Chrysler AS Town Country Caravan Voyager 1994 Service Manual Electrical PDF

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ELECTRICAL 8A - 1
ELECTRICAL
GROUP INDEX
group group
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8F POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . 8T

BATTERY/STARTER/GENERATOR SERVICE . . . 8B POWER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . 8R
BATTERY/STARTING/CHARGING SYSTEMS POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . 8S
DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . 8A REAR WINDOW DEFOGGER . . . . . . . . . . . . . . . 8N
CHIME WARNING/REMINDER SYSTEM . . . . . . 8U RESTRAINT SYSTEMS . . . . . . . . . . . . . . . . . . . 8M
HORNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G TURN SIGNALS AND HAZARD WARNING
IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . 8D FLASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J
INSTRUMENT PANEL AND GAUGES . . . . . . . . . 8E VEHICLE SPEED CONTROL SYSTEM . . . . . . . . 8H
LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L WINDSHIELD WIPERS AND WASHER
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . 8C SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K
POWER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . 8P WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 8W
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BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS
CONTENTS
page page
BATTERY TEST PROCEDURES ON-VEHICLE . . . 3 IGNITION OFF DRAW (IOD) . . . . . . . . . . . . . . . . 8

DIAGNOSTIC CODES—ON BOARD DIAGNOSTICS . 21 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 25
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 STARTER TEST PROCEDURES ON VEHICLE . . 10
GENERATOR TEST PROCEDURES ON VEHICLE . 17
GENERAL INFORMATION
For Battery, Starter or Generator Replacement, recover Starting (Fig. 1) and Charging System (Fig. 2)
fer to Group 8B, Battery/Starter/Generator Service. diagnostic procedures. These will be covered from the
Group 8A, Battery/Starting/Charging Systems Diag- most basic conventional methods to On Board Diag-
nostics will cover diagnostics only. nostics (OBD) built into the vehicle’s electronics. The
The Battery, Starting, and Charging Systems oper- need for conventional testing equipment has not been
ate in conjunction with one another, and must be eliminated by the introduction of OBD. Frequent use
thoroughly tested as a complete system. To enable of an ammeter, volt/ohmmeter, battery charger, car-
the vehicle to start and charge properly, it must have bon pile rheostat (load tester), and 12 volt (low watt-
a battery that will perform to specifications. The age) test light will be required.
starter motor, generator, wiring, and electronics also All front wheel drive vehicles are equipped with
OBD and all OBD sensing systems are monitored by
must perform within specifications. Group 8A will
the Powertrain Control Module. The powertrain con-
trol module will store in electronic memory, any de-
tectable failure within the monitored circuits. It will
retain this information for a period of 50 engine
8A - 2 BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS .
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Fig. 1 Starting System Components Fig. 2 Charging System Components

The Malfunction Indicator (Check Engine) Lamp on For numbered Diagnostic Codes pertaining to com-
the instrument cluster will flash in predetermined ponents within this particular Group, refer to Diag-
sequences to show Diagnostic Codes. However, the nostic Codes—On Board Diagnostics in Group 8A.
Malfunction Indicator (Check Engine) Lamp cannot
For other numbered Diagnostic Codes not pertaining
express diagnostic codes for all failures. Diagnostic
to this Group (8A), refer to On Board Diagnostics in
codes are easier to obtain and more complete with
the General Diagnosis section of Group 14, Fuel Sys-
the use of Diagnostic Tool (DRB). This tool is plugged
tem for more information.
into the diagnostic connector located in the engine
compartment (Fig. 2). Refer to the instructions pro-
vided with the DRB tool being used.
. BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS 8A - 3
BATTERY TEST PROCEDURES ON-VEHICLE
INDEX
page page
Battery Charging . . . . . . . . . . . . ... . . . . . . . . . . . . 6 General Information . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery Load Test . . . . . . . . . . . ... . . . . . . . . . . . . 5 State of Charge Tests . . . . . . . . . . . . . . . . . . . . . . . 4
Battery Open Circuit Voltage Test .. . . . . . . . . . . . . 4 Test Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Causes of Battery Discharging . ... . . . . . . . . . . . . 4
GENERAL INFORMATION
The battery stores, stabilizes, and produces electri-
cal current to operate various electrical systems in
the vehicle. The determination of whether a battery
is good or bad is made by its ability to accept a
charge. It also must produce high-amperage current
output over an extended period to be able to start the
vehicle. The capability of the battery to store electri-
cal current comes from a chemical reaction. This re-
action takes place between the sulfuric acid solution
electrolyte and the lead +/- plates in each cell of the
battery. As the battery discharges, the plates react Fig. 4 Built in Test Indicator
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with the acid from the electrolyte. When the charging When the electrolyte level is below the top of the
system charges the battery, the water is converted to plates a yellow or bright color indicator in sight glass
sulfuric acid in the battery. The amount of acid, spe- (Figs. 4 and 5), the battery must be replaced. Refer
cific gravity in the electrolyte can be measured with to Test Indicator. The battery must be completely
a hydrometer. The factory installed battery is charged with a green color in sight glass. The top,
equipped with a built-in hydrometer, as a test indica- posts, and terminals should be properly cleaned be-
tor (Figs. 3, 4 and 5) to assist in decide its state of fore diagnostic procedures are performed. Also refer
charge. The factory installed battery is also sealed. to Group 8B, Battery/Starter/Generator Service for
Water cannot and should not be added. additional information.
Fig. 5 Test Indicator Sight Glass

TEST INDICATOR
Fig. 3 Battery Construction and Test Indicator A test indicator a hydrometer viewed through a
The battery is vented to release gases that are cre- sight glass, is built into the top of battery case (Figs.
ated when the battery is being charged and dis- 3, 4 and 5). This provides visual information for bat-
charged. The battery top, posts, and terminals should tery testing. The test indicator sight glass is to be
be cleaned when other under hood maintenance is used with diagnostic procedures described in this
performed (Fig. 3). Group.
It is important when using the Test Indicator that
WARNING: DO NOT ASSIST BOOST, CHARGE, ADD
the battery be level and have a clean top to see the
WATER, OR LOAD TEST BATTERY WHEN ELEC-
correct indications. A light may be required to view
TROLYTE LEVEL IS BELOW THE TOP OF THE
the Indicator.
PLATES. PERSONAL INJURY MAY OCCUR.
WARNING: DO NOT USE OPEN FLAME NEAR BAT-

TERY. EXPLOSIVE GASES FORM ABOVE BATTERY.
STATE OF CHARGE TESTS
USING TEST INDICATOR
The built-in test hydrometer (Figs. 3, 4 and 5) measures
the specific gravity of the electrolyte. Specific Gravity
(SG) of the electrolyte will show state-of-charge (voltage).
The test indicator WILL NOT show cranking capacity of
the battery. Refer to Battery Load Test for more informa-
tion. Look into the sight glass (Figs. 4 and 5) and note the
color of the indicator (Fig. 5). Refer to the following de-
scription as color show:
• GREEN = 75 to 100
• state-of-charge
The battery is adequately charged for further testing
and may be returned to use. If the vehicle will not
crank for a maximum 15 seconds, refer to BATTERY
LOAD TEST in this Group for more information.
BLACK OR DARK = 0 to 75
state-of-charge
The battery is INADEQUATELY charged and must
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be charged until green dot is visible, (12.4 volts or

greater) before the battery is tested or returned to
use. Refer to Causes of Battery Discharging in this
Group for more information.
YELLOW OR BRIGHT COLOR = Battery must be
replaced. Fig. 6 IOD Fuse
(3) Electrical loads that exceed the output of the
WARNING: DO NOT CHARGE, ASSIST BOOST, charging system due to equipment or accessories in-
LOAD TEST, OR ADD WATER TO THE BATTERY stalled after delivery.
WHEN YELLOW OR BRIGHT COLOR DOT IS VISI- (4) Slow driving speeds in heavy traffic conditions
BLE. PERSONAL INJURY MAY OCCUR. or prolonged idling with high-amperage electrical
systems in use.
A yellow or bright color dot shows electrolyte level
(5) Defective electrical circuit or component caus-
in battery is below the test indicator (Fig. 5). Water ing excess Ignition Off Draw (IOD). Refer to Ignition
cannot be added to a maintenance free battery. The Off Draw (IOD).
battery must be replaced. A low electrolyte level may (6) Defective charging system.
be caused by an over charging condition. Refer to (7) Defective battery.
Generator Test Procedures on Vehicle.
BATTERY OPEN CIRCUIT VOLTAGE TEST
CAUSES OF BATTERY DISCHARGING An open circuit voltage no load test shows the state
It is normal to have a small 5 to 30 milliamperes contin- of charge of a battery. Also, if it will pass a load test
uous electrical draw from the battery. This draw will take of 50 percent of the battery cold crank rating. Refer
place with the ignition in the OFF position, and the cour- to Battery Load Test. If a battery has an open circuit
tesy, dome, storage compartments, and engine compart- voltage reading of 12.4 volts or greater, and will not
ment lights OFF. The continuous draw is due to various endure a load test, it is defective and replacement
electronic features or accessories that require electrical cur- would be required. To test open circuit voltage, per-
rent with the ignition OFF to function properly. When a ve- form the following operation:
hicle is not used over an extended period of approximately (1) Remove both battery cables, negative cable
20 days the IOD fuse in the power distribution center (Fig. first. If the battery has been boosted, charged, or
6) should be disconnected. When the vehicle is not going to loaded just prior to this operation, allow the battery
be use for 75 days or more disconnect battery negative ca- a few minutes to stabilize.
ble and isolate. (2) Using a voltmeter connected to the battery
posts and measure the open circuit voltage (Fig. 7).
ABNORMAL BATTERY DISCHARGING This voltage reading will show the state of charge
(1) Corroded battery posts, cables or terminals. of the battery. It will not reveal battery cranking ca-
(2) Loose or worn generator drive belt. pacity (Fig. 8).
Fig. 7 Testing Open Circuit Voltage Fig. 9 Volt-Ammeter-Load Tester

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Fig. 8 Battery Open Circuit Voltage

BATTERY LOAD TEST
A fully charged battery must have reserve cranking
capacity. This will enable the starter motor and igni- Fig. 10 Volt-Ammeter-Load Tester Connections
tion system enough power to start the engine over a
broad range of ambient temperatures. A battery load
test will verify the actual cranking performance
based on the cold crank rating of the battery.
WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-

ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY
LOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
BURNS OR AN EXPLOSIVE CONDITION MAY RE-
SULT.
(1) Remove both battery cables, NEGATIVE cable

first. Battery top, cables and posts should be clean. If
green dot is not visible in indicator, charge the bat-
tery. Refer to Battery Charging Procedures.
(2) Use a suitable Volt/Ammeter/Load tester (Fig. Fig. 11 Remove Surface Charge from Battery
9) connected to the battery posts (Fig. 10). Check the
(5) Rotate the load control knob on the tester to
open circuit voltage of the battery. Voltage should be
maintain 50% of the battery cold crank rating for a
equal to or greater than 12.4 volts with the green dot
minimum 15 seconds (Fig. 12).
visible in test indicator.
After 15 seconds, record the loaded voltage reading
(3) Rotate the load control knob of the Carbon pile
rheostat to apply a 300 amp load. Apply this load for and return the load control to off.
15 seconds to remove the surface charge from the (6) Voltage drop will vary according to battery tem-
battery, and return the control knob to off (Fig. 11). perature at the time of the load test. Battery temper-
(4) Allow the battery to stabilize for 15 seconds, ature can be estimated by the temperature of
and then verify open circuit voltage. exposure over the preceding several hours. If the bat-
EXPLOSIVE GASES FORM OVER THE BATTERY.

