWAYS IS IN THE OFF POSITION, UNLESS THEROCEDURE REQUIRES IT TO BE ON.
ARNING: SET THE PARKING BRAKE WHENORKING ON ANY VEHICLE. AN AUTOMATIC
RANSMISSION SHOULD BE IN PARK. A MANUALRANSMISSION SHOULD BE IN NEUTRAL.
ARNING: OPERATE THE ENGINE ONLY IN AELL-VENTILATED AREA.
ARNING: KEEP AWAY FROM MOVING PARTSHEN THE ENGINE IS RUNNING, ESPECIALLY THE
AN AND BELTS.
ARNING: TO PREVENT SERIOUS BURNS, AVOIDONTACT WITH HOT PARTS SUCH AS THE RADIA-OR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-YTIC CONVERTER, AND MUFFLER.
ARNING: DO NOT ALLOW FLAME OR SPARKSEAR THE BATTERY. GASES ARE ALWAYSRESENT IN AND AROUND THE BATTERY.
ARNING: ALWAYS REMOVE RINGS, WATCHES,OOSE HANGING JEWELRY, AND LOOSE CLOTH-
NG.
AKE OUTSThe abbreviation T/O is used in the component
ocation section to indicate a point in which the wir-ng harness branches out to a component.
LECTROSTATIC DISCHARGE (ESD) SENSITIVEEVICESAll ESD sensitive components are solid state and a
ymbol (Fig. 4) is used to indicate this. When han-ling any component with this symbol comply withhe following procedures to reduce the possibility oflectrostatic charge build up on the body and inad-ertent discharge into the component. If it is notnown whether the part is ESD sensitive, assumehat it is.
(1) Always touch a known good ground before han-ling the part. This should be repeated while han-ling the part and more frequently after slidingcross a seat, sitting down from a standing position,r walking a distance.(2) Avoid touching electrical terminals of the part,
nless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect theground lead first.
(4) Do not remove the part from its protectivepacking until it is time to install the part.
(5) Before removing the part from its package,ground the package to a known good ground on thevehicle.
DIAGNOSIS AND TESTING
TROUBLESHOOTING TOOLSWhen diagnosing a problem in an electrical circuit
there are several common tools necessary. These toolsare listed and explained below.
• Jumper Wire - This is a test wire used to con-nect two points of a circuit. It can be used to bypassan open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSSA LOAD, SUCH AS A MOTOR, CONNECTEDBETWEEN A BATTERY FEED AND GROUND.
• Voltmeter - Used to check for voltage on a cir-cuit. Always connect the black lead to a known goodground and the red lead to the positive side of thecircuit.
CAUTION: Most of the electrical components usedin today’s vehicle are solid state. When checkingvoltages in these circuits use a meter with a 10-me-gohm or greater impedance rating.
• Ohmmeter - Used to check the resistancebetween two points of a circuit. Low or no resistancein a circuit means good continuity.
CAUTION: - Most of the electrical components usedin today’s vehicle are Solid State. When checkingresistance in these circuits use a meter with a10-megohm or greater impedance rating. In addi-tion, make sure the power is disconnected from thecircuit. Circuits that are powered up by the vehicleelectrical system can cause damage to the equip-ment and provide false readings.
Fig. 4 Electrostatic Discharge Symbol
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TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 9
DIAGNOSIS AND TESTING (Continued)
• Probing Tools - These tools are used for probingerminals in connectors (Fig. 5). Select the properize tool from Special Tool Package 6807, and insertt into the terminal being tested. Use the other endf the tool to insert the meter probe.
NTERMITTENT AND POOR CONNECTIONSMost intermittent electrical problems are caused
y faulty electrical connections or wiring. It is alsoossible for a sticking component or relay to cause aroblem. Before condemning a component or wiringssembly check the following items.• Connectors are fully seated• Spread terminals, or terminal push out• Terminals in the wiring assembly are fully
eated into the connector/component and locked inosition• Dirt or corrosion on the terminals. Any amount
f corrosion or dirt could cause an intermittent prob-em
• Damaged connector/component casing exposinghe item to dirt and moisture
• Wire insulation that has rubbed through causingshort to ground• Some or all of the wiring strands broken inside
f the insulation covering.• Wiring broken inside of the insulation
ROUBLESHOOTING TESTSBefore beginning any tests on a vehicles electrical
ystem use the Wiring Diagrams and study the cir-uit. Also refer to the Troubleshooting Wiring Prob-ems in this section.
ESTING FOR VOLTAGE POTENTIAL(1) Connect the ground lead of a voltmeter to a
nown good ground (Fig. 6).(2) Connect the other lead of the voltmeter to the
elected test point. The vehicle ignition may need toe turned ON to check voltage. Refer to the appropri-te test procedure.
Fig. 5 Probing Tool
TESTING FOR CONTINUITY(1) Remove the fuse for the circuit being checked
or, disconnect the battery.(2) Connect one lead of the ohmmeter to one side
of the circuit being tested (Fig. 7).(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means goodcontinuity.
Fig. 6 Testing for Voltage Potential
Fig. 7 Testing for Continuity
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8W - 01 - 10 8W - 01 GENERAL INFORMATION TJ
DIAGNOSIS AND TESTING (Continued)
ESTING FOR A SHORT TO GROUND(1) Remove the fuse and disconnect all items
nvolved with the fuse.(2) Connect a test light or a voltmeter across the
erminals of the fuse.(3) Starting at the fuse block, wiggle the wiring
arness about six to eight inches apart and watchhe voltmeter/test lamp.
(4) If the voltmeter registers voltage or the testamp glows, there is a short to ground in that gen-ral area of the wiring harness.
ESTING FOR A SHORT TO GROUND ON FUSESOWERING SEVERAL LOADS(1) Refer to the wiring diagrams and disconnect or
solate all items on the suspected fused circuits.(2) Replace the blown fuse.(3) Supply power to the fuse by turning ON the
gnition switch or re-connecting the battery.(4) Start connecting the items in the fuse circuit
ne at a time. When the fuse blows the circuit withhe short to ground has been isolated.
ESTING FOR A VOLTAGE DROP(1) Connect the positive lead of the voltmeter to
he side of the circuit closest to the battery (Fig. 8).(2) Connect the other lead of the voltmeter to the
ther side of the switch or component.(3) Operate the item.(4) The voltmeter will show the difference in volt-
ge between the two points.
Fig. 8 Testing for Voltage Drop
TROUBLESHOOTING WIRING PROBLEMSWhen troubleshooting wiring problems there are
six steps which can aid in the procedure. The stepsare listed and explained below. Always check for non-factory items added to the vehicle before doing anydiagnosis. If the vehicle is equipped with these items,disconnect them to verify these add-on items are notthe cause of the problem.
(1) Verify the problem.(2) Verify any related symptoms. Do this by per-
forming operational checks on components that arein the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-grams to determine what the circuit is doing, wherethe problem most likely is occurring and where thediagnosis will continue.
(4) Isolate the problem area.(5) Repair the problem.(6) Verify proper operation. For this step check for
proper operation of all items on the repaired circuit.Refer to the wiring diagrams.
SERVICE PROCEDURES
WIRING REPAIRWhen replacing or repairing a wire, it is important
that the correct gage be used as shown in the wiringdiagrams. The wires must also be held securely inplace 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 longenough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on eachpart of the exposed wire (example 1) (Fig. 9).
(5) Push the two ends of wire together until thestrands of wire are close to the insulation (example2) (Fig. 9).
(6) Twist the wires together (example 3) (Fig. 9).(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 thetubing is tightly sealed and sealant comes out of bothends of the tubing.
(9) Secure the wire to the existing ones to preventchafing or damage to the insulation.
(10) Connect battery and test all affected systems.
TERMINAL/CONNECTOR REPAIR-MOLEXCONNECTORS
(1) Disconnect battery.
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TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 11
SERVICE PROCEDURES (Continued)
(2) Disconnect the connector from its mating half/omponent.(3) Insert the terminal releasing special tool 6742
nto the terminal end of the connector (Fig. 10).