DO NOT SMOKE, USE FLAME, OR CREATE
SPARKS NEAR BATTERY.
DO NOT ASSIST BOOST OR CHARGE A FROZEN
BATTERY. BATTERY CASING MAY FRACTURE.
BATTERY ACID IS POISON, AND MAY CAUSE SE-
VERE BURNS. BATTERIES CONTAIN SULFURIC
ACID. AVOID CONTACT WITH SKIN, EYES, OR
CLOTHING. IN THE EVENT OF CONTACT, FLUSH
WITH WATER AND CALL PHYSICIAN IMMEDIATELY.
KEEP OUT OF REACH OF CHILDREN.
CAUTION: Disconnect the battery NEGATIVE cable

first (Fig. 14) before charging battery to avoid dam-
Fig. 12 Load 50% Cold Crank Rating
age to electrical systems. Do not exceed 16.0 volts
tery has been charged, boosted, or loaded a few min- while charging battery. Refer to the instructions
utes prior to the test, the battery would be slightly supplied with charging equipment
warmer. Refer to Fig. 13 for proper loaded voltage
reading.
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Fig. 14 Disconnect Battery Negative Cable

Battery electrolyte will bubble inside of battery
case while being charged properly. If the electrolyte
boils violently, or is discharged from the vent holes
while charging, immediately reduce charging rate or
Fig. 13 Load Test Temperature turn off charger. Evaluate battery condition. Battery
damage may occur if charging is excessive.
(7) If battery passes load test, it is in good condi- Some battery chargers are equipped with polarity
tion and further tests are not necessary. If it fails sensing devices to protect the charger or battery from
load test, it should be replaced. being damaged if improperly connected. If the bat-
tery state of charge is too low for the polarity sensor
BATTERY CHARGING to detect, the sensor must be bypassed for charger to
A battery is considered fully charged when it will operate. Refer to operating instructions provided
meet all the following requirements: with battery charger being used.
• It has an open circuit voltage charge of at least
12.4 volts (Fig. 8). CAUTION: Charge battery until test indicator ap-
• It passes the 15 second load test (Fig. 13). pears green. Do not overcharge.
• The built in test indicator dot is GREEN (Fig. 5).
It may be necessary to jiggle the battery or vehicle
The battery cannot be refilled with water, it must
to bring the green dot in the test indicator into view.
be replaced. After the battery has been charged to 12.4 volts or
greater, perform a load test to determine cranking
WARNING: DO NOT CHARGE A BATTERY THAT
capacity. Refer to BATTERY LOAD TEST in this
HAS EXCESSIVELY LOW ELECTROLYTE LEVEL.
Group. If the battery will endure a load test, return
BATTERY MAY SPARK INTERNALLY AND EX-
the battery to use. If battery will not endure a load
PLODE. test, it must be replaced. Properly clean and inspect
battery hold downs, tray, terminals, cables, posts,
and top before completing service. Also refer to CHARGING COMPLETELY DISCHARGED
Group 8B, Battery/Starter/Generator Service. BATTERY
The following procedure should be used to recharge
CHARGING TIME REQUIRED a completely discharged battery. Unless procedure is
The time required to charge a battery will vary de- properly followed, a good battery may be needlessly
pending upon the following factors: replaced (Fig. 16).
• SIZE OF BATTERY
A completely discharged of a large heavy-duty bat-
tery requires more than twice the recharging time as
a completely discharged small capacity battery (Fig.
15).
Fig. 16 CHARGE RATE

(1) Measure the voltage at battery posts with a
voltmeter accurate to 1/10 volt (Fig. 17). If below 10
volts, charge current will be low, and it could take
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some time before it accepts a current in excess of a

Fig. 15 BATTERY CHARGING TIME few milliamperes. Such low current may not be de-
tectable on amp meters built into many chargers.
• TEMPERATURE
A longer time will be needed to charge a battery at
-18°C (0°F) than at 27°C (80°F). When a fast charger
is connected to a cold battery, current accepted by
battery will be very low at first. In time, the battery
will accept a higher rate as battery warms.
• CHARGER CAPACITY
A charger which can supply only five amperes will
require a much longer period of charging than a
charger that can supply 30 amperes or more.
• STATE OF CHARGE
A completely discharged battery requires more
charging time than a partially charged battery. Elec-
trolyte is nearly pure water in a completely dis-
charged battery. At first, the charging current Fig. 17 Voltmeter Accurate to 1/10 Volt (Connected)
amperage will be low. As water is converted to sulfu-
(2) Connect charger leads. Some chargers feature
ric acid inside the battery, the current amp rate will polarity protection circuitry that prevents operation
rise. Also, the specific gravity of the electrolyte will unless charger is connected to battery posts correctly.
rise, bringing the green dot (Fig. 5) into view. A completely discharged battery may not have
enough voltage to activate this circuitry. This may
WARNING: NEVER EXCEED 20 AMPS WHEN happen though the leads are connected properly.
CHARGING A COLD -1°C (30°F) BATTERY. PER- (3) Battery chargers vary in the amount of voltage
SONAL INJURY MAY RESULT. and current they provide. For the time required for
the battery to accept measurable charger current at
various voltages, refer to Fig. 16. If charge current is
still not measurable after charging times, the battery
should be replaced. If charge current is measurable
during charging time, the battery may be good, and
charging should be completed in the normal manner.
IGNITION OFF DRAW (IOD)

GENERAL INFORMATION (4) Connect a typical 12-volt test light low wattage
A normal electrical system will draw from 5 to 30 lamp between the negative cable clamp and the bat-
milliamperes from the battery. This is with the igni- tery negative post (Fig. 18). The test light may be
tion in the OFF position, and all non-ignition con- brightly lit for three minutes or may not be lit at all.
trolled circuits in proper working order. The amount (a) The term brightly used throughout the fol-
of IOD will depend on body model and electrical com- lowing tests. This implies the brightness of the test
ponents. A vehicle that has not been operated for an light will be the same as if it were connected across
extended period approximately 20 days may dis- the battery posts. This would be with a fully
charge the battery to an inadequate level. In this charged battery.
case, the IOD fuse should be disconnected. The IOD (b) The test light or the milliamp meter MUST
fuse is located in the power distribution center. be positively connected to the battery post and the
battery cable during all IOD testing.
(c) Do not allow the test light or the milliamp
meter to become disconnected during any of the
IOD tests. If this happens, the electronic timer
functions will be activated and all IOD tests must
be repeated from the beginning. Clamp the test
light at both ends to prevent accidental disconnec-
tion.
(d) After three minutes time has elapsed, the
test light should turn off or be dimly lit. This will
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depending on the electronic components on the ve-

hicle. If the test light remains brightly lit, do not
disconnect test light. Disconnect each fuse or cir-
cuit breaker (refer to Group 8W, Wiring Diagrams)
until test light is either off or dimly lit. This will
identify the high amperage IOD circuit. Repair cir-
cuit as necessary. It is now safe to install milliamp
Fig. 18 IOD Test meter to check for low amperage IOD.
If the IOD is over 30 milliamperes, the defect must (e) Possible sources of high IOD are usually ve-
be found and corrected before replacing the battery. hicle trunk lamp, glove compartment, luggage com-
Usually, the battery can be charged and returned to partment and etc..
service (Fig. 15). (f) If test light is still BRIGHTLY lit after discon-
necting each fuse and circuit breaker, disconnect
IGNITION OFF DRAW (IOD) TESTS the wiring harness from the generator. Refer to
Generator Testing. Do not disconnect test light.
VEHICLES WITHOUT ELECTRONIC AUTOMATIC
TRANSMISSION CAUTION: The last test has higher amperage IOD
Testing for HIGHER AMPERAGE IOD must be must be performed before proceeding with low am-
performed first to prevent damage to most milliamp perage IOD tests. The higher amperage IOD must
meters. be eliminated before hooking up milliamp meter to
A standard 12 volt test light and a milliamp meter check for low amperage IOD. If higher amperage
that is equipped with two leads must be used for the IOD has not been eliminated, milliamp meter may
following tests. The milliamp meter should be able to be damaged. Most milliamp meters will not handle
handle up to two amps. over one or two amps. Do not hook up meter if test
(1) Verify that all electrical accessories are OFF. light is glowing brightly. Refer to maximum amper-
Turn off all lights, close trunk lid, close glove box age specifications and instructions supplied with
door, turn off sun visor vanity lights, close all doors milliamp meter.
and remove ignition key. Allow the Illuminated Entry
System if equipped to time out in approximately 30 After higher amperage IOD has been corrected, low
seconds. amperage IOD may be checked. The MAXIMUM IOD
(2) Verify the engine compartment lamp is working = 30 MILLIAMPERES.
by opening/closing hood. Remove the lamp. (5) With test light still connected, connect milliamp
(3) Disconnect battery negative cable (Fig. 14). meter between battery negative post and battery
negative cable (Fig. 19). Do not open any doors or (a) The 60 way connector at the powertrain con-
turn on any electrical accessories with the test light trol module located outboard of the battery. Refer
disconnected and the milliamp meter connected. to Group 8D, Ignition, for more information.
Meter may be damaged. (b) The 25 way connectors on the body control
module computer.
(c) The circuits to the clock and radio.
(d) The wiring harness from the generator. Refer
to Generator Testing in this Group.
Check each component until excessive IOD is
found.
Each time the test light or milliamp meter is dis-
connected and connected, all electronic timer func-
tions will be activated. Tests must be repeated from
the beginning.
Test light or meter MUST remain connected for all
tests.
VEHICLES WITH ELECTRONIC AUTOMATIC TRANSMISSION

This vehicle will have temporary high IOD of 50
milliamp or more for up to 25 minutes. This higher
IOD can often mask another problem and should be
Fig. 19 Low Amperage IOD Test
considered when performing IOD testing.
(6) Disconnect test light. Milliamp meter reading If high or low IOD is suspected, allow an additional
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should be less than 30 milliamperes. If low amperage 25 minutes (minimum) of electronic shut off time.
IOD is not within specifications, disconnect: To defeat the timer, disconnect the 60-way connec-
tor on the transmission control module. This com-
puter is located behind the right front strut tower.
STARTER TEST PROCEDURES ON VEHICLE
INDEX
page page
Diagnostic Preparation . . . . . . . . . . . . . . . . . . . . . 10 Starter Feed Circuit Resistance Test . . . . . . . . . . . 12
General Information . . . . . . . . . . . . . . . . . . . . . . . 10 Starter Feed Circuit Tests . . . . . . . . . . . . . . . . . . . 10
Starter Control Circuit Tests . . . . . . . . . . . . . . . . . . 13
GENERAL INFORMATION
The starting system (Fig. 1) has:
• Ignition switch
• Starter relay (Fig. 2)
• Neutral starting and back-up switch with auto-
matic transmissions only
• Wiring harness
• Battery
• Starter motor with an integral solenoid
These components form two separate circuits. A
high amperage circuit that feeds the starter motor up
to 300+ amps, and a control circuit that operates on
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less than 20 amps.
Fig. 2 Starter Relay

(2) The generator drive belt tension and condition
is correct.
(3) The battery state-of-charge is correct.
(4) The battery will endure load test.
(5) The battery cable connections at the starter
and engine block are clean and free from corrosion.
(6) The wiring harness connectors and terminals
are clean and free from corrosion.
(7) Proper circuit grounding.
(8) Refer to Starter System Diagnostics (Fig. 3).
STARTER FEED CIRCUIT TESTS

The following procedure will require a suitable
volt-ampere tester (Fig. 4).
CAUTION: Ignition system also must be disabled to

prevent engine start while performing the following
tests.
(1) Connect a volt-ampere tester (Fig. 4) to the bat-

tery terminals (Fig. 5). Refer to the operating in-
structions provided with the tester being used.
Fig. 1 Starting System Components/Wiring
(2) Disable ignition system as follows:
DIAGNOSTIC PREPARATION • VEHICLES WITH CONVENTIONAL DISTRIBU-
Before proceeding with starting system diagnostics, TORS: Disconnect the ignition coil cable from the dis-
verify:
(1) The battery top, posts, and terminals are clean.
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Fig. 3 Starter System Diagnostics
Fig. 4 Volt Ampere Tester Fig. 5 Volt-Ampere Tester Connections

tributor cap. Connect a suitable jumper wire between (4) Rotate and hold the ignition switch in the
the coil cable end-terminal and a good body ground START position. Observe the volt-ampere tester (Fig.
(Fig. 6). 8).
• VEHICLES WITH DIRECT IGNITION SYSTEM: • If voltage reads above 9.6 volts, and amperage
Disconnect the ignition coils electrical connector (Fig. draw reads above 250 amps, go to the starter feed
7). circuit resistance test.
(3) Verify that all lights and accessories are OFF, • If voltage reads 12.4 volts or greater and amperage
and the transmission shift selector is in the PARK. reads 0 to 10 amps, go to starter control circuit test.
Set parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
charge battery if necessary. Disconnect all testing

equipment and connect ignition coil cable or ignition
coil connector. Start the vehicle several times to as-
sure the problem has been corrected.
STARTER FEED CIRCUIT RESISTANCE TEST

Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter, ac-
curate to 1/10 of a volt.
CAUTION: Ignition system also must be disabled to

prevent engine start while performing the following
tests.
Fig. 6 Ground Ignition Coil Cable
(1) Disable ignition system as follows:
• VEHICLES WITH CONVENTIONAL DISTRIBU-
TORS
Disconnect the ignition coil cable from the distrib-
utor cap. Connect a suitable jumper wire between the
coil cable end-terminal and a good body ground (Fig.
6).
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• VEHICLES WITH DIRECT IGNITION SYSTEM:

Disconnect the ignition coils electrical connector (Fig.
7).
(2) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp (Fig. 9). Rotate and
hold the ignition switch in the START position. Ob-
serve the voltmeter. If voltage is detected, correct
poor contact between cable clamp and post.
Fig. 7 Ignition Coils Electrical Connection
Fig. 9 Test Battery Connection Resistance

(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp. Rotate and hold the igni-
Fig. 8 Starter Draw Tests tion switch key in the START position. Observe the
(5) After the starting system problems have been voltmeter. If voltage is detected, correct poor con-
corrected, verify the battery state-of-charge and tact between the cable clamp and post.
(c) Connect negative lead of voltmeter to battery If reading is still above 0.2 volt after correcting
negative terminal, and positive lead to engine block poor contacts, replace battery positive cable.
near the battery cable attaching point (Fig. 10). Ro-
tate and hold the ignition switch in the START po-
sition. If voltage reads above 0.2 volt, correct poor
contact at ground cable attaching point. If voltage
reading is still above 0.2 volt after correcting poor
contacts, replace ground cable.
Fig. 12 Test Battery Positive Cable Resistance

(c) If resistance tests do not detect feed circuit
failures, remove the starter motor and go to Bench
Testing Starter Solenoid in this Group.
STARTER CONTROL CIRCUIT TESTS

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Fig. 10 Test Ground Circuit Resistance The starter control circuit has:
(3) Remove starter heat shield. Refer to Group 8B, • Starter solenoid
Starter Replacement to gain access to the starter mo- • Starter relay (Fig. 2)
tor and solenoid connections. Perform the following • Neutral starting and back-up switch with auto-
steps: matic transmissions
(a) Connect positive voltmeter lead to the starter • Ignition switch
motor housing and the negative lead to the battery • Battery
negative terminal (Fig. 11). Hold the ignition • All related wiring and connections
switch key in the START position. If voltage reads
above 0.2 volt, correct poor starter to engine CAUTION: Before performing any starter tests, the
ignition system must be disabled.
ground.
VEHICLES EQUIPPED WITH A CONVEN-
TIONAL DISTRIBUTOR: Disconnect coil wire from
distributor cap center tower. Secure wire to a good
ground to prevent engine from starting (Fig. 6).
• VEHICLES EQUIPPED WITH DIRECT IGNI-
TION SYSTEM: Unplug the coils electrical connector
(Fig. 7).
STARTER SOLENOID TEST
WARNING: CHECK TO ENSURE THAT THE TRANS-

MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in

Fig. 11 Test Starter Motor Ground good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(b) Connect the positive voltmeter lead to the (2) Perform this starter solenoid test BEFORE per-
battery positive terminal, and negative lead to bat- forming the starter relay test.
tery cable terminal on starter solenoid (Fig. 12). (3) Raise the vehicle.
Rotate and hold the ignition switch in the START (4) Perform a visual inspection of the starter/start-
position. If voltage reads above 0.2 volt, correct er solenoid for corrosion, loose connections or faulty
poor contact at battery cable to solenoid connection. wiring.
(5) Lower the vehicle. (7) Remove the starter relay from the connector.
(6) Locate the starter relay (Fig. 13). (8) Connect a remote starter switch or a jumper
wire between the battery positive post and terminal
87 on the starter relay connector. To determine the
starter relay terminal numbers, refer to Fig. 14.
• If engine cranks, starter/starter solenoid is good.
Go to the Starter Relay Test.
• If engine does not or solenoid chatters, check wir-
ing and connectors from starter relay to starter sole-
noid for loose or corroded connections. Particularly at
starter terminals.
• Repeat test. If engine still fails to crank properly,
trouble is within starter or starter mounted solenoid,
and it must be removed for repairs. Refer to Group
8B, Battery/Starter/Generator Service, for Starter
Replacement.
STARTER RELAY TEST
WARNING: CHECK TO ENSURE THAT THE TRANS-

MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED
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(1) Verify battery condition. Battery must be in

good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform the preceding starter solenoid tests
BEFORE performing starter relay tests. Refer to
Starter Solenoid Test.
(3) Locate and remove the starter relay (Fig. 13).
(4) After the starter relay has been located and re-
Fig. 13 Starter Relay Location moved, refer to Starter Relay Tests (Fig. 14).
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Fig. 14 Starter Relay Tests

NEUTRAL STARTING AND BACK-UP SWITCH (2) Check for continuity between solenoid terminal
and field coil terminal with a continuity tester. Con-
AUTOMATIC TRANSMISSION ONLY tinuity should be detected (Figs. 17 or 18).
For electrical diagnostics, when checking starter
circuits, refer to Starter Relay Tests (Fig. 14).
For removal and installation of neutral switch, re-
fer to Neutral Starting and Back-up Switch in Group
21, Transaxle.
IGNITION SWITCH TEST

After testing starter solenoid and relay, test igni-
tion switch and wiring. Refer to Group 8D, Ignition Fig. 17 Continuity Test Between Solenoid Terminal
Systems or Group 8W, Wiring Diagrams. Check all and Field Coil Terminal—Bosch
wiring for opens or shorts, and all connectors for be-
ing loose or corroded.
BENCH TESTING STARTER SOLENOID

(1) Disconnect field coil wire from field coil termi-
nal (Figs. 15 or 16).
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Fig. 18 Continuity Test Between Solenoid Terminal

and Field Coil Terminal—Nippondenso
(3) Check for continuity between solenoid terminal
and solenoid housing (Figs. 19 or 20). Continuity
should be detected. If continuity is detected, solenoid
is good.
Fig. 15 Field Coil Wire Terminal—Bosch

and Solenoid Case —Bosch
Fig. 16 Field Coil Wire Terminal—Nippondenso

and Solenoid Case —Nippondenso
(4) If continuity is not detected in either test, sole-

noid has an open circuit and is defective. Replace the
starter assembly
GENERATOR TEST PROCEDURES ON VEHICLE
INDEX
page page
Charging System Diagnostics (Fig. 1) . . . . . . . . . . 17 Output Wire Resistance Test . . . . . . . . . . . . . . . . . 17
Current Output Test . . . . . . . . . . . . . . . . . . . . . . . . 17
CHARGING SYSTEM DIAGNOSTICS (Fig. 1) (2) Adjust engine speed and carbon pile to main-
tain 20 amperes flowing in the circuit. Observe volt-
OUTPUT WIRE RESISTANCE TEST meter reading. Voltmeter reading should not exceed
The generator output wire resistance test shows 0.5 volts.
the amount of voltage drop across the generator out-
put wire between the generator B+ terminal and the RESULTS
battery positive post. If a higher voltage drop is shown, inspect, clean
and tighten all connections between generator B+
PREPARATION terminal and battery positive post. A voltage drop
Before starting test, make sure the vehicle has a test may be performed at each connection to locate a
fully charged battery. Tests and procedures to check connection with excessive resistance. If resistance
for a fully charged battery are shown in the Battery tests are satisfactory, reduce engine speed, turn off
section of this Group. carbon pile, and turn off ignition switch.
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(1) Turn the ignition switch OFF. (1) Disconnect battery negative cable.
(2) Disconnect battery negative cable. (2) Remove test ammeter, voltmeter, carbon pile,
(3) Disconnect the generator B+ output wire from and tachometer.
the generator output battery terminal (Fig. 2). (3) Remove jumper wire.
(4) Connect a 0-150 ampere scale (DC) ammeter in (4) Connect output wire to B+ terminal.
series between B+ terminal and output wire (Figs. 2 (5) Connect battery negative cable.
and 3). Connect positive lead to B+ terminal, and (6) Connect fresh air hose between powertrain con-
negative lead to output wire. trol module and air cleaner if removed.
(5) Using 0-18 volt scale voltmeter, connect the
positive lead to the disconnected (B+) output wire. CURRENT OUTPUT TEST
Connect the negative lead to battery positive post. The current output test determines whether or not
(6) Remove fresh air hose between powertrain con- the generator is capable of delivering its rated cur-
trol module and air cleaner if necessary. rent output. For generator identification and output
(7) Connect jumper wire between a good ground, amperage specifications, refer to Generator Specifica-
and K20 circuit terminal at the back of the genera- tions.
tor. For generator maximum voltage at individual tem-
peratures, refer to Generator Output Voltage Specifi-
CAUTION: Do not connect the A142 circuit terminal cations.
(Fig. 1) to ground the Fusible link will burn.
PREPARATION
(8) Connect an engine tachometer and connect bat- Before starting any tests, make sure the vehicle
tery negative cable. has a fully charged battery. Tests and procedures to
(9) Connect a volt/amp tester equipped with a vari- check for a fully charged battery are shown in Bat-
able carbon pile rheostat between battery terminals tery section.
(Fig. 4). (1) Disconnect battery negative cable.
(2) Disconnect output wire at the B+ terminal
Caution: Be sure the carbon pile is in OFF position (Figs. 2 and 5).
before connecting leads. (3) Connect a 0-150 ampere scale (DC) ammeter in
series between the B+ terminal and output wire.
Connect Positive lead to B+ terminal and negative
TEST
lead to output wire.
(1) Start engine. Immediately after starting, re-
(4) Using 0-18 voltmeter, connect the positive lead
duce engine speed to idle. to B+ terminal (Figs. 2 and 4). Connect negative lead
to a good ground.
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Fig. 1 Charging Diagnostics

Fig. 4 Volt/Amp Tester Connections

Fig. 2 Generator Wiring Connections
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Fig. 3 Generator Output Wire Resistance Test

(5) Connect an engine tachometer and connect bat- (8) Full field the generator. Connect a jumper wire
tery negative cable. between a good ground and to the K20 circuit termi-
(6) Connect a volt/amp tester equipped with a vari- nal at the back of the generator (Figs. 2 and 5).
able carbon pile rheostat between battery terminals
(Fig. 6). Be sure carbon pile is in OFF position before CAUTION: Do not connect the A142 circuit terminal
connecting leads. (Fig. 2) to ground the Fusible link will burn.
(7) Remove fresh air hose between powertrain con-
trol module and air cleaner if necessary.
TEST
(1) Start the engine. Immediately after starting,
reduce engine speed to idle.
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Fig. 5 Generator Current Output Test

tested. Refer to Generator Specifications for genera-
tor identification and amperage outputs.
RESULTS
(1) If amperage reading is less than specified, and
generator output wire resistance is not found exces-
sive from the previous test, generator should be re-
placed. Refer to Generator replacement in Group 8B,
Battery/Starter/Generator Service. These generators
are not intended to be disassembled for service. It
must be replaced as an assembly.
(2) After current output test is completed, reduce
engine speed, turn off carbon pile, and turn off igni-
tion switch.
Fig. 6 Volt/Amp Tester Connections (3) Disconnect battery negative cable.
(4) Remove test ammeter, voltmeter, tachometer
(2) Adjust the carbon pile and engine speed in and carbon pile.
steps until an engine speed of 1250 rpm, and a volt- (5) Remove jumper wire between K20 circuit ter-
meter reading of 15 volts is obtained. minal and ground.
CAUTION: Do not allow the battery voltage to ex- (6) Connect output wire to B+ terminal.
ceed 16 volts. (7) Connect battery negative cable.
(8) Connect fresh air hose between powertrain con-
(3) The generator amperage must meet the output trol module and air cleaner if removed.
requirements for the particular generator being
DIAGNOSTIC CODES—ON BOARD DIAGNOSTICS
INDEX
page page
Diagnostic Testing Using Diagnostic Codes . . . . . . 22 General Description/Information . . . . . . . . . . . . . . . 21
DRB Diagnostic Tester . . . . . . . . . . . . . . . . . . . . . 25
GENERAL DESCRIPTION/INFORMATION POWERTRAIN CONTROL MODULE