(4) Using special tool 6742 release the locking fin-ers on the terminal (Fig. 11).(5) Pull on the wire to remove it from the connec-
or.(6) Repair or replace the connector or terminal, as
(2) Disconnect the connector from its mating half/component.
(3) Push in the two lock tabs on the side of theconnector (Fig. 12).
(4) Insert the probe end of special tool 6934 intothe back of the connector cavity (Fig. 13).
(5) Grasp the wire and tool 6934 and slowlyremove the wire and terminal from the connector.
(6) Repair or replace the terminal.(7) Install the wire and terminal in the connector.
Fully seat the terminal in the connector.(8) Push in the single lock tab on the side of the
connector (Fig. 14).
CONNECTOR REPLACEMENT(1) Disconnect battery.(2) Disconnect the connector that is to be repaired
from its mating half/component.(3) Remove the connector locking wedge, if
required (Fig. 15).
Fig. 11 Using Special Tool 6742
Fig. 12 Thomas and Betts Connector Lock ReleaseTabs
Fig. 13 Removing Wire Terminal
8W - 01 - 12 8W - 01 GENERAL INFORMATION TJ
SERVICE PROCEDURES (Continued)
(4) Position the connector locking finger away fromthe terminal using the proper pick from special toolkit 6680. Pull on the wire to remove the terminalfrom the connector (Fig. 16) (Fig. 17).
(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 insertedinto the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams.
(8) Insert the connector locking wedge into therepaired connector, if required.
(9) Connect connector to its mating half/compo-nent.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL REPLACEMENT(1) Disconnect battery.(2) Disconnect the connector (that is to be
repaired) from its mating half/component.
Fig. 16 Terminal Removal
Fig. 17 Terminal Removal Using Special Tool
Fig. 14 Single Lock Tab
Fig. 15 Connector Locking Wedge
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TJ 8W - 01 GENERAL INFORMATION 8W - 01 - 13
SERVICE PROCEDURES (Continued)
(3) Cut off the existing wire connector directlyehind the insulator. Remove six inches of tape fromhe harness.
(4) Stagger cut all wires on the harness side at 1/2nch intervals (Fig. 18).
(5) Remove 1 inch of insulation from each wire onhe harness side.
(6) Stagger cut the matching wires on the repaironnector assembly in the opposite order as was donen the harness side of the repair. Allow extra lengthor soldered connections. Check that the overallength is the same as the original (Fig. 18).
(7) Remove 1 inch of insulation from each wire.(8) Place a piece of heat shrink tubing over one
ide of the wire. Be sure the tubing will be longnough to cover and seal the entire repair area.(9) Spread the strands of the wire apart on each
art of the exposed wires.(10) Push the two ends of wire together until the
trands of wire are close to the insulation.(11) Twist the wires together.(12) Solder the connection together using rosin
ore type solder only. Do not use acid core solder.(13) Center the heat shrink tubing over the joint
nd heat using a heat gun. Heat the joint until theubing is tightly sealed and sealant comes out of bothnds of the tubing.(14) Repeat steps 8 through 13 for each wire.(15) Re-tape the wire harness starting 1-1/2 inches
ehind the connector and 2 inches past the repair.(16) Re-connect the repaired connector.(17) Connect the battery, and test all affected sys-
ems.
ERMINAL REPLACEMENT(1) Disconnect battery.(2) Disconnect the connector being repaired from
(3) Remove connector locking wedge, if required(Fig. 19).
(4) Position the connector locking finger away fromthe terminal using the proper pick from special toolkit 6680. Pull on the wire to remove the terminalfrom the connector (Fig. 20) (Fig. 21).
(5) Cut the wire 6 inches from the back of the con-nector.
(6) Remove 1 inch of insulation from the wire onthe harness side.
(7) Select a wire from the terminal repair assem-bly that best matches the color wire being repaired.
(8) Cut the repair wire to the proper length andremove 1 inch of insulation.
(9) Place a piece of heat shrink tubing over oneside of the wire. Make sure the tubing will be longenough to cover and seal the entire repair area.
(10) Spread the strands of the wire apart on eachpart of the exposed wires.
(11) Push the two ends of wire together until thestrands of wire are close to the insulation.
Fig. 19 Connector Locking Wedge Tab (Typical)
Fig. 20 Terminal Removal
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8W - 01 - 14 8W - 01 GENERAL INFORMATION TJ
SERVICE PROCEDURES (Continued)
(12) Twist the wires together.(13) Solder the connection together using rosin
ore type solder only. Do not use acid core solder.(14) Center the heat shrink tubing over the joint
nd heat using a heat gun. Heat the joint until theubing is tightly sealed and sealant comes out of bothnds of the tubing.(15) Insert the repaired wire into the connector.(16) Install the connector locking wedge, if
equired, and reconnect the connector to its matingalf/component.(17) Re-tape the wire harness starting 1-1/2 inches
ehind the connector and 2 inches past the repair.(18) Connect battery, and test all affected systems.
Fig. 21 Terminal Removal Using Special Tool
DIODE REPLACEMENT(1) Disconnect the battery.(2) Locate the diode in the harness, and remove
the protective covering.(3) Remove the diode from the harness, pay atten-
tion to the current flow direction (Fig. 22).
(4) Remove the insulation from the wires in theharness. Only remove enough insulation to solder inthe new diode.
(5) Install the new diode in the harness, makingsure current flow is correct. If necessary refer to theappropriate wiring diagram for current flow.
(6) Solder the connection together using rosin coretype solder only. Do not use acid core solder.
(7) Tape the diode to the harness using electricaltape making, sure the diode is completely sealedfrom the elements.
(8) Re-connect the battery, and test affected sys-tems.
ESCRIPTIONA large capacity, low-maintenance storage battery
s standard factory-installed equipment on thisodel. This battery is designed to provide a safe, effi-
ient and reliable means of storing electrical energyn a chemical form. This means of energy storagellows the battery to produce the electrical energyequired to operate the engine starting system, asell as to operate many of the other vehicle acces-
ory systems for limited durations while the enginend/or the charging system are not operating.The factory-installed low-maintenance bat-
ery has removable battery cell caps. Water cane added to this battery. The battery is not sealednd has vent holes in the cell caps (Fig. 1). Thehemical composition within the low-maintenanceattery reduces battery gassing and water loss, atormal charge and discharge rates.
Fig. 1 Low-Maintenance Battery - Typical
Rapid loss of electrolyte can be caused by an over-charging condition. Be certain to diagnose the charg-ing system before returning the vehicle to service.Refer to Charging System in the Diagnosis andTesting section of Group 8C - Charging System formore information.
The factory-installed battery also has a built-intest indicator (hydrometer). The color visible in thesight glass of the indicator will reveal the batterycondition. Refer to Built-In Test Indicator in theDiagnosis and Testing section of this group for moreinformation.
This group covers only the battery diagnostic andservice procedures. For battery maintenance sched-ules and jump starting procedures, see the owner’smanual in the vehicle glove box, or refer to Mainte-nance Schedules and Jump Starting, Towingand Hoisting in Group 0 - Lubrication and Mainte-nance. While battery charging can be considered amaintenance procedure, battery charging informationis located in this group. This was done because thebattery must be fully-charged before any diagnosiscan be performed.
Group 8A covers the Battery, Group 8B covers theStarting Systems, and Group 8C covers the ChargingSystem. We have separated these systems to make iteasier to locate the information you are seekingwithin this Service Manual. However, when attempt-ing to diagnose any of these systems, it is importantthat you keep their interdependency in mind.
The battery, starting, and charging systems in thevehicle operate with one another, and must be testedas a complete system. In order for the vehicle to startand charge properly, all of the components that areused in these systems must perform within specifica-tions. It is important that the battery, starting, andcharging systems be thoroughly tested and inspectedany time a battery needs to be charged or replaced.The cause of abnormal discharge, overcharging, orearly battery failure must be diagnosed and correctedbefore a battery is replaced or returned to service.