Another way of diagnosing charging system prob- The powertrain control module is equipped with
lems can be accomplished using the On-Board Diag- On-Board Diagnostic features and monitors all en-
nostic System Codes. gine control circuits during a run/drive period. If a
A Diagnostic Code shows a potential problem in a circuit or system does not perform properly, the pow-
ertrain control module will file in memory a predeter-
monitored circuit, or a condition caused by a faulty
mined diagnostic code. This can be used to help in
component. A Diagnostic Code can be retrieved by
diagnosing a problem. After 50 to 100 ignition switch
turning the ignition switch ON-OFF-ON-OFF-ON ON/RUN cycles, the memory will be erased if the
without starting the engine, and counting the possi- code does not reoccur.
ble number of flashes of the Malfunction Indicator The powertrain control module is located in the en-
(Check Engine) Lamp in the instrument cluster. gine compartment outboard of the battery (Fig. 7).
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EXAMPLES:
• If the Malfunction Indicator (Check Engine) Lamp
flashes four times, pauses, and flashes one more
time, a Code 41 is shown. The first set of four flashes
indicates the number four. The second set of one
flash indicates one.
flashes four times, pauses, and flashes six more
times, a Code 46 is shown. The first set of four
flashes indicates the number four. The second set of
six flashes indicates six.
flashes four times, pauses, and flashes seven more
times, a Code 47 is indicated. The first set of four
flashes indicates the number four. The second set of
seven flashes indicates seven. Fig. 7 Powertrain Control Module
Fig. 8 Generator Diagnostic Codes

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Refer to Fig. 8 Generator Diagnostic Code chart for DIAGNOSTIC TESTING USING DIAGNOSTIC CODES
relationships of generator/charging system diagnostic For diagnostic testing when using the diagnostic
code numbers. codes, refer to Figs. 9 through 13.
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Fig. 9 CHECK FOR INADEQUATE/LOW CHARGING—USING ON BOARD DIAGNOSTIC CODES

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Fig. 10 CHECK FOR OVERCHARGING—USING ON BOARD DIAGNOSTIC CODES

Fig. 11 Generator Wiring Connections Fig. 13 Electrical Resistance Test

DRB DIAGNOSTIC TESTER
TESTING
A more accurate device to retrieve diagnostic codes
is Diagnostic Tool (DRB). This diagnostic tool,
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plugged into the data link connector (Fig. 6) located

near the left shock tower will display code descrip-
tions. The DRB can also test various circuits and
component functions. Refer to the instructions pro-
vided with the DRB tool being used. Descriptions of
Diagnostic Codes for other vehicle systems can be
found in the General Diagnosis section of Group 14,
Fuel System.
Fig. 12 Powertrain Control Module Connector
SPECIFICATIONS
GENERATOR AMPERAGE/IDENTIFICATION NUMBERS
STARTER/BATTERY
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TORQUE SPECIFICATIONS
. BATTERY/STARTER/GENERATOR SERVICE 8B - 1
BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page page
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 11
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
BATTERY
GENERAL INFORMATION
This first section will cover Battery replacement
and service procedures only. For Battery diagnostic
procedures, refer to Group 8A, Battery/Starting/
Charging Systems Diagnostics.
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Fig. 2 Remove Battery Cables

WARNING: TO PROTECT THE HANDS FROM BATTERY
ACID, A SUITABLE PAIR OF HEAVY DUTY RUBBER
GLOVES, NOT THE HOUSEHOLD TYPE, SHOULD BE
WORN WHEN REMOVING OR SERVICING A BATTERY.
SAFETY GLASSES ALSO SHOULD BE WORN.
(3) Remove battery hold down clamp (Fig. 3) and

Fig. 1 Maintenance Free Battery—Typical remove battery from vehicle.
Factory installed batteries (Fig. 1) do not have re-
CAUTION: Do not allow baking soda solution to
movable battery cell caps. Water cannot be added to
enter vent holes, as damage to battery can result.
factory installed battery. Battery is sealed, except for
small vent holes in the top. Chemical composition in- (4) Clean top of battery with a solution of warm
side the battery produces an extremely small amount water and baking soda. Apply solution with a bristle
of gases at normal charging voltages. The factory in- brush and allow to soak until acid deposits loosen
stalled battery is equipped with a test indicator (Fig. (Fig. 4). Rinse with clear water and blot dry with pa-
1) that displays a colored ball to show battery state- per toweling. Dispose of toweling in a safe manner.
of-charge. Refer to the WARNINGS on top of battery.
• Green Indicator = Full charge (5) Inspect battery case and cover for cracks or
• Black Indicator = Discharged leakage. If leakage is present battery must be re-
• Yellow Indicator = Battery replacement required. placed.
(6) Inspect battery tray (Fig. 3) for damage caused
BATTERY VISUAL INSPECTION AND SERVICE by acid from battery. If acid damage is present, it
(1) Make sure ignition switch is in OFF position will be necessary to clean area with same solution
and all accessories are OFF. described in Step (4).
(2) Disconnect and remove the battery terminals (7) Clean battery posts with a suitable battery post
from the battery posts. Remove battery negative ca- cleaning tool (Fig. 5).
ble first (Fig. 2).
8B - 2 BATTERY/STARTER/GENERATOR SERVICE .
Fig. 3 Battery Hold-Down/Tray Fig. 5 Cleaning Battery Posts

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Fig. 4 Cleaning Battery

(8) Clean inside surfaces of battery terminal
Fig. 6 Cleaning Battery Cable Terminal
clamps with a suitable battery terminal cleaning tool
(Fig. 6). Replace damaged or frayed cables and bro- (13) Connect battery cable clamps to battery posts
ken terminal clamps. making sure top of clamp is flush with top of post.
(9) Inspect battery for proper or damaged hold Install POSITIVE cable first.
down ledge. (14) Tighten clamp nuts securely.
(10) Install battery in vehicle making sure that
battery is properly positioned on battery tray (Fig. 3).
(11) Install battery hold down clamp, making sure
that it is properly positioned on battery.
(12) Place felt grease washer onto battery positive
post.
STARTER
INDEX
page page
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 Starter Motor Replacement . . . . . . . . . . . . . . . . . . . 3
Neutral Starting and Back-Up Switch . . . . . . . . . . . . 7 Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Starter Component Replacement . . . . . . . . . . . . . . . 5 Supply Circuit and Control Circuit . . . . . . . . . . . . . . 3
GENERAL INFORMATION
This section will cover STARTER replacement and
service procedures only. For starter diagnostic proce-
dures, refer to Group 8A, Battery/Starting/Charging
Systems Diagnostics.
STARTING SYSTEM
The starting system has:
• Ignition switch
• Starter relay
• Neutral starting and back up switch
• Wiring harness
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Fig. 1 Remove or Install Battery Cable

• Battery
• Starter motor with an integral solenoid
BOSCH STARTERS
Bosch permanent magnet starter motor is available
on 2.5L and 3.0L engines on all vehicles. A planetary
gear train transmits power between starter motor
and pinion shaft. The fields have six permanent mag-
nets.
NIPPONDENSO STARTERS
• A Nippondenso reduction gear-field coil starter mo-
tor is available on 3.0L, and 3.3L engines.
SUPPLY CIRCUIT AND CONTROL CIRCUIT

Both starter systems consists of two separate cir-
cuits:
Fig. 2 Starter Heat Shield—4 Cylinder Engines
• A high amperage supply to feed the starter motor.
• A low amperage circuit to control the starter sole- (5) Remove starter/starter solenoid assembly from
noid. engine. Position the starter to gain access to the wir-
For additional information on starter motor supply ing connectors.
and control circuits, refer to Group 8A, Battery/Start- (6) Disconnect the battery positive cable and wir-
ing/Charging Systems Diagnostics. ing at the starter.
(7) Remove the starter from vehicle.
STARTER MOTOR REPLACEMENT (8) For installation, reverse above procedures.
Clean corrosion/dirt from the cable and wire termi-
BOSCH STARTER 2.5L ENGINE nals before installing wiring to the solenoid.
(1) Disconnect battery negative cable (Fig. 1).
(2) Raise vehicle. BOSCH OR NIPPONDENSO STARTER—3.0L OR
(3) Remove heat shield clip from the starter and 3.3L ENGINE
heat shield (Fig. 2). For easier servicing, do not re- (1) Disconnect battery negative cable (Fig. 1).
move the wiring from starter at this time. (2) Raise vehicle.
(4) Remove two bolts and one nut attaching starter (3) Remove three starter attaching bolts from en-
to engine (Fig. 3). gine/transaxle (Fig. 4).
Fig. 3 Bosch Starter—2.5L Engine

Fig. 6 Wire Terminal Connections—3.0L Engine—
Nippondenso Starter
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Fig. 4 Remove or Install Attaching Bolts

(3) Remove two wire connector terminal nuts and
remove connector (Bosch, Fig. 5) (Nippondenso, Fig. 6 Fig. 7 Wire Terminal Connections—3.3L Engine—
or 7). Nippondenso Starter
Fig. 5 Wire Terminal Connections—Bosch Starter Fig. 8 Remove/Install Starter—Bosch—Typical

(4) Remove starter from vehicle (Bosch, Fig. 8) (5) For installation, reverse above procedures.
(Nippondenso, Fig. 9). Clean corrosion/dirt from the cable and wire termi-
nals before installing wiring to the solenoid.
Fig. 9 Remove/Install Starter—Nippondenso— Fig. 11 Remove or Install Drive and Pinion Gears
Typical
STARTER COMPONENT REPLACEMENT
Caution: When servicing the starter assembly off
the vehicle, do not clamp the starter to a vice. In-
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ternal damage may result.
NIPPONDENSO STARTER GEAR AND CLUTCH

(1) Remove the two gear housing attaching screws
and separate the gear housing from the solenoid
housing (Fig. 10). The pinion gear, pinion gear bear-
ing, and drive gear will be loose between the solenoid
housing and gear housing (Fig. 11). When reinstall-
ing pinion gear and bearing, wipe with a clean rag
and coat with lightweight high temperature wheel
bearing grease. Place the lubricated bearing and gear
over bearing shaft in the gear housing (Fig. 12). Fig. 12 Lubricate and Install Pinion Gear Bearing
Fig. 10 Remove or Install Gear Housing Fig. 13 Gear and Clutch Assembly
(2) Remove the starter gear and clutch assembly

from the solenoid housing (Fig. 13).
(3) For installation, reverse above procedures.
BOSCH STARTER SOLENOID (4) Remove three solenoid mounting screws (Fig. 17).
(1) Remove field terminal nut (Fig. 14).
Fig. 17 Solenoid Mounting Screws

Fig. 14 Field Terminal Nut (5) Remove the solenoid from the starter assembly.
(2) Remove field terminal (Fig. 15). (6) For installation, reverse above procedures.
BOSCH STARTER GEAR AND CLUTCH

(1) Remove solenoid assembly (Fig. 18).
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Fig. 15 Field Coil Terminal

(3) Remove field washer (Fig. 16).
Fig. 18 Solenoid
(2) Remove the two through-bolts securing the
starter drive end housing to the motor housing (Fig.
19) and separate housings.
Fig. 16 Field Terminal Washer
Fig. 19 Through-Bolt
Fig. 20 Rubber Seal Fig. 21 Starter Drive Gear Train

(3) Remove rubber seal (Fig. 20). For removal and installation of switch, refer to
(4) Pull the gear and clutch assembly from the Neutral Starting and Back-up Switch Replacement in
drive end housing (Fig. 21). Group 21, Transaxle.
NEUTRAL STARTING AND BACK-UP SWITCH

For electrical diagnostics, when checking the
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starter circuits, refer to the STARTER RELAY