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8A - 2 BATTERY TJ
DESCRIPTION AND OPERATION (Continued)
The diagnostic procedures used in each of theseroups include the most basic conventional diagnosticethods, to the more sophisticated On-Board Diag-ostics (OBD) built into the Powertrain Control Mod-le (PCM). Use of an induction-type milliamperemmeter, volt/ohmmeter, battery charger, carbon pileheostat (load tester), and 12-volt test lamp may beequired.All OBD-sensed systems are monitored by the
CM. Each monitored circuit is assigned a Diagnos-ic Trouble Code (DTC). The PCM will store a DTC inlectronic memory for any failure it detects. Refer ton-Board Diagnostic Test For Charging System
n the Diagnosis and Testing section of Group 8C -harging System for more information.
PERATIONThe storage battery is a device used to store elec-
rical energy potential in a chemical form. When anlectrical load is applied to the battery terminals, anlectrochemical reaction occurs within the battery.his reaction causes the battery to discharge electri-al current.The battery is made up of six individual cells that
re connected in series. Each cell contains positivelyharged plate groups made of lead oxide, and nega-ively charged plate groups made of sponge lead.hese dissimilar metal plates are submerged in aulfuric acid and water solution called an electrolyte.As the battery discharges, a gradual chemical
hange takes place within each cell. The sulfuric acidn the electrolyte combines with the plate materials,ausing both plates to slowly change to lead sulfate.t the same time, oxygen from the positive plateaterial combines with hydrogen from the sulfuric
cid, causing the electrolyte to become mainly water.The chemical changes within the battery are
aused by the movement of excess or free electronsetween the positive and negative plate groups. Thisovement of electrons produces a flow of electrical
urrent through the load device attached to the bat-ery terminals.
As the plate materials become more similar chem-cally, and the electrolyte becomes less acid, the volt-ge potential of each cell is reduced. However, byharging the battery with a voltage higher than thatf the battery, the battery discharging process iseversed.Charging the battery gradually changes the sul-
ated lead plates back into sponge lead and leadxide, and the water back into sulfuric acid. Thisction restores the difference in the electron chargeseposited on the plates, and the voltage potential ofhe battery cells.
For a battery to remain useful, it must be able toroduce high-amperage current over an extended
a
period. A battery must also be able to accept acharge, so that its voltage potential may be restored.
In addition to producing and storing electricalenergy, the battery serves as a capacitor, or voltagestabilizer, for the electrical system of the vehicle. Itabsorbs most abnormal or transient voltages causedby the switching of any of the electrical componentsin the vehicle.
The battery is vented to release excess hydrogengas that is created when the battery is being chargedor discharged. However, even with these vents, thehydrogen gas can collect in or around the battery. Ifhydrogen gas is exposed to flame or sparks, it mayignite.
If the electrolyte level is low, the battery may arcinternally and explode. If the battery is equippedwith removable cell caps, add distilled water when-ever the electrolyte level is below the top of theplates. If the battery cell caps cannot be removed, thebattery must be replaced if the electrolyte levelbecomes low.
BATTERY SIZE AND RATINGSThe battery Group Size number, the Cold Cranking
Amperage (CCA) rating, and the Reserve Capacity(RC) rating or Ampere-Hours (AH) rating can befound on the original equipment battery label. Becertain that a replacement battery has the correctGroup Size number, as well as CCA, and RC or AHratings that equal or exceed the original equipmentspecification for the vehicle being serviced.
Refer to Battery Classifications and Ratings inhe Specifications section of this group for more infor-ation. Battery sizes and ratings are discussed inore detail below.
ROUP SIZEThe outside dimensions and terminal placement of
he battery conform to standards established by theattery Council International (BCI). Each battery isssigned a BCI Group Size number to help identify aorrectly-sized replacement.
OLD CRANKING AMPERAGEThe Cold Cranking Amperage (CCA) rating speci-
ies how much current (in amperes) the battery caneliver for thirty seconds at -18° C (0° F). Terminaloltage must not fall below 7.2 volts during or afterhe thirty second discharge period. The CCA requireds generally higher as engine displacement increases,epending also upon the starter current drawequirements.
ESERVE CAPACITYThe Reserve Capacity (RC) rating specifies the
ime (in minutes) it takes for battery terminal volt-
ge to fall below 10.5 volts, at a discharge rate of 25
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TJ BATTERY 8A - 3
DESCRIPTION AND OPERATION (Continued)
mperes. RC is determined with the battery fully-harged at 26.7° C (80° F). This rating estimates howong the battery might last after a charging systemailure, under minimum electrical load.
MPERE-HOURSThe Ampere-Hours (AH) rating specifies the cur-
ent (in amperes) that a battery can deliver steadilyor twenty hours, with the voltage in the battery notalling below 10.5 volts. This rating is also sometimesdentified as the twenty-hour discharge rating.
OUNTINGThe battery is mounted in a stamped steel located
n the passenger side rear corner of the engine com-artment. A J-bolt is hooked through in the front andear edges of the tray. A hold down strap fits acrosshe top of the battery case. The J-bolts pass throughhe hold down strap on each side of the battery, and
nut secures the hold down strap to each of the-bolts.A plastic bubble-wrap style thermoguard slides
ver the battery case to enclose the sides of the bat-ery. The thermoguard protects the battery fromngine compartment temperature extremes.The battery tray is secured with four screws to a
upport bracket mounted between the front fendernner wheelhouse and the dash panel, rearward ofhe passenger side front wheel.
A hole in the bottom of the battery tray is fittedith a battery temperature sensor. Refer to Batteryemperature Sensor in the Description and Opera-ion section of Group 8C - Charging System for morenformation on this component.
When installing a battery, be certain that the holdown fasteners are tightened to the proper specifica-ions. Improper hold down fastener tightness,hether too loose or too tight, can result in damage
o the battery. Refer to Battery in the Removal andnstallation section of this group for the correct bat-ery hold down fastener tightness specifications.
IAGNOSIS AND TESTING
ATTERY
IAGNOSISThe battery, starting, and charging systems oper-
te with one another, and must be tested as a com-lete system. In order for the vehicle to start andharge properly, all of the components involved inhese systems must perform within specifications.
Group 8A covers the Battery, Group 8B covers thetarting Systems, and Group 8C covers the Chargingystem. We have separated these systems to make itasier to locate the information you are seeking
within this Service Manual. However, when attempt-ing to diagnose any of these systems, it is importantthat you keep their interdependency in mind.
The diagnostic procedures used in these groupsinclude the most basic conventional diagnostic meth-ods, to the more sophisticated On-Board Diagnostics(OBD) built into the Powertrain Control Module(PCM). Use of an induction-type milliampere amme-ter, volt/ohmmeter, battery charger, carbon pile rheo-stat (load tester), and 12-volt test lamp may berequired.
All OBD-sensed systems are monitored by thePCM. Each monitored circuit is assigned a Diagnos-tic Trouble Code (DTC). The PCM will store a DTC inelectronic memory for any failure it detects. Refer toOn-Board Diagnostic Test For Charging Systemin the Diagnosis and Testing section of Group 8C -Charging System for more information.
The battery must be completely charged and thetop, posts, and terminal clamps should be properlycleaned and inspected before diagnostic proceduresare performed. Refer to Battery in the Removal andInstallation section of this group for the proper bat-tery cleaning and inspection procedures. Refer toBattery Charging in the Service Procedures sectionof this group for the proper charging procedures.
WARNING:• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORCHARGE. THE BATTERY MAY ARC INTERNALLYAND EXPLODE. PERSONAL INJURY AND/OR VEHI-CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN ANDAROUND THE BATTERY. DO NOT SMOKE, USEFLAME, OR CREATE SPARKS NEAR THE BATTERY.PERSONAL INJURY AND/OR VEHICLE DAMAGEMAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,WHICH IS POISONOUS AND CAUSTIC. AVOID CON-TACT WITH THE SKIN, EYES, OR CLOTHING. INTHE EVENT OF CONTACT, FLUSH WITH WATERAND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTOF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-ABLE CELL CAPS, BE CERTAIN THAT EACH OFTHE CELL CAPS IS IN PLACE AND TIGHT BEFORETHE BATTERY IS RETURNED TO SERVICE. PER-SONAL INJURY AND/OR VEHICLE DAMAGE MAYRESULT FROM LOOSE OR MISSING CELL CAPS.
The condition of a battery is determined by two cri-teria:
1. State-Of-Charge - This can be determined bychecking the specific gravity of the battery electrolyte(built-in test indicator or hydrometer test), or by
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8A - 4 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
hecking the battery voltage (open-circuit voltageest).
2. Cranking Capacity - This can be determinedy performing a battery load test, which measureshe ability of the battery to supply high-amperageurrent.First, determine the battery state-of-charge. This
an be done in one of three ways. If the battery has auilt-in test indicator, view the test indicator toetermine the state-of-charge. If the battery has noest indicator, but has removable cell caps, performhe hydrometer test to determine the state-of-charge.f the cell caps are not removable, or a hydrometer isot available, perform the open-circuit voltage test toetermine the state-of-charge.The battery must be charged before proceedingith a load test if:• The battery built-in test indicator has a black or
ark color visible.• The temperature corrected specific gravity of the
attery electrolyte is less than 1.235.• The battery open-circuit voltage is less than 12.4
olts.
A battery that will not accept a charge is faulty,and must be replaced. Further testing is notrequired. A fully-charged battery must be load testedto determine its cranking capacity. A battery that isfully-charged, but does not pass the load test, isfaulty and must be replaced.
NOTE: Completely discharged batteries may takeseveral hours to accept a charge. Refer to BatteryCharging - Charging A Completely Discharged Bat-tery in the Service Procedures section of this groupfor more information.
A battery is fully-charged when:• All cells are gassing freely during charging.• A green color is visible in the sight glass of the
built-in test indicator.• Three corrected specific gravity tests, taken at
one-hour intervals, indicate no increase in the spe-cific gravity.
• Open-circuit voltage is 12.4 volts or greater.
TJ BATTERY 8A - 5
DIAGNOSIS AND TESTING (Continued)
Battery Diagnosis
Condition Possible Causes Correction
The battery seems weak ordead when attempting to startthe engine.
1. The battery has anincorrect size or rating forthis vehicle.2. The battery is physicallydamaged.3. The battery terminalconnections are loose orcorroded.4. The battery is discharged.5. The electrical systemignition-off draw is excessive.6. The battery is faulty.7. The starting system isfaulty.8. The charging system isfaulty.
1. Refer to Battery in the Specifications section ofthis group. Replace an incorrect battery with thecorrect battery.2. Inspect the battery for loose terminal posts or acracked and leaking case. Replace the battery, ifdamaged.3. Refer to Voltage Drop Test in the Diagnosisand Testing section of this group. Clean andtighten the battery terminal connections, ifrequired.4. Determine the battery state-of-charge. Refer toBuilt-In Test Indicator, Hydrometer Test, orOpen-Circuit Voltage Test in the Diagnosis andTesting section of this group. Charge the battery,if required.5. Refer to Ignition-Off Draw Test in the Diagnosisand Testing section of this group. Repair theelectrical system, if required.6. Determine the battery cranking capacity. Referto Load Test in the Diagnosis and Testing sectionof this group. Replace the battery, if required.7. Determine if the starting system is performingto specifications. Refer to Starting System in theDiagnosis and Testing section of Group 8B -Starting Systems for more information. Repair thestarting system, if required.8. Determine if the charging system is performingto specifications. Refer to Charging System in theDiagnosis and Testing section of Group 8C -Charging System for more information. Repair thecharging system, if required.
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8A - 6 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
Battery Diagnosis
Condition Possible Causes Correction
The battery state-of-chargecannot be maintained.
1. The battery has anincorrect size or rating forthis vehicle.2. The battery terminalconnections are loose orcorroded.3. The generator drive belt isslipping.4. The electrical systemignition-off draw is excessive.5. The battery is faulty.6. The starting system isfaulty.7. The charging system isfaulty.8. Electrical loads exceed theoutput of the chargingsystem.9. Slow driving or prolongedidling with high-amperagedraw systems in use.
1. Refer to Battery in the Specifications section ofthis group. Replace an incorrect battery with thecorrect battery.2. Refer to Voltage Drop Test in the Diagnosisand Testing section of this group. Clean andtighten the battery terminal connections, ifrequired.3. Refer to Accessory Drive Belt Diagnosis in theDiagnosis and Testing section of Group 7 -Cooling System for more information. Replace oradjust the generator drive belt, if required.4. Refer to Ignition-Off Draw Test in the Diagnosisand Testing section of this group. Repair theelectrical system, if required.5. Determine the battery cranking capacity. Referto Load Test in the Diagnosis and Testing sectionof this group. Replace the battery, if required.6. Determine if the starting system is performingto specifications. Refer to Starting System in theDiagnosis and Testing section of Group 8B -Starting Systems for more information. Repair thestarting system, if required.7. Determine if the charging system is performingto specifications. Refer to Charging System in theDiagnosis and Testing section of Group 8C -Charging System for more information. Repair thecharging system, if required.8. Inspect the vehicle for aftermarket electricalequipment which might cause excessive electricalloads.9. Advise the vehicle operator, as required.
The battery will not accept acharge.
1. The battery is faulty. 1. Refer to Battery Charging in the ServiceProcedures section of this group. Replace thefaulty battery, if required.
BNORMAL BATTERY DISCHARGINGAny of the following conditions can result in abnor-al battery discharging:1. Corroded or loose battery posts and terminal
lamps.2. A loose or worn generator drive belt.3. Electrical loads that exceed the output of the
harging system. This can be due to equipmentnstalled after manufacture, or repeated short tripse.4. Slow driving speeds (heavy traffic conditions) or
rolonged idling, with high-amperage draw systemsn use.
5. A faulty circuit or component causing excessivegnition-off draw. Refer to Ignition-Off Draw Testn the Diagnosis and Testing section of this group for
ore information.
6. A faulty or incorrect charging system compo-nent. Refer to Charging System in the Diagnosisand Testing section of Group 8C - Charging Systemfor more information.
7. A faulty or incorrect battery.
TESTING
BUILT-IN TEST INDICATORA test indicator (hydrometer) built into the top of
the battery case provides visual information for bat-tery testing (Fig. 2). Like a hydrometer, the built-intest indicator measures the specific gravity of theelectrolyte. The test indicator reveals the batterystate-of-charge; however, it will not reveal the crank-ing capacity of the battery. A load test must be per-formed to determine the battery cranking capacity.
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DIAGNOSIS AND TESTING (Continued)
efer to Load Test in the Diagnosis and Testing sec-ion of this group for more information.
ARNING:• IF THE BATTERY SHOWS SIGNS OF FREEZ-
NG, LEAKING, LOOSE POSTS, OR LOW ELECTRO-YTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORHARGE. THE BATTERY MAY ARC INTERNALLYND EXPLODE. PERSONAL INJURY AND/OR VEHI-LE DAMAGE MAY RESULT.• EXPLOSIVE HYDROGEN GAS FORMS IN AND
ROUND THE BATTERY. DO NOT SMOKE, USELAME, OR CREATE SPARKS NEAR THE BATTERY.ERSONAL INJURY AND/OR VEHICLE DAMAGEAY RESULT.• THE BATTERY CONTAINS SULFURIC ACID,HICH IS POISONOUS AND CAUSTIC. AVOID CON-
ACT WITH THE SKIN, EYES, OR CLOTHING. INHE EVENT OF CONTACT, FLUSH WITH WATERND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTF THE REACH OF CHILDREN.• IF THE BATTERY IS EQUIPPED WITH REMOV-
BLE CELL CAPS, BE CERTAIN THAT EACH OFHE CELL CAPS IS IN PLACE AND TIGHT BEFOREHE BATTERY IS RETURNED TO SERVICE. PER-ONAL INJURY AND/OR VEHICLE DAMAGE MAYESULT FROM LOOSE OR MISSING CELL CAPS.