TESTS chart in Group 8A, Battery/Starting/Charging
Systems Diagnostics.
GENERATOR
INDEX
page page
General Information . . . . . . . . . . . . . . . . . . . . . . . . 8 Generator Replacement—3.0L Engine . . . . . . . . . . . 9
Generator Replacement—2.5L Engine . . . . . . . . . . . 8 Generator Replacement—3.3L Engine . . . . . . . . . . . 9
GENERAL INFORMATION
This section will cover generator replacement only.
Information covering generator on-vehicle testing and
diagnosis can be found in Group 8A, Battery/Start-
ing/Charging Systems Diagnostics. To identify the
generator, refer to the Generator Specification chart
at the rear of this section.
These generators are not intended to be dis-
assembled for service. It must be replaced as an
assembly.
GENERATOR REPLACEMENT—2.5L ENGINE

Removal and repositioning of A/C Compressor with-
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out disconnecting refrigerant lines is necessary on

some models to gain access to generator.
Fig. 2 A/C Compressor Removal and Installation—

2.5 L Engine
(4) Remove the two generator mounting bolts (Fig.
3) and position the generator to gain access to all the
wire connectors. If equipped with:
Fig. 1 Remove battery negative cable

(2) If Equipped With air conditioning:
(a) Remove the A/C drive belt. Refer to Group 7,
Cooling System.
(b) Remove the four bolts retaining the A/C com-
pressor to the mounting bracket (Fig. 2).
(c) Do not disconnecting the A/C refrigerant
lines, position the A/C compressor to allow genera-
tor removal.
WARNING: THE A/C REFRIGERANT SYSTEM IS

UNDER PRESSURE EVEN WHEN THE ENGINE IS
OFF. REFER TO THE SAFETY PRECAUTIONS AND Fig. 3 Remove or Install Mounting Bolts
WARNINGS SECTION IN HEATING AND A/C, • BOSCH GENERATOR. Remove B+ terminal nut,
GROUP 24, BEFORE PERFORMING ANY SERVICE field terminal nuts, and ground harness hold down
OPERATION.
nuts (Fig. 4). Remove wire connector assembly.
(3) Remove the generator drive belt. Refer to • NIPPONDENSO GENERATOR. Remove nuts from
Group 7, Cooling System. field terminals, ground terminal, wire harness and
Fig. 6 Remove or Install Generator Mounting

Fig. 4 Remove or Install Wire Connector Bolts—3.0L Engine
Assembly—Bosch Generator
B+ terminal (Fig. 5). B+ terminal nut must be re- Tighten all fasteners to the proper torque. Refer to the
moved last to prevent damage to terminal insulator. Torque Specifications chart at the rear of this group.

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(2) Remove generator drive belt. Refer to Group 7,
Cooling System.
(3) Loosen, but do not remove the nut on the sup-
port bracket at exhaust manifold (Fig. 7).
Fig. 5 Remove or Install Wire Connector

Assembly—Nippondenso Generator
(5) Remove the generator from the vehicle.
Tighten all fasteners to the proper torque. Refer to
the Torque Specifications chart at the rear of this
group.

(2) Remove generator drive belt. Refer to Group 7,
Cooling System.
(3) Remove the generator mounting bolts and sepa-
rate the generator from the mounting bracket (Fig. 6).
(4) Remove the B+ terminal nut, field terminal
nuts, and ground/wire harness hold-down nuts. Re-
move wire connectors.
(5) Remove the generator from the vehicle.
Fig. 7 Support Bracket for Generator Tensioner
Power Steering Bracket
(4) Remove the generator tensioner power steering

bracket bolt.
(5) Remove the tensioner stud nut and the ten-
sioner (Fig. 8).
(6) Remove the generator mounting bolts.
(7) Remove and position the power steering reser-
voir from the generator mounting bracket. Do not re-
move the hoses from the reservoir.
(8) Remove the three generator support bracket
bolts (Fig. 7).
(9) Remove intake plenum-to-generator mounting
bracket bolt.
(10) Remove generator support bracket (Fig. 8).
(11) Position generator and remove generator wir-
ing.
(12) Remove generator.
Tighten all fasteners to the proper torque. Refer to
the Torque Specifications chart at the rear of this
group.
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Fig. 8 Generator/Support Bracket—3.3L Engine

SPECIFICATIONS
STARTER/BATTERY
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GENERATOR AMPERAGE/IDENTIFICATION NUMBERS

TORQUE SPECIFICATIONS
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. OVERHEAD CONSOLE 8C - 1
OVERHEAD CONSOLE
CONTENTS
page page
COMPASS MINI-TRIP COMPUTER (CMTC) . . . . 2 MAP/READING LAMPS . . . . . . . . . . . . . . . . . . . . 1

COMPASS MODULE REPLACEMENT . . . . . . . . . 4 OVERHEAD CONSOLE REPLACEMENT . . . . . . . . 4
FRONT HEADER READING LAMP . . . . . . . . . . . . 4 REAR VENT WINDOWS SWITCHES . . . . . . . . . . 1
FRONT HEADER READING LAMP
REPLACEMENT/LAMP REPLACEMENT . . . . . . 5
The overhead console includes: sure the tool is between the lamp and bracket.
• Four map reading lamps Carefully pry the lamp from the bracket until it
• Storage compartments for sunglasses and garage clears one of the four retaining clips. Locate other
door opener transmitter clip on the same side and pry along side clip. Do the
• Rear vent windows switches same to other two clips until it is free.
• Digital electronic display
The Compass Mini Trip Computer (CMTC) elec- LENS/LAMP REPLACEMENT
tronic display shows 6 conditions (optional): (1) Insert a long flat blade tool at inside edge of
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• Compass/Temperature. the lens. Carefully pry the lens from the housing and
• Trip odometer (ODO). pivot the lens out. May need to move the tool along
• Average miles per gallon (ECO). the edge to free lens.
• Instant miles per gallon (ECO). (2) Remove bulb by pulling straight down.
• Distance to empty (DTE). (3) Install new bulb by pushing firmly into socket.
• Elapsed time (ET). (4) Begin at outboard edge pivot lens into position
As the driver pushes the STEP button they will and snap in. Test by pressing lens from proper oper-
display individually. ation and lighting.
The US/M button changes the display from US to
metric units. For complete operating instructions, re-
LAMP TEST
(1) Close vehicle doors.
fer to owner’s manual provided with vehicle.
(2) Press each lamp lens. Right hand lens should
MAP/READING LAMPS light passenger lamp and left hand lens should light
The four map reading lamps are turned on and off drivers lamp.
by pressing the lens cover indent. The rear lamps op- (3) If either of the rear lamps fail to illuminate,
erate as courtesy lamps when the doors are open or open vehicle doors.
closed. The lamps also operated when the headlamp (a) If rear lamp does not illuminate check for a
POD switch is slid to the full right position. The burned out bulb.
front reading lamps do not come ON with the doors (b) If front lamp illuminates when doors are open
open or headlamp dimmer switch in courtesy mode check switch and wiring (Fig. 2).
(Fig. 1).
REAR VENT WINDOWS SWITCHES
The switch on the right side operates the right rear
vent window and switch on the left operates the left
rear window.
SWITCH VOLTAGE TEST

(1) Remove the overhead console and disconnect
wire connectors.
(2) Ignition switch in the run position.
Fig. 1 Overhead Console (3) Connect voltmeter to terminal 4 and 5. Test for
battery voltage.
LAMP HOUSING REPLACEMENT
(4) If no voltage, test 20 amp fuse or wiring.
(1) Insert a long flat blade tool at either side be-
(5) If OK, go to Switch Module Test.
tween the lamp housing and mounting bracket. En-
8C - 2 OVERHEAD CONSOLE .
1994 Town&Country, Caravan, and Voyager
Publication No. 81-370-4105
TSB 08-78-94 December 30, 1994
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Fig. 2 Map Lamp Diagnosis

SWITCH MODULE TEST THERMOMETER AND COMPASS
(1) Remove the overhead console and disconnect Engine temperature can increase the displayed
wire connectors. temperature. The CMTC is designed to dampen tem-
(2) Using an Ohmmeter refer to Fig. 3 to test perature readings when the vehicle is moving at a
switches. rate slower than 18 miles per hour.
(3) If no continuity, at any of the positions, replace The outside temperature is measured from a sensor
switch module. mounted in the front of the vehicle. If the tempera-
ture is more than 55°C (131°F) or the temperature
SWITCH REMOVAL sending line is shorted to ground, the temperature
(1) Remove the overhead console and disconnect display should read SC. If the temperature is less
wire connectors. than -40°C (-40°F), or the sending line is an open cir-
(2) Remove switch from overhead console by mov- cuit, the display should read OC.
ing the four retaining tabs. Two are located on the
The CMTC is self calibrating and requires no ad-
sides and two at the rear of the module. Take care in
justing. The word CAL is displayed to show that the
pressing tabs and pivot module out of console.
compass is in calibration mode. CAL will turn off af-
COMPASS MINI-TRIP COMPUTER (CMTC) ter the vehicle has gone through three complete cir-
cles without stopping, in an area free of magnetic
CMTC is a module that combines Traveler and
Compass / Temperature features. Actuating the STEP disturbance. If the module displays temperature
switch will cause the CMTC to change mode of oper- while the compass is blank, then demagnetize the ve-
ation when ignition is ON. Example: hicle with the ignition off.
• Compass/Temperature
• Trip odometer (ODO)
• Average miles per gallon (ECO)
• Instant miles per gallon (ECO)
• Distance to empty (DTE)
• Elapsed time (ET)
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Fig. 3 Power Vent Window Continuity Test

VARIANCE PROCEDURE
Variance is the difference between magnetic North
and geographic North refer to Fig. 4 for variance
number. To adjust the compass variance set the
CMTC to Compass/Temperature mode and depress
both the US/M and STEP buttons for 5 seconds. The
word VAR and the last variance zone will be dis-
played. Depress the US/M button to select the de-
sired zone. Depress the STEP button to set the new
variance zone and resume normal operation. If both
buttons are held for 10 seconds instead of 5 seconds
the CMTC will set variance to 8 and enter the fast
calibration mode.
TRAVELER MESSAGES
Traveler data is obtained from the Body Control
Module on the CCD lines. If the brightness level is
improper or the data displayed is wrong then check
CCD communication by the following test. STEP the
CMTC to the elapsed time ET mode and simulta-
neously press both the US/M and STEP buttons to
reset the module. If the elapsed time clock does not
reset or fails to up-date then check the CCD lines
and Body Control Module. Run self diagnostics before
replacing CMTC. The DRB is recommended for
checking out the CCD lines and Body Control Mod-
ule.
DEMAGNETIZING PROCEDURE Fig. 4 Variance Settings

Every vehicle has its own magnetic field. This mag- • Magnetic C.B. Antenna
netic field is created by the various processes a steel • Magnetic tipped screwdriver
roof goes through when the vehicle is built. A mag-
• etc.
netic field can also be created if the roof is subjected
to a magnet. Example:
8C - 4 OVERHEAD CONSOLE .
TSB 08-78-94 December 30, 1994
If the roof becomes magnetized use a demagnetizer (3) Displays one of three messages, “PASS”,
tool 6029 to demagnetize the roof. “FAIL”, or “ccd”.
In this demagnetizing procedure you will use the (4) Pressing the STEP or the C/T switch causes the
demagnetizing tool to demagnetize the roof and CMTC to exit diagnostic mode and return to normal
mounting screws in the overhead console. It is impor- operation.
tant that you follow the instructions below exactly. (5) If the test message fails or “ccd” is displayed
The mounting screws and the mounting brackets then do the following.
around the compass area are steel, and therefore aid (a) Check wiring
in the demagnetizing of the roof panel. (b) Check any other body controller function, if
(1) Be sure the ignition switch is in the OFF posi- CCD functions are OK, and wiring is OK, then re-
tion before you begin the demagnetize procedure. place module.
(2) Plug the demagnetizing tool into a standard
110/115 volt AC outlet, keeping the demagnetizing OVERHEAD CONSOLE REPLACEMENT
tool at least 12 inches away from the compass area
(1) Unscrew the mounting screws (Fig. 5).
when plugging it in.
(3) Slowly approach and contact the console
mounting screw with the plastic coated tip of the tool
for at least two seconds.
(4) With the demagnetizing tool still energized,
slowly back it away from the screw until the tip is at
least 12 inches from the screw head.
(5) After you have pulled at least 12 inches from
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the last screw, remove the demagnetizing tool from

inside vehicle and disconnect it from the electrical
outlet.
(6) Place an 8-1/2 X 11 inch piece of paper length-
wise on the roof of vehicle directly above compass.
The purpose of the paper is to protect the roof panel
from scratches and define the area to be demagne-
tized.
(7) Plug in the demagnetizing tool, keeping it at
least two feet away from the compass unit. Fig. 5 Overhead Console Mounting
(8) Slowly approach the center of the roof panel at (2) Slide console forward toward windshield until
the windshield with the demagnetizing tool plugged the console unhooks from roof bracket.
in. (3) Disconnect wire harness from console.
(9) Contact the roof panel with the tip of the tool. (4) For installation reverse above procedures.
Using slow sweeping motions of 1/2 inch between
sweeps. Move the tool approximately four inches ei- COMPASS MODULE REPLACEMENT
ther side of the centerline and at least 11 inch back (1) Remove overhead console and disconnect wir-
from the windshield. ing.
(10) With the demagnetizing tool still energized,
(2) Remove two forward screws and pry rear of
slowly back away from the roof panel until the tip is
compass module along the sides from the console
at least two feet from the roof before unplugging the
housing so 1 of the 2 compass pins clear the console.
tool.
Rotate module out of the console.
(11) Recalibrate compass.
(3) For installation reverse above procedures.
SELF-DIAGNOSTIC TEST
(1) The ignition switch in the OFF position, press FRONT HEADER READING LAMP
both the STEP button and the US/M button. The front header reading lamps are turned ON and
(2) Turn ignition switch ON. OFF by pressing on their individual lens cover in-
dents.
FRONT HEADER READING LAMP REPLACEMENT/

LAMP REPLACEMENT
(1) Pull the lamp assembly down, along the sides
from the bracket. Four metal clips hold the lamp in
the bracket (Fig. 6).
(2) Disconnect the wire harness connector from the
lamp assembly.
(3) After the lamp assembly is free of the vehicle,
pull the metal center reflector to gain access to the
lamp.
Fig. 6 Header Reading Lamp
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. IGNITION SYSTEMS 8D - 1
IGNITION SYSTEMS
CONTENTS
page page
2.5L AND 3.0L IGNITION SYSTEMS— 3.3L AND 3.8L DIRECT IGNITION SYSTEM—
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 10 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . 23
2.5L AND 3.0L IGNITION SYSTEMS—SERVICE 3.3L AND 3.8L DIRECT IGNITION SYSTEMS—
PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 13 SERVICE PROCEDURES . . . . . . . . . . . . . . . . . 33
2.5L AND 3.0L IGNITION SYSTEMS—SYSTEM IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3L AND 3.8L DIRECT IGNITION SYSTEM—
DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . . 30
2.5L AND 3.0L IGNITION SYSTEMS—SYSTEM OPERATION

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INDEX
page page
Auto Shutdown (ASD) Relay and Fuel Pump Relay . . . 8 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Distributor Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Manifold Absolute Pressure (MAP) Sensor . . . . . . . . 8
Distributor Pick-Up—3.0L Engine . . . . . . . . . . . . . . . 7 Powertrain Control Module (PCM) . . . . . . . . . . . . . . 6
Engine Coolant Temperature Sensor . . . . . . . . . . . . 7 Rotor—2.5L TBI and 3.0L Engines . . . . . . . . . . . . . 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1 Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hall Effect Pick-Up—2.5L Engines . . . . . . . . . . . . . . 6 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
This section describes the ignition systems of the
2.5L and 3.0L engines.
On Board Diagnostics is described in the Fuel In-
jection Sections of Group 14.
Group 0, Lubrication and Maintenance, contains
general maintenance information for ignition related
items. The Owner’s Manual also contains mainte-
nance information.
DISTRIBUTOR CAP
Remove the distributor cap and inspect the inside
for flashover, cracking of carbon button, lack of
spring tension on carbon button, cracking of cap, and
burned, worn terminals (Fig. 1). Also check for bro-
ken distributor cap towers. If any of these conditions Fig. 1 Distributor Cap Inspection—Typical
are present the distributor cap and/or cables should
be replaced. Light scaling of the terminals can be cleaned with
When replacing the distributor cap, transfer spark a sharp knife. If the terminals are heavily scaled, re-
plug wires from the original cap to the new cap one place the distributor cap.
at a time. Ensure that each wire is installed into the A cap that is greasy, dirty or has a powder-like sub-
tower of the new cap that corresponds to its tower stance on the inside should be cleaned with a solu-
position in the original cap. Fully seat the wires into tion of warm water and a mild detergent. Scrub the
the towers. If necessary, refer to the appropriate en- cap with a soft brush. Thoroughly rinse the cap and
gine firing order diagram (Fig. 2 or Fig. 3). dry it with a clean soft cloth.
8D - 2 IGNITION SYSTEMS .
SPARK PLUG CABLES

Spark Plug cables are sometimes referred to as sec-
ondary ignition wires. They transfer electrical cur-
rent from the distributor to individual spark plugs at
each cylinder. 2.5L and 3.0L engines use suppression
type cables. The cables suppress radio frequency
emissions from the ignition system.
Check the spark plug cable connections for good
contact at the coil and distributor cap towers and at
the spark plugs. Terminals should be fully seated.
The nipples and spark plug covers should be in good
condition. Nipples should fit tightly on the coil and
distributor cap towers and spark plug cover should
Fig. 2 Engine Firing Order—2.5L Engine
fit tight around spark plug insulators. Cable connec-
tions that are loose will corrode and increase the re-
sistance and permit water to enter the towers
causing ignition malfunction. To maintain proper
sealing at the terminal connections, the connec-
tions should not be broken unless testing indi-
cates high resistance, an open circuit or other
damage.
CAUTION: Do not pull spark plug cables from dis-

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tributor cap of four cylinder engines. The cables

must be released from inside the distributor cap
(Fig. 5).
Fig. 3 Engine Firing Order—3.0L Engine

ROTOR—2.5L TBI AND 3.0L ENGINES
Replace the rotor if it is cracked, the tip is exces-
sively burned or heavily scaled (Fig. 4). If the spring
terminal does not have adequate tension, replace the
rotor.
Fig. 5 Spark Plug Cable Removal/Installation—2.5L

Engines
Clean high tension cables with a cloth moistened
with a non-flammable solvent and wipe dry. Check
for brittle or cracked insulation.
When testing secondary cables for punctures and
cracks with an oscilloscope and an inductive probe,
follow the equipment manufacturers instructions.
WARNING: THE IGNITION SYSTEM GENERATES AP-

PROXIMATELY 35,000 VOLTS. PERSONAL INJURY
COULD RESULT FROM CONTACT WITH THIS SYS-
TEM.
Fig. 4 Rotor Inspection—Typical
If an oscilloscope is not available, secondary cables and check the cable. If resistance is still not within
can be tested as follows: tolerance, replace cable assembly. Test all spark
plug cables in same manner.
CAUTION: Do not leave any one spark plug cable
CABLE RESISTANCE CHART
disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic
converter. Total test time must not exceed ten min-
utes.
(a) With the engine not running, connect one end

of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing. To test coil to distributor cap ignition, remove dis-
(b) With engine running, move test probe along tributor cap with the cable intact. Do not remove
entire length of all cables (approximately 0 to 1/8 cable from the cap. Connect the ohmmeter between
inch gap). If punctures or cracks are present there center contact in the cap and remove the cable at coil
will be a noticeable spark jump from the faulty tower and check cable resistance. If resistance is not
area to the probe. Check the coil cable the same within tolerance, replace the cable. Also, check for a
way. Replace cracked, leaking or faulty cables. loose connection at the tower or for a faulty coil.
When replacing the cables, install the ignition Inspect coil tower for cracks or carbon tracking.
cable and nipple assembly over cap or coil
tower. When entering the terminal into the SPARK PLUGS
tower, push lightly, then pinch the large diame- Resistor spark plugs are used in all engines and
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ter of nipple to release air trapped between the have resistance values of 6,000 to 20,000 ohms when
nipple and tower. Continue pushing on the ca- checked with at least a 1000 volt tester.
ble and nipple until cables are properly seated Remove the spark plugs and examine them for
in the cap towers. Snap should be heard as ter- burned electrodes and fouled, cracked or broken por-
minal goes into place. celain insulators. Keep plugs arranged in the order
Use the same procedure to install cable in coil in which they were removed from the engine. An iso-
tower. Wipe the spark plug insulator clean before related plug displaying an abnormal condition indicates
installing cable and cover. that a problem exists in the corresponding cylinder.
Use the following procedure when removing the ig- Replace spark plugs at the intervals recommended in
nition cable from the spark plug. First, remove the Group O.
cable from the retaining bracket. Then grasp the ter- Undamaged low milage spark plugs can be cleaned
minal as close as possible to the spark plug. Rotate and reused. Refer to the Spark Plug Condition sec-
the cover and pull the cable straight back. Pulling tion of this group. After cleaning, file the center elec-
on the cable itself will damage the conductor trode flat with a small point file or jewelers file.
and terminal connection. Do not use pliers and Adjust the gap between the electrodes (Fig. 6) to the
do not pull the cable at an angle. Doing so will dimensions specified in the chart at the end of this
damage the insulation, cable terminal or the section.
spark plug insulator. Wipe spark plug insulator Always tighten spark plugs to the specified torque.
clean before reinstalling cable and cover. Over tightening can cause distortion resulting in a
Resistance type cable is identified by the words change in the spark plug gap. Tighten 2.5L and 3.0L
Electronic Suppression printed on the cable engine spark plugs to 28 Nzm (20 ft. lbs.) torque.
jacket.
Use an ohmmeter to check resistance type cable for SPARK PLUG CONDITION
open circuits, loose terminals or high resistance as
follows: NORMAL OPERATING CONDITIONS
(a) Remove cable from spark plug. The few deposits present will be probably light tan
(b) Lift distributor cap from distributor with ca- or slightly gray in color with most grades of commer-
bles intact. Do not remove cables from cap. The cial gasoline (Fig. 7). There will not be evidence of
cables must be removed from the spark plugs. electrode burning. Gap growth will not average more
(c) Connect the ohmmeter between spark plug than approximately 0.025 mm (.001 in) per 1600 km
end terminal and the corresponding electrode in- (1000 miles) of operation. Spark plugs that have nor-
side the cap, make sure ohmmeter probes are in mal wear can usually be cleaned, have the electrodes
good contact. Resistance should be within tolerance filed and regapped, and then reinstalled.
shown in the cable resistance chart. If resistance is Some fuel refiners in several areas of the United
not within tolerance, remove cable at cap tower States have introduced a manganese additive (MMT)
Cold fouling is normal after short operating peri-

ods. The spark plugs do not reach a high enough op-
erating temperature to burn off conductive deposits
during short operating periods. Carbon fouled spark
plugs with low mileage can be cleaned and reused.
FUEL FOULING
A spark plug that is coated with excessive wet fuel
is called fuel fouled. This condition is normally ob-
served during hard start periods. Clean fuel fouled
spark plugs with compressed air and reinstall them
in the engine.
OIL FOULING
A spark plug that is coated with excessive wet oil is
oil fouled. In older engines, wet fouling can be caused
by worn rings or excessive cylinder wear. Break-in
fouling of new engines may occur before normal oil
control is achieved. Replace oil fouled spark plugs
with new ones.
OIL OR ASH ENCRUSTED

Fig. 6 Setting Spark Plug Electrode Gap—Typical If one or more plugs are oil or ash encrusted, eval-
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uate the engine for the cause of oil entering the com-
bustion chambers (Fig. 8). Sometimes fuel additives
can cause ash encrustation on an entire set of spark
plugs. Clean ash encrusted spark plugs using a spark
plug cleaning machine.
Fig. 7 Normal Operation and Cold (Carbon) Fouling

for unleaded fuel. During combustion, fuel with MMT
coats the entire tip of the spark plug with a rust
color deposit. The rust color deposits could be misdi-
agnosed as being caused by coolant in the combustion
chamber. MMT deposits do not effect spark plug per-
formance.
COLD FOULING (CARBON FOULING)