Before testing, visually inspect the battery for anyamage (a cracked case or cover, loose posts, etc.)hat would cause the battery to be faulty. In order tobtain correct indications from the built-in test indi-ator, it is important that the battery be level andave a clean sight glass. Additional light may beequired to view the indicator. Do not use openlame as a source of additional light.
To read the built-in test indicator, look into theight glass and note the color of the indicator (Fig. 3).he battery condition that each color indicates isescribed in the following list:• Green - indicates 75% to 100% state-of-charge.
he battery is adequately charged for further testingr return to use. If the starter will not crank for ainimum of fifteen seconds with a fully-charged bat-
Fig. 2 Built-In Test Indicator
tery, the battery must be load tested. Refer to LoadTest in the Diagnosis and Testing section of thisgroup for more information.
• Black or Dark - indicates 0% to 75% state-of-charge. The battery is inadequately charged andmust be charged until a green indication is visible inthe sight glass (12.4 volts or more), before the bat-tery is tested further or returned to service. Refer toBattery Charging in the Service Procedures sectionof this group for more information. Also refer toAbnormal Battery Discharging in the Diagnosisand Testing section of this group for possible causesof the discharged condition.
• Clear or Bright - indicates a low electrolytelevel. The electrolyte level in the battery is below thetest indicator. A maintenance-free battery with non-removable cell caps must be replaced if the electro-lyte level is low. Water must be added to a low-maintenance battery with removable cell caps beforeit is charged. Refer to Battery Charging in the Ser-vice Procedures section of this group for more infor-mation. A low electrolyte level may be caused by anovercharging condition. Refer to Charging Systemin the Diagnosis and Testing section of Group 8C -Charging System to diagnose an overcharging condi-tion.
HYDROMETER TESTThe hydrometer test reveals the battery state-of-
charge by measuring the specific gravity of the elec-trolyte. This test cannot be performed onmaintenance-free batteries with non-removablecell caps. If the battery has non-removable cell caps,refer to Built-In Test Indicator or Open-CircuitVoltage Test in the Diagnosis and Testing section ofthis group.
Specific gravity is a comparison of the density ofthe electrolyte to the density of pure water. Purewater has a specific gravity of 1.000, and sulfuricacid has a specific gravity of 1.835. Sulfuric acidmakes up approximately 35% of the electrolyte byweight, or 24% by volume.
Fig. 3 Built-In Test Indicator Sight Glass
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8A - 8 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
In a fully-charged battery the electrolyte will havetemperature-corrected specific gravity of 1.260 to
.290. However, a specific gravity of 1.235 or above isatisfactory for battery load testing and/or return toervice.
ARNING:• IF THE BATTERY SHOWS SIGNS OF FREEZ-
NG, LEAKING, LOOSE POSTS, OR LOW ELECTRO-YTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORHARGE. THE BATTERY MAY ARC INTERNALLYND EXPLODE. PERSONAL INJURY AND/OR VEHI-LE DAMAGE MAY RESULT.• EXPLOSIVE HYDROGEN GAS FORMS IN AND
ROUND THE BATTERY. DO NOT SMOKE, USELAME, OR CREATE SPARKS NEAR THE BATTERY.ERSONAL INJURY AND/OR VEHICLE DAMAGEAY RESULT.• THE BATTERY CONTAINS SULFURIC ACID,HICH IS POISONOUS AND CAUSTIC. AVOID CON-
ACT WITH THE SKIN, EYES, OR CLOTHING. INHE EVENT OF CONTACT, FLUSH WITH WATERND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTF THE REACH OF CHILDREN.• IF THE BATTERY IS EQUIPPED WITH REMOV-
BLE CELL CAPS, BE CERTAIN THAT EACH OFHE CELL CAPS IS IN PLACE AND TIGHT BEFOREHE BATTERY IS RETURNED TO SERVICE. PER-ONAL INJURY AND/OR VEHICLE DAMAGE MAYESULT FROM LOOSE OR MISSING CELL CAPS.
Before testing, visually inspect the battery for anyamage (a cracked case or cover, loose posts, etc.)hat would cause the battery to be faulty. Thenemove the cell caps and check the electrolyte level.dd distilled water if the electrolyte level is below
he top of the battery plates.See the instructions provided by the manufacturer
f the hydrometer for recommendations on the cor-ect use of the hydrometer that you are using.emove only enough electrolyte from the battery cello that the float is off the bottom of the hydrometerarrel with pressure on the bulb released.
AUTION: Exercise care when inserting the tip ofhe hydrometer into a cell to avoid damaging thelate separators. Damaged plate separators canause early battery failure.
To read the hydrometer correctly, hold it with theop surface of the electrolyte at eye level (Fig. 4).ydrometer floats are generally calibrated to indi-
ate the specific gravity correctly only at 26.7° C (80°). When testing the specific gravity at any otheremperature, a correction factor is required.
The correction factor is approximately a specificravity value of 0.004, which may also be identified
as four points of specific gravity. For each 5.5° Cabove 26.7° C (10° F above 80° F), add four points.For each 5.5° C below 26.7° C (10° F below 80° F),subtract four points. Always correct the specific grav-ity for temperature variation. Test the specific grav-ity of the electrolyte in each battery cell.
EXAMPLE: A battery is tested at -12.2° C (10° F)and has a specific gravity of 1.240. Determine theactual specific gravity as follows:
(1) Determine the number of degrees above orbelow 26.7° C (80° F):26.6° C - -12.2° C = 38.8° C (80°F - 10° F = 70° F)
(2) Divide the result from Step 1 by 5.5 (10):38.8°C 4 5.5 = 7 (70° F 4 10 = 7)
(3) Multiply the result from Step 2 by the temper-ature correction factor (0.004):7 X 0.004 = 0.028
(4) The temperature at testing was below 26.7° C(80° F); therefore, the temperature correction factoris subtracted:1.240 - 0.028 = 1.212
The corrected specific gravity of the battery cell inthis example is 1.212.
If the specific gravity of all cells is above 1.235, butthe variation between cells is more than fifty points(0.050), the battery should be replaced. If the specificgravity of one or more cells is less than 1.235, chargethe battery at a rate of approximately five amperes.
Continue charging the battery until three consecu-tive specific gravity tests, taken at one-hour inter-vals, are constant. If the cell specific gravityvariation is more than fifty points (0.050) at the endof the charge period, replace the battery.
When the specific gravity of all cells is above 1.235,and the cell variation is less than fifty points (0.050),
Fig. 4 Hydrometer - Typical
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DIAGNOSIS AND TESTING (Continued)
he battery may be load tested to determine itsranking capacity. Refer to Load Test in the Diagno-is and Testing section of this group for more infor-ation.
PEN-CIRCUIT VOLTAGE TESTA battery open-circuit voltage (no load) test will
how the state-of-charge of a battery. This test can besed in place of the hydrometer test when a hydrom-ter is not available, or for maintenance-free batter-es with non-removable cell caps.
ARNING:• IF THE BATTERY SHOWS SIGNS OF FREEZ-
NG, LEAKING, LOOSE POSTS, OR LOW ELECTRO-YTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORHARGE. THE BATTERY MAY ARC INTERNALLYND EXPLODE. PERSONAL INJURY AND/OR VEHI-LE DAMAGE MAY RESULT.• EXPLOSIVE HYDROGEN GAS FORMS IN AND
ROUND THE BATTERY. DO NOT SMOKE, USELAME, OR CREATE SPARKS NEAR THE BATTERY.ERSONAL INJURY AND/OR VEHICLE DAMAGEAY RESULT.• THE BATTERY CONTAINS SULFURIC ACID,HICH IS POISONOUS AND CAUSTIC. AVOID CON-
ACT WITH THE SKIN, EYES, OR CLOTHING. INHE EVENT OF CONTACT, FLUSH WITH WATERND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTF THE REACH OF CHILDREN.• IF THE BATTERY IS EQUIPPED WITH REMOV-
BLE CELL CAPS, BE CERTAIN THAT EACH OFHE CELL CAPS IS IN PLACE AND TIGHT BEFOREHE BATTERY IS RETURNED TO SERVICE. PER-ONAL INJURY AND/OR VEHICLE DAMAGE MAYESULT FROM LOOSE OR MISSING CELL CAPS.