Cold fouling is sometimes referred to as carbon
fouling. The deposits that cause cold fouling are ba- Fig. 8 Oil or Ash Encrusted
sically carbon (Fig. 7). A dry, black deposit on one or
two plugs in a set may be caused by sticking valves HIGH SPEED MISS
or defective spark plug cables. Cold (carbon) fouling When replacing spark plugs because of a high
of the entire set may be caused by a clogged air speed miss condition; wide open throttle opera-
cleaner. A clogged air cleaner can cause over-rich fu- tion should be avoided for approximately 80 km
el/air mixtures. (50 miles) after installation of new plugs. This
will allow deposit shifting in the combustion chamber
to take place gradually and avoid plug destroying

splash fouling shortly after the plug change.
ELECTRODE GAP BRIDGING

Loose deposits in the combustion chamber can
cause electrode gap bridging. The deposits accumu-
late on the spark plugs during continuous stop-
and-go driving. When the engine is suddenly
subjected to a high torque load, the deposits partially
liquefy and bridge the gap between the electrodes
(Fig. 9). This short circuits the electrodes. Spark
plugs with electrode gap bridging can be cleaned us-
ing a spark plug cleaning machine.
Fig. 10 Scavenger Deposits

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Fig. 9 Electrode Gap Bridging

SCAVENGER DEPOSITS
Fuel scavenger deposits may be either white or yel-
low (Fig. 10). They may appear to be harmful, but
Fig. 11 Chipped Electrode Insulator
are a normal condition caused by chemical additives
in certain fuels. These additives are designed to rect heat range rating for the engine, if ignition tim-
change the chemical nature of deposits and decrease ing is over advanced or if other operating conditions
spark plug misfire tendencies. Notice that accumula- are causing engine overheating. (The heat range rat-
tion on the ground electrode and shell area may be ing refers to the operating temperature of a particu-
heavy but the deposits are easily removed. Spark lar type spark plug. Spark plugs are designed to
plugs with scavenger deposits can be considered nor- operate within specific temperature ranges depend-
mal in condition and be cleaned using a spark plug ing upon the thickness and length of the center elec-
cleaning machine. trode and porcelain insulator.)
CHIPPED ELECTRODE INSULATOR SPARK PLUG OVERHEATING

A chipped electrode insulator usually results from Overheating is indicated by a white or gray center
bending the center electrode while adjusting the electrode insulator that also appears chalky or blis-
spark plug electrode gap. Under certain conditions, tered (Fig. 13). The increase in electrode gap will be
severe detonation also can separate the insulator considerably in excess of 0.001 in per 1000 miles of
from the center electrode (Fig. 11). Replace spark operation. This suggests that a plug with a cooler
plugs with chipped electrode insulators. heat range rating should be used. Over advanced ig-
nition timing, detonation and cooling system mal-
PREIGNITION DAMAGE functions also can cause spark plug overheating.
Excessive combustion chamber temperature can
cause preignition damage. The center electrode dis- SPARK PLUG SERVICE
solves first and the ground electrode dissolves some- When replacing the spark plug and coil cables,
what later (Fig. 12). Insulators appear relatively route the cables correctly and secure them in the ap-
deposit free. Determine if the spark plug has the cor- propriate retainers. Failure to route the cables prop-
SPARK PLUG GAP ADJUSTMENT

Check the spark plug gap with a gap gauge. If the
gap is not correct, adjust it by bending the ground
electrode (Fig. 6).
SPARK PLUG INSTALLATION

(1) To avoid cross threading, start the spark plug
into the cylinder head by hand.
(2) Tighten spark plugs to 28 Nzm (20 ft. lbs.)
torque.
(3) Install ignition cables over spark plugs.
POWERTRAIN CONTROL MODULE (PCM)

The ignition system is regulated by the powertrain
control module (PCM) (Fig. 14). The PCM supplies
Fig. 12 Preignition Damage battery voltage to the ignition coil through the Auto
Shutdown (ASD) Relay. The controller also controls
the ground circuit for the ignition coil. By switching
the ground path for the coil on and off, the PCM ad-
justs ignition timing to meet changing engine operat-
ing conditions.
During the crank-start period the controller ad-
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vances ignition timing a set amount. During engine

operation, the amount of spark advance provided by
the PCM is determined by three input factors:
• engine coolant temperature
• engine RPM
• available manifold vacuum
The PCM also regulates the fuel injection system.
Refer to the Fuel Injection sections of Group 14.
Fig. 13 Spark Plug Overheating

erly can cause the radio to reproduce ignition noise,
cross ignition of the spark plugs or short circuit the
cables to ground.
Never Wire Brush Spark Plugs. The spark plug
insulator tip is harder than the bristles of wire
brushes. Bristles of wire brushes can leave a conduc-
tive, metallic film on the insulator which could lead
to conductive deposits. Conductive deposits can cause
spark plug failure and engine misfire. Use a jewelers
file to remove deposits from the electrode gap. Use a
spark plug cleaning machine to clean spark plugs.
SPARK PLUG REMOVAL

Always remove the ignition cable by grasping at Fig. 14 Powertrain Control Module
the spark plug boot turning, the boot 1/2 turn and HALL EFFECT PICK-UP—2.5L ENGINES
pulling straight back in a steady motion. The hall effect pick-up (Fig. 15) is located in the
(1) Prior to removing the spark plug spray com- distributor assembly. It supplies engine rpm and ig-
pressed air around the spark plug hole and the area
nition timing data to the powertrain control module
around the spark plug.
(PCM). This allows the PCM to advance or retard the
(2) Remove the spark plug using a quality socket
ignition spark as required by different operating con-
with a rubber or foam insert.
ditions.
(3) Inspect the spark plug condition. Refer to
Spark Plug Condition in this section.
the PCM that the next piston at TDC will be number

6. Each piston’s position is referenced by one of the
six inner slots (Fig. 17).
As each slot on the timing disk passes between the
diodes, they interrupt the beam from the light emit-
ting diode. This creates an alternating voltage in
each photo diode which is converted into on-off
pulses. The pulses are the input to the PCM.
During cranking, the PCM cannot determine which
cylinder will be at TDC until the 10 degree flat spot
on the outer set of slots rotates through the optical
unit. Once the flat spot is detected, the controller
knows piston in cylinder number 6 will be the next
piston at TDC.
Since the disk rotates at half crankshaft speed, it
Fig. 15 Hall Effect Distributor—2.5L Engines may take up to 2 engine revolutions during cranking
before the PCM determines the position of piston
DISTRIBUTOR PICK-UP—3.0L ENGINE number 6. For this reason the PCM energizes all six
The distributor pick-up provides two inputs to the injectors at the same time until it senses the position
powertrain control module (PCM). From one input of piston number 6.
the PCM determines RPM (engine speed). From the
other input it derives crankshaft position. The PCM
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regulates injector synchronization and adjusts igni-

tion timing and engine speed based on these inputs.
The distributor pick-up contains two signal genera-
tors. The pick-up unit consists of 2 light emitting di-
odes (LED), 2 photo diodes, and a separate timing
disk. The timing disk contains two sets of slots. Each
set of slots rotates between a light emitting diode
and a photo diode (Fig. 16). The inner set contains 6
large slots, one for each cylinder. The outer set con-
tains several smaller slots.
Fig. 17 Inner and Outer Slots of Rotating Disk—3.0L

Engine
ENGINE COOLANT TEMPERATURE SENSOR
On 2.5L engines, the engine coolant temperature
(ECT) sensor is installed behind the thermostat
housing and ignition coil in the hot box (Fig. 18). On
3.0L engines the sensor is located next to the ther-
mostat housing (Fig. 19). The sensor provides an in-
put voltage to the powertrain control module (PCM).
The sensor is a variable resistance (thermistor) with
a range of -40°F to 265°F. As coolant temperature
varies, the sensors resistance changes, resulting in a
Fig. 16 Distributor Pick-up—3.0L Engine different input voltage to the PCM.
The outer set of slots on the rotating disk repre- The PCM contains different spark advance sched-
sents 2 degrees of crankshaft rotation. Up to 1200 ules for cold and warm engine operation. The sched-
engine RPM, the controller uses the input from the ules reduce engine emissions and improve
outer set of slots to increase ignition timing accuracy. driveability. Because spark advance changes at differ-
ent engine operating temperatures during warm-up,
The outer set of slots contains a 10 degree flat spot.
all spark advance testing should be done with the en-
This area is not slotted (Fig. 17). The flat spot tells
gine fully warmed.
When the engine is cold, the PCM demands The input voltage level supplies the PCM with in-
slightly richer air-fuel mixtures and higher idle formation relating to ambient barometric pressure
speeds until normal operating temperatures are during engine start-up (cranking) and engine load
reached. while its operating. The PCM uses this input along
The engine coolant sensor input is also used for with inputs from other sensors to adjust air-fuel mix-
cooling fan control. ture.
On 2.5L engines, the MAP sensor is mounted to the
dash panel (Fig. 20). On 3.0L engines, the sensor is
mounted to a bracket across from the distributor
(Fig. 21). The sensor is connected to the throttle body
with a vacuum hose and to the PCM electrically.
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Fig. 18 Engine Coolant Temperature Sensor—2.5L Fig. 20 MAP Sensor—2.5L TBI Engines
Engines
Fig. 21 MAP Sensor—3.0L Engine

Fig. 19 Engine Coolant Temperature Sensor—3.0L
Engines AUTOMATIC SHUTDOWN (ASD) RELAY AND FUEL
PUMP RELAY
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR The powertrain control module (PCM) operates the
The MAP sensor reacts to absolute pressure in the auto shutdown (ASD) relay and fuel pump relay
intake manifold and provides an input voltage to the through one ground path. The controller operates the
powertrain control module (PCM). As engine load relays by switching the ground path on and off. Both
changes, manifold pressure varies. The changes in relays turn on and off at the same time.
engine load causes the MAP sensors resistance to
change. The change in MAP sensor resistance results
in a different input voltage to the PCM.
The ASD relay connects battery voltage to the fuel does not receive an input from the distributor pick-
injector and ignition coil. The fuel pump relay con- up. Refer to Auto Shutdown (ASD) Relay and Fuel
nects battery voltage to the fuel pump and oxygen Pump Relay in this section.
sensor heating element. On 2.5L engines the ignition coil is mounted to the
The PCM turns the ground path off when the igni- thermostat housing (Fig. 23). On 3.0L engines the
tion switch is in the Off position. Both relays are off. coil is mounted on the rear of the intake manifold
When the ignition switch is in the On or Crank po- next to the air cleaner (Fig. 24).
sition, the PCM monitors the distributor pick-up sig-
nal to determine engine speed and ignition timing
(coil dwell). If the PCM does not receive a distributor
signal when the ignition switch is in the Run posi-
tion, it will de-energize both relays. When the relays
are de-energized, battery voltage is not supplied to
the fuel injector, ignition coil, fuel pump and oxygen
sensor heating element.
The ASD and fuel pump relays are located in the
power distribution center (PDC). The PDC is located
in the engine compartment above the PCM (Fig. 22).
A label affixed to the underside of the PDC cover
identifies the relays and fuses in the PDC.
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Fig. 23 Ignition Coil—2.5L Engine
Fig. 22 Auto Shutdown Relay and Fuel Pump Relay