Before proceeding with this test, completely chargehe battery. Refer to Battery Charging in the Ser-ice Procedures section of this group for the properattery charging procedures.(1) Before measuring the open-circuit voltage, the
urface charge must be removed from the battery.urn on the head lamps for fifteen seconds, thenllow up to five minutes for the battery voltage totabilize.(2) Disconnect and isolate both battery cables, neg-
tive cable first.
(3) Using a voltmeter connected to the batteryposts (see the instructions provided by the manufac-turer of the voltmeter), measure the open-circuit volt-age (Fig. 5).
See the Open-Circuit Voltage chart. This voltagereading will indicate the battery state-of-charge, butwill not reveal its cranking capacity. If a battery hasan open-circuit voltage reading of 12.4 volts orgreater, it may be load tested to reveal its crankingcapacity. Refer to Load Test in the Diagnosis andTesting section of this group for more information.
LOAD TESTA battery load test will verify the battery cranking
capacity. The test is based on the Cold CrankingAmperage (CCA) rating of the battery. See the labelaffixed to the battery case, or refer to Battery Clas-sifications and Ratings in the Specifications sec-tion of this group for the CCA rating of the factory-installed battery.
Fig. 5 Testing Open-Circuit Voltage - Typical
Open Circuit Voltage
Open Circuit Volts Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.4 volts 75%
12.6 volts or more 100%
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DIAGNOSIS AND TESTING (Continued)
ARNING:• IF THE BATTERY SHOWS SIGNS OF FREEZ-
NG, LEAKING, LOOSE POSTS, OR LOW ELECTRO-YTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORHARGE. THE BATTERY MAY ARC INTERNALLYND EXPLODE. PERSONAL INJURY AND/OR VEHI-LE DAMAGE MAY RESULT.• EXPLOSIVE HYDROGEN GAS FORMS IN AND
ROUND THE BATTERY. DO NOT SMOKE, USELAME, OR CREATE SPARKS NEAR THE BATTERY.ERSONAL INJURY AND/OR VEHICLE DAMAGEAY RESULT.• THE BATTERY CONTAINS SULFURIC ACID,HICH IS POISONOUS AND CAUSTIC. AVOID CON-
ACT WITH THE SKIN, EYES, OR CLOTHING. INHE EVENT OF CONTACT, FLUSH WITH WATERND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTF THE REACH OF CHILDREN.• IF THE BATTERY IS EQUIPPED WITH REMOV-
BLE CELL CAPS, BE CERTAIN THAT EACH OFHE CELL CAPS IS IN PLACE AND TIGHT BEFOREHE BATTERY IS RETURNED TO SERVICE. PER-ONAL INJURY AND/OR VEHICLE DAMAGE MAYESULT FROM LOOSE OR MISSING CELL CAPS.
Before proceeding with this test, completely chargehe battery. Refer to Battery Charging in the Ser-ice Procedures section of this group for the properattery charging procedures.(1) Disconnect and isolate both battery cables, neg-
tive cable first. The battery top and posts should belean.(2) Connect a suitable volt-ammeter-load tester
Fig. 6) to the battery posts (Fig. 7). See the instruc-ions provided by the manufacturer of the tester youre using. Check the open-circuit voltage (no load) ofhe battery. Refer to Open-Circuit Voltage Test inhe Diagnosis and Testing section of this group forhe test procedures. The battery open-circuit voltageust be 12.4 volts or greater.
Fig. 6 Volt-Ammeter-Load Tester - Typical
(3) Rotate the load control knob (carbon pile rheo-stat) to apply a 300 ampere load to the battery forfifteen seconds, then return the control knob to theOff position (Fig. 8). This will remove the surfacecharge from the battery.
(4) Allow the battery to stabilize to open-circuitvoltage. It may take up to five minutes for the bat-tery voltage to stabilize.
(5) Rotate the load control knob to maintain a loadequal to 50% of the CCA rating of the battery (Fig.9). After fifteen seconds, record the loaded voltagereading, then return the load control knob to the Offposition.
(6) The voltage drop will vary with the batterytemperature at the time of the load test. The batterytemperature can be estimated by using the ambienttemperature during the past several hours. If thebattery has been charged, boosted, or loaded a fewminutes prior to the test, the battery will be some-what warmer. See the Load Test Temperature chartfor the proper loaded voltage reading.
Fig. 8 Remove Surface Charge from Battery -Typical
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DIAGNOSIS AND TESTING (Continued)
(7) If the voltmeter reading falls below 9.6 volts, atminimum battery temperature of 21° C (70° F), the
attery is faulty and must be replaced.
OLTAGE DROP TESTThe voltage drop test will determine if there is
xcessive resistance in the battery terminal connec-ions or the battery cables. When performing theseests, it is important to remember that the voltagerop is giving an indication of the resistance betweenhe two points at which the voltmeter probes arettached.Example: When testing the resistance of the bat-
ery positive cable, touch the voltmeter leads to theattery positive cable clamp and the cable connectort the starter solenoid. If you probe the battery pos-tive terminal post and the cable connector at thetarter solenoid, you are reading the combined volt-ge drop in the battery positive cable clamp-to-termi-al post connection and the battery positive cable.
ARNING:• IF THE BATTERY SHOWS SIGNS OF FREEZ-
NG, LEAKING, LOOSE POSTS, OR LOW ELECTRO-YTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR
ig. 9 Load 50% CCA Rating - Note Voltage - Typical
Load Test Temperature
Minimum VoltageTemperature
°F °C
9.6 volts 70° and above 21° and above
9.5 volts 60° 16°
9.4 volts 50° 10°
9.3 volts 40° 4°
9.1 volts 30° -1°
8.9 volts 20° -7°
8.7 volts 10° -12°
8.5 volts 0° -18°
CHARGE. THE BATTERY MAY ARC INTERNALLYAND EXPLODE. PERSONAL INJURY AND/OR VEHI-CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN ANDAROUND THE BATTERY. DO NOT SMOKE, USEFLAME, OR CREATE SPARKS NEAR THE BATTERY.PERSONAL INJURY AND/OR VEHICLE DAMAGEMAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,WHICH IS POISONOUS AND CAUSTIC. AVOID CON-TACT WITH THE SKIN, EYES, OR CLOTHING. INTHE EVENT OF CONTACT, FLUSH WITH WATERAND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTOF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-ABLE CELL CAPS, BE CERTAIN THAT EACH OFTHE CELL CAPS IS IN PLACE AND TIGHT BEFORETHE BATTERY IS RETURNED TO SERVICE. PER-SONAL INJURY AND/OR VEHICLE DAMAGE MAYRESULT FROM LOOSE OR MISSING CELL CAPS.
The following operation will require a voltmeteraccurate to 1/10 (0.10) volt. Before performing thetests, be certain the following procedures are accom-plished:
• The battery is fully-charged. Refer to BatteryCharging in the Service Procedures section of thisgroup for more information.
• Fully engage the parking brake.• If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in thePark position. If the vehicle is equipped with a man-ual transmission, place the gearshift selector lever inthe Neutral position and fully depress the clutchpedal.
• Unplug the Automatic ShutDown (ASD) relay toprevent the engine from starting. The ASD relay islocated in the Power Distribution Center (PDC). Seethe label on the PDC for ASD relay identification andlocation.
(1) Connect the positive lead of the voltmeter tothe battery negative terminal post. Connect the neg-ative lead of the voltmeter to the battery negativecable clamp (Fig. 10). Rotate and hold the ignitionswitch in the Start position. Observe the voltmeter. Ifvoltage is detected, correct the poor contact betweenthe cable clamp and the terminal post.
(2) Connect the positive lead of the voltmeter tothe battery positive terminal post. Connect the nega-tive lead of the voltmeter to the battery positive cableclamp (Fig. 11). Rotate and hold the ignition switchin the Start position. Observe the voltmeter. If volt-age is detected, correct the poor contact between thecable clamp and the terminal post.
(3) Connect the voltmeter to measure between thebattery positive terminal post and the starter sole-noid battery terminal stud (Fig. 12). Rotate and hold
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8A - 12 BATTERY TJ
DIAGNOSIS AND TESTING (Continued)
he ignition switch in the Start position. Observe theoltmeter. If the reading is above 0.2 volt, clean andighten the battery cable connection at the solenoid.epeat the test. If the reading is still above 0.2 volt,eplace the faulty battery positive cable.(4) Connect the voltmeter to measure between the
attery negative terminal post and a good cleanround on the engine block (Fig. 13). Rotate and holdhe ignition switch in the Start position. Observe theoltmeter. If the reading is above 0.2 volt, clean andighten the battery negative cable attachment on thengine block. Repeat the test. If the reading is stillbove 0.2 volt, replace the faulty battery negativeable.
GNITION-OFF DRAW TESTThe term Ignition-Off Draw (IOD) identifies a nor-al condition where power is being drained from the
attery with the ignition switch in the Off position. Aormal vehicle electrical system will draw from five
Fig. 10 Test Battery Negative ConnectionResistance - Typical
Fig. 11 Test Battery Positive Connection Resistance- Typical
to twenty-five milliamperes (0.005 to 0.025 ampere)with the ignition switch in the Off position, and allnon-ignition controlled circuits in proper workingorder. The twenty-five milliamperes are needed toenable the memory functions for the Powertrain Con-trol Module (PCM), digital clock, electronically tunedradio, and other modules which may vary with thevehicle equipment.
A vehicle that has not been operated for approxi-mately twenty days, may discharge the battery to aninadequate level. When a vehicle will not be used fortwenty days or more (stored), remove the IOD fusefrom the Power Distribution Center (PDC). This willreduce battery discharging.
Excessive IOD can be caused by:• Electrical items left on• Faulty or improperly adjusted switches• Faulty or shorted electronic modules and compo-
nents• An internally shorted generator• Intermittent shorts in the wiring.If the IOD is over twenty-five milliamperes, the
problem must be found and corrected before replac-
Fig. 12 Test Battery Positive Cable Resistance -Typical
Fig. 13 Test Ground Circuit Resistance - Typical
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DIAGNOSIS AND TESTING (Continued)
ng a battery. In most cases, the battery can beharged and returned to service after the excessiveOD condition has been corrected.
(1) Verify that all electrical accessories are off.urn off all lamps, remove the ignition key, and closell doors. If the vehicle is equipped with an illumi-ated entry system or an electronically tuned radio,llow the electronic timer function of these systemso automatically shut off (time out). This may takep to three minutes.(2) Determine that the under-hood lamp is operat-
ng properly, then disconnect the lamp wire harnessonnector or remove the lamp bulb.(3) Disconnect the battery negative cable.(4) Set an electronic digital multi-meter to its
ighest amperage scale. Connect the multi-meteretween the disconnected battery negative cablelamp and the battery negative terminal post. Makeure that the doors remain closed so that the illumi-ated entry system is not activated. The multi-metermperage reading may remain high for up to threeinutes, or may not give any reading at all while set
n the highest amperage scale, depending upon thelectrical equipment on the vehicle. The multi-metereads must be securely clamped to the battery nega-ive cable clamp and the battery negative terminalost. If continuity between the battery negative ter-inal post and the negative cable clamp is lost dur-
ng any part of the IOD test, the electronic timerunction will be activated and all of the tests willave to be repeated.(5) After about three minutes, the high-amperage
OD reading on the multi-meter should become veryow or nonexistent, depending upon the electricalquipment on the vehicle. If the amperage readingemains high, remove and replace each fuse or circuitreaker in the Power Distribution Center (PDC) andhen in the fuseblock module (refer to Power Distri-ution Center and Fuse Block in the Componentndex of Group 8W - Wiring Diagrams for fuse andircuit breaker identification) one at a time until themperage reading becomes very low, or nonexistent.his will isolate each circuit and identify the sourcef the high-amperage IOD. If the amperage readingemains high after removing and replacing each fusend circuit breaker, disconnect the wire harness fromhe generator. If the amperage reading now becomesery low or nonexistent, refer to Charging Systemn the Diagnosis and Testing section of Group 8C -harging System to diagnose the condition. After theigh-amperage IOD has been corrected, switch theulti-meter to progressively lower amperage scales
nd, if necessary, repeat the fuse and circuit breakeremove-and-replace process to identify and correct allources of excessive IOD. It is now safe to select the
lowest milliampere scale of the multi-meter to checkthe low-amperage IOD.
CAUTION: Do not open any doors, or turn on anyelectrical accessories with the lowest milliamperescale selected, or the multi-meter may be damaged.
(6) Observe the multi-meter reading. The low-am-perage IOD should not exceed twenty-five milliam-peres (0.025 ampere). If the draw exceeds twenty-fivemilliamperes, isolate each circuit using the fuse andcircuit breaker remove-and-replace process. Themulti-meter reading will drop to within the accept-able limit when the source of the excessive draw isdisconnected. Repair this circuit as required; whethera wiring short, incorrect switch adjustment, or acomponent failure is at fault.
SERVICE PROCEDURES
BATTERY CHARGINGA battery is fully-charged when:• All cells are gassing freely during battery charg-
ing.• A green color is visible in the sight glass of the
built-in test indicator.• Three hydrometer tests, taken at one-hour inter-
vals, indicate no increase in the temperature-cor-rected specific gravity.
• Open-circuit voltage is 12.4 volts or above.
WARNING:• IF THE BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO-LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, ORCHARGE. THE BATTERY MAY ARC INTERNALLYAND EXPLODE. PERSONAL INJURY AND/OR VEHI-CLE DAMAGE MAY RESULT.
• EXPLOSIVE HYDROGEN GAS FORMS IN ANDAROUND THE BATTERY. DO NOT SMOKE, USEFLAME, OR CREATE SPARKS NEAR THE BATTERY.PERSONAL INJURY AND/OR VEHICLE DAMAGEMAY RESULT.
• THE BATTERY CONTAINS SULFURIC ACID,WHICH IS POISONOUS AND CAUSTIC. AVOID CON-TACT WITH THE SKIN, EYES, OR CLOTHING. INTHE EVENT OF CONTACT, FLUSH WITH WATERAND CALL A PHYSICIAN IMMEDIATELY. KEEP OUTOF THE REACH OF CHILDREN.
• IF THE BATTERY IS EQUIPPED WITH REMOV-ABLE CELL CAPS, BE CERTAIN THAT EACH OFTHE CELL CAPS IS IN PLACE AND TIGHT BEFORETHE BATTERY IS RETURNED TO SERVICE. PER-SONAL INJURY AND/OR VEHICLE DAMAGE MAYRESULT FROM LOOSE OR MISSING CELL CAPS.
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8A - 14 BATTERY TJ
SERVICE PROCEDURES (Continued)
AUTION:• Always disconnect and isolate the battery neg-
tive cable before charging a battery. Do not exceedixteen volts while charging a battery. Damage tohe vehicle electrical system components mayesult.
• Battery electrolyte will bubble inside the bat-ery case during normal battery charging. Electro-yte boiling or being discharged from the batteryents indicates a battery overcharging condition.mmediately reduce the charging rate or turn off theharger to evaluate the battery condition. Damageo the battery may result from overcharging.
• The battery should not be hot to the touch. Ifhe battery feels hot to the touch, turn off theharger and let the battery cool before continuinghe charging operation. Damage to the battery mayesult.
Some battery chargers are equipped with polarity-ensing circuitry. This circuitry protects the chargernd/or the battery from being damaged if they aremproperly connected. If the battery state-of-charges too low for the polarity-sensing circuitry to detect,he charger will not operate. This makes it appearhat the battery will not accept charging current. Seehe instructions provided by the manufacturer of theattery charger for details on how to bypass theolarity-sensing circuitry.After the battery has been charged to 12.4 volts or
reater, perform a load test to determine the batteryranking capacity. Refer to Load Test in the Diagno-is and Testing section of this group for the proce-ures. If the battery will endure a load test, returnhe battery to use. If the battery will not endure aoad test, it is faulty and must be replaced.
Clean and inspect the battery hold downs, tray,erminals, posts, and top before completing service.efer to Battery in the Removal and Installationection of this group for the proper cleaning andnspection procedures.
HARGING A COMPLETELY DISCHARGEDATTERYThe following procedure should be used to rechargecompletely discharged battery. Unless this proce-
ure is properly followed, a good battery may beeedlessly replaced.(1) Measure the voltage at the battery posts with a
oltmeter, accurate to 1/10 (0.10) volt (Fig. 14). If theeading is below ten volts, the charge current will beow. It could take some time before the batteryccepts a current greater than a few milliamperes.uch low current may not be detectable on themmeters built into many battery chargers.
(2) Disconnect and isolate the battery negativecable. Connect the battery charger leads. Some bat-tery chargers are equipped with polarity-sensing cir-cuitry. This circuitry protects the charger and/or thebattery from being damaged if they are improperlyconnected. If the battery state-of-charge is too low forthe polarity-sensing circuitry to detect, the chargerwill not operate. This makes it appear that the bat-tery will not accept charging current. See the instruc-tions provided by the manufacturer of the batterycharger for details on how to bypass the polarity-sensing circuitry.
(3) Battery chargers vary in the amount of voltageand current they provide. The amount of timerequired for a battery to accept measurable chargercurrent at various voltages is shown in the ChargeRate chart. If the charge current is still not measur-able at the end of the charging time, the battery isfaulty and must be replaced. If the charge current ismeasurable during the charging time, the batterymay be good and the charging should be completed inthe normal manner.
CHARGING TIME REQUIREDThe time required to charge a battery will vary,
depending upon the following factors:• Battery Capacity - A completely discharged
heavy-duty battery requires twice the charging timeof a small capacity battery.
• Temperature - A longer time will be needed tocharge a battery at -18° C (0° F) than at 27° C (80°F). When a fast charger is connected to a cold bat-
Fig. 14 Voltmeter Accurate to 1/10 Volt Connected -Typical
Charge Rate
Voltage Hours
16.0 volts maximum up to 4 hours
14.0 to 15.9 volts up to 8 hours
13.9 volts or less up to 16 hours
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TJ BATTERY 8A - 15
SERVICE PROCEDURES (Continued)
ery, the current accepted by the battery will be veryow at first. As the battery warms, it will accept aigher charging current rate (amperage).• Charger Capacity - A battery charger that
upplies only five amperes will require a longerharging time. A battery charger that supplieswenty amperes or more will require a shorter charg-ng time.
• State-Of-Charge - A completely dischargedattery requires more charging time than a partiallyischarged battery. Electrolyte is nearly pure watern a completely discharged battery. At first, theharging current (amperage) will be low. As the bat-ery charges, the specific gravity of the electrolyteill gradually rise.
ARNING: NEVER EXCEED TWENTY AMPERESHEN CHARGING A COLD (-1° C or 30° F) BAT-
ERY. THE BATTERY MAY ARC INTERNALLY ANDXPLODE. PERSONAL INJURY AND/OR VEHICLEAMAGE MAY RESULT.
EMOVAL AND INSTALLATION
ATTERY
EMOVAL(1) Turn the ignition switch to the Off position. Be
ertain that all electrical accessories are turned off.(2) Loosen the battery cable terminal clamps and
isconnect both battery cables, negative cable first. Ifecessary, use a puller to remove the terminallamps from the battery posts (Fig. 15).(3) Inspect the battery cable terminal clamps for
orrosion and damage. Remove any corrosion using aire brush or a post and terminal cleaning tool, andsodium bicarbonate (baking soda) and warm water
Battery Charging Timetable
ChargingAmperage
5Amperes
10Amperes
20Amperes
OpenCircuitVoltage
Hours Charging at 21° C (70° F)
12.25 to12.49
6 hours 3 hours 1.5 hours
12.00 to12.24
10 hours 5 hours 2.5 hours
10.00 to11.99
14 hours 7 hours 3.5 hours
*Below10.00
18 hours 9 hours 4.5 hours
*Refer to Charging A Completely Discharged Battery
cleaning solution (Fig. 16). Replace any battery cablethat has damaged or deformed terminal clamps.
WARNING: WEAR A SUITABLE PAIR OF RUBBERGLOVES (NOT THE HOUSEHOLD TYPE) WHENREMOVING A BATTERY BY HAND. SAFETYGLASSES SHOULD ALSO BE WORN. IF THE BAT-TERY IS CRACKED OR LEAKING, THE ELECTRO-LYTE CAN BURN THE SKIN AND EYES.
(4) Remove the battery hold downs and remove thebattery from the battery tray (Fig. 17).
(5) Inspect the battery tray and hold downs forcorrosion or damage. Remove any corrosion using awire brush and a sodium bicarbonate (baking soda)and warm water cleaning solution. Paint any exposedbare metal and replace any damaged parts.
(6) Slide the thermoguard off of the battery case.Inspect the battery case for cracks or other damage
hat could result in electrolyte leaks. Also, check theattery terminal posts for looseness. Batteries withamaged cases or loose posts must be replaced.(7) Check the electrolyte level in the battery. Use a
utty knife or another suitable wide flat-bladed toolo pry the cell caps off (Fig. 18). Do not use a screw-river. Add distilled water to each cell until the liq-id reaches the bottom of the vent well. DO NOTVERFILL.
(8) Inspect the battery built-in test indicator sightlass for an indication of the battery condition. If theattery is discharged, charge as required. Refer to
Fig. 17 Battery Hold Downs
Fig. 18 Removing Cell Caps - Typical
Built-In Test Indicator in the Diagnosis and Test-ing section of this group for more information. Alsorefer to Battery Charging in the Service Proceduressection of this group for more information.
(9) If the battery is to be reinstalled, clean the out-side of the battery case and the top cover with asodium bicarbonate (baking soda) and warm watercleaning solution to remove any acid film (Fig. 19).Rinse the battery with clean water. Ensure that thecleaning solution does not enter the battery cellsthrough the vent holes. If the battery is beingreplaced, refer to Battery Ratings and Classifica-tions in the Specifications section of this group. Con-firm that the replacement battery is the correct sizeand has the correct ratings for the vehicle.
(10) Clean any corrosion from the battery terminalposts with a wire brush or a post and terminalcleaner, and a sodium bicarbonate (baking soda) andwarm water cleaning solution (Fig. 20).
INSTALLATION(1) Reinstall the battery thermoguard by sliding it
over the battery case.(2) Position the battery in the tray. Ensure that
the positive and negative terminal posts are correctlypositioned. The cable terminal clamps must reach thecorrect battery terminal post without stretching thecables (Fig. 21).
(3) Loosely install the battery hold down hard-ware. Ensure that the battery base is correctly posi-tioned in the tray, then tighten the hold downs to 4N·m (35 in. lbs.).
Fig. 19 Clean Battery - Typical
TJ BATTERY 8A - 17
REMOVAL AND INSTALLATION (Continued)
Fig. 20 Clean Battery Terminal Post - Typical
Fig. 21 Battery Cables
CAUTION: Be certain that the battery cables areconnected to the correct battery terminals. Reversepolarity may damage electrical components.
(4) Connect and tighten the battery positive cableterminal clamp. Then connect and tighten the bat-tery negative cable terminal clamp. Tighten both bat-tery cable terminal clamp bolts to 6.2 N·m (55 in.lbs.).
(5) Apply a thin coating of petroleum jelly or chas-sis grease to the exposed surfaces of the battery cableterminal clamps and battery terminal posts.