IGNITION COIL
The 2.5L and 3.0L engines use an epoxy type coil.
The coils are not oil filled. The windings are embed-
ded in a heat and vibration resistant epoxy com-
pound.
The powertrain control module (PCM) operates the
ignition coil through the auto shutdown (ASD) relay.
When the relay is energized by the PCM, battery
voltage is connected to the ignition coil positive ter- Fig. 24 Ignition Coil—3.0L Engine
minal. The PCM will de-energize the ASD relay if it
2.5L AND 3.0L IGNITION SYSTEMS—DIAGNOSTIC PROCEDURES
INDEX
page page
Engine Coolant Temperature Sensor Test . . . . . . . . 11 Manifold Absolute Pressure (MAP) Sensor Test . . . 12
Failure to Start Test—2.5L TBI and 3.0L Engines . . 10 Poor Performance Test . . . . . . . . . . . . . . . . . . . . . 11
General Information . . . . . . . . . . . . . . . . . . . . . . . 10 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Testing for Spark at Coil . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION Remove the coil secondary cable from the distribu-
For additional information, refer to On Board Diag- tor cap. Hold the end of cable about 6 mm (1/4-inch)
nostics sections of Group 14. away from a good engine ground using non-conduc-
tive ignition pliers (Fig. 1). Crank the engine and in-
SPARK PLUGS spect for spark at the coil secondary cable.
Faulty or fouled spark plugs may perform well at
idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of
ways: poor fuel economy, power loss, decrease in en-
gine speed, hard starting and, in general, poor engine
performance.
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Spark plugs also malfunction because of carbon

fouling, excessive electrode air gap, or a broken insu-
lator. Refer to the General Information Section of
this group for spark plug diagnosis.
IGNITION COIL
The ignition coil is designed to operate without an
external ballast resistor.
Inspect the coil for arcing. Test the coil according to
coil tester manufacturer’s instructions. Test coil pri-
Fig. 1 Checking for Spark
mary and secondary resistance. Replace any coil that
does not meet specifications. Refer to the Ignition There must be a constant spark at the coil second-
Coil chart in the Specifications section at the end of ary cable. If the spark is constant, have a helper con-
this group. tinue to crank engine and, while slowly moving coil
If the ignition coil is replaced due to a burned secondary cable away from ground, look for arcing at
tower, carbon tracking, arcing at the tower, or dam- the coil tower. If arcing occurs at the tower, replace
age to the terminal or boot on the coil end of the sec- the coil. If spark is not constant or there is no spark,
ondary cable, the cable must be replaced. Arcing at proceed to the failure to start test.
the tower will carbonize the nipple which, if it is con- If a constant spark is present and no arcing occurs
nected to a new coil, will cause the coil to fail. at the coil tower, the ignition system is producing the
If a secondary cable shows any signs of damage, necessary high secondary voltage. However, make
the cable should be replaced with a new cable and sure that the spark plugs are firing. Inspect the dis-
new terminal. Carbon tracking on the old cable can tributor rotor, cap, spark plug cables, and spark
cause arcing and the failure of a new coil. plugs. If they are in proper working order, the igni-
tion system is not the reason why the engine will not
TESTING FOR SPARK AT COIL start. Inspect the fuel system and engine for proper
operation.
WARNING: APPLY PARKING BRAKE AND/OR
BLOCK THE WHEELS BEFORE PERFORMING ANY
FAILURE TO START TEST—2.5L TBI AND 3.0L
TEST WITH THE ENGINE RUNNING.
ENGINES
Before proceeding with this test make sure
CAUTION: Spark plug cables may be damaged if Testing For Spark At Coil has been performed.
this test is performed with more than 1/4 inch clear- Failure to do this may lead to unnecessary di-
ance between the cable and engine ground. agnostic time and wrong test results.
WARNING: BE SURE TO APPLY PARKING BRAKE (5) Remove the connector to coil (+) and connect a
AND/OR BLOCK WHEELS BEFORE PERFORMING jumper wire between battery (+) and coil (+).
ANY TEST WITH THE ENGINE RUNNING. (6) Using the special jumper (Fig. 4), momentarily
ground terminal #19 of the 60-way connector (Fig. 5).
(1) Battery voltage must be at least 12.4 volts to A spark should be generated when the ground is re-
perform test. moved.
(2) Crank the engine for 5 seconds while monitor-
ing the voltage at the coil positive (+) terminal (Fig.
2 or Fig. 3). If the voltage remains near zero during
the entire period of cranking, refer to Group 14 for
On-Board Diagnostic checks. These checks will help
diagnose problems with the PCM and auto shutdown
relay.
Fig. 4 Special Jumper to Ground Coil Negative

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Fig. 5 PCM 60-Way Electrical Connector

Fig. 2 Coil Terminals—2.5L Engines (7) If spark is generated, replace the PCM.
(8) If no spark is seen, use the special jumper to
ground the coil (-) terminal directly.
(9) If spark is produced, inspect wiring harness for
an open condition.
(10) If no spark is produced, replace the ignition
coil.
POOR PERFORMANCE TEST

To prevent unnecessary diagnostic time and
possible incorrect results, the Testing For
Spark At Coil procedure should be performed
before this test.
WARNING: APPLY PARKING BRAKE AND/OR

BLOCK THE WHEELS BEFORE PERFORMING ANY
ENGINE RUNNING TESTS.
Fig. 3 Coil Terminals—3.0L Engine
Check and adjust basic timing (refer to the specifi-
(3) If voltage is at near-battery voltage and drops cation section of this group and see service proce-
to zero after 1-2 seconds of cranking, see Group 14 dures).
for On-Board Diagnostic check for the distributor ref- Refer to Group 14, On-Board Diagnostics sections.
erence pickup circuit to the PCM.
(4) If voltage remains at near battery voltage dur- ENGINE COOLANT TEMPERATURE SENSOR TEST
ing the entire 5 seconds, with the key off, remove (1) With key off, disconnect wire connector from
the PCM 60-way connector. Check the 60-way con- coolant engine temperature (ECT) sensor (Fig. 6).
nector for any terminals that are pushed out or loose. (2) Connect one lead of ohmmeter to one terminal
of engine coolant temperature sensor.
(3) Connect the other lead of ohmmeter to remain-

ing connector of coolant temperature sensor. The
ohmmeter should read as follows;
• Engine/Sensor at normal operating temperature
around 200°F should read approximately 700 to
1,000 ohms.
• Engine/Sensor at room temperature around 70°F,
ohmmeter should read approximately 7,000 to 13,000
ohms.
• See On Board Diagnostics section of Group
14, or refer to the appropriate diagnostic man-
ual for further test procedures. Fig. 6 Engine Coolant Temperature Sensor Test
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR dures manual for further test procedures.
TEST
Refer to On-Board Diagnostics sections of Group 14
and the appropriate Powertrain Diagnostic Proce-
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2.5L AND 3.0L IGNITION SYSTEMS—SERVICE PROCEDURES
INDEX
page page
Distributor Pick-Up—2.5L Engine . . . . .. . . . . . . . . 17 Ignition Timing Procedure—2.5L TBI and 3.0L
Distributor Service—3.0L Engine . . . . .. . . . . . . . . 18 Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Distributor—2.5L Engine . . . . . . . . . . .. . . . . . . . . 16 Manifold Absolute Pressure (MAP) Sensor
Engine Coolant Temperature Sensor . .. . . . . . . . . 13 Service—2.5L TBI and 3.0L Engines . . . . . . . . . . 22
Idle RPM Test—2.5L and 3.0L Engines . . . . . . . . . 15 Powertrain Control Module . . . . . . . . . . . . . . . . . . 13
Ignition Coil—2.5L TBI Engines . . . . . .. . . . . . . . . 14 Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . 14
Ignition Coil—3.0L Engines . . . . . . . . .. . . . . . . . . 14
POWERTRAIN CONTROL MODULE ENGINE COOLANT TEMPERATURE SENSOR

The powertrain control module (PCM) is located On 2.5L engines the engine coolant temperature
next to the battery (Fig. 1). (ECT) sensor is located behind the ignition coil (Fig.
2). On 3.0L engines the sensor is located next to the
thermostat housing (Fig. 3).
REMOVAL
(1) Drain cooling system until coolant level is be-
low coolant sensor. Refer to Group 7, Cooling System.
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(2) Disconnect electrical connector from sensor.

(3) Remove sensor from engine.
INSTALLATION
(1) Install coolant sensor. Tighten 2.5L engine cool-
ant sensor to 28 Nzm (20 ft. lbs.) torque. Tighten the
3.0L engine coolant sensor to 7 Nzm (60 in. lbs.)
torque.
(2) Connect electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
Fig. 1 Powertrain Control Module

REMOVAL
(1) Remove air cleaner duct or air cleaner assem-
bly.
(2) Remove battery.
(3) Remove PCM mounting screws.
(4) Remove 60-way wiring connector from the
PCM.
(5) Remove controller.
INSTALLATION
(1) Connect 60-Way electrical connector to PCM
(Fig. 1).
(2) Install PCM. Tighten mounting screws.
(3) Install battery.
(4) Install air cleaner duct or air cleaner assembly. Fig. 2 Engine Coolant Temperature Sensor—2.5L
TBI Engines
INSTALLATION
(1) Install ignition coil onto the bracket. Tighten
the screws to 9.5 Nzm (85 in. lbs.) torque.
(2) Connect the wiring harness connector.
(3) Connect the coil to distributor ignition cable.
IGNITION COIL—3.0L ENGINES

The ignition coil is located at the back of the intake
manifold (Fig. 5).
Fig. 3 Engine Coolant Temperature Sensor—3.0L

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Engine
IGNITION COIL—2.5L TBI ENGINES
The ignition coil mounts to the thermostat housing Fig. 5 Ignition Coil—3.0L Engine
(Fig. 4).
REMOVAL
(1) Remove air cleaner assembly.
(2) Disconnect ignition cable from coil.
(3) Disconnect wiring harness connector from coil.
(4) Remove coil mounting screws.
INSTALLATION
(1) Loosely install ignition coil on intake manifold.
Tighten the intake manifold fastener to 13 Nzm (115
in.lbs.) torque. Tighten ignition coil bracket fasteners
to 10 Nzm (96 in. lbs.) torque.
(2) Connect the wiring harness connector.
(3) Connect the coil to distributor ignition cable.
(4) Install the air cleaner assembly. Tighten the air
cleaner fasteners to 25 Nzm (225 in. lbs.) torque.
SPARK PLUG SERVICE

When replacing the spark plug and coil cables,
route the cables correctly and secure them in the ap-
propriate retainers. Failure to route the cables prop-
erly can cause the radio to reproduce ignition noise,
cause cross ignition of the spark plugs or short cir-
cuit the cables to ground.
Fig. 4 Ignition Coil—2.5L Engines Never Wire Brush Spark Plugs. The spark plug
REMOVAL brushes. Bristles of wire brushes can leave a conduc-
(1) Disconnect the coil to distributor ignition cable tive, metallic film on the insulator which could lead
(Fig. 4). to conductive deposits. Conductive deposits can cause
(2) Disconnect the wiring harness connector from spark plug failure and engine misfire. Use a jewelers
the coil. file to remove deposits from the electrode gap. Use a
(3) Remove ignition coil mounting screws. spark plug cleaning machine to clean spark plugs.
SPARK PLUG REMOVAL shop for testing. This will assist in diagnosing com-
Always remove cables by grasping at boot, rotating plaints of engine stalling, creeping and hard shifting
the boot 1/2 turn, and pulling straight back in a on vehicles equipped with automatic transmissions.
steady motion. Proceed to the Throttle Body Minimum Airflow pro-
(1) Prior to removing the spark plug spray com- cedures in Group 14.
pressed air around the spark plug hole and the area
around the spark plug. IGNITION TIMING PROCEDURE—2.5L TBI AND
(2) Remove the spark plug using a quality socket 3.0L ENGINES
with a rubber or foam insert.
(3) Inspect the spark plug condition. Refer to WARNING: BE SURE TO APPLY PARKING BRAKE
Spark Plug Condition in this section. AND/OR BLOCK WHEELS BEFORE PERFORMING
SETTING IGNITION TIMING OR PERFORMING ANY
SPARK PLUG GAP ADJUSTMENT TEST ON AN OPERATING ENGINE.
Check the spark plug gap with a gap gauge. If the
Proper ignition timing is required to obtain opti-
gap is not correct, adjust it by bending the ground
mum engine performance. The distributor must be
electrode (Fig. 6).
correctly indexed to provide correct initial ignition
timing.
(1) Set the gearshift selector in park or neutral
and apply the parking brake. All lights and accesso-
ries must be off.
(2) If using a magnetic timing light, insert the
pickup probe into the open receptacle next to the tim-
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ing scale window. If a magnetic timing unit is not

available, use a conventional timing light connected
to the number one cylinder spark plug cable.
Do not puncture cables, boots or nipples with
test probes. Always use proper adapters. Punc-
turing the spark plug cables with a probe will
damage the cables. The probe can separate the
conductor and cause high resistance. In addi-
tion breaking the rubber insulation may permit
secondary current to arc to ground.
(3) Turn selector switch to the appropriate cylinder
position.
(4) Start engine and run until operating tempera-
ture is obtained.
(5) With the engine at normal operating tempera-
ture, connect the DRB scan tool to the data link con-
Fig. 6 Setting Spark Plug Gap—Typical nector. Access the State Display screen. Refer to the
SPARK PLUG INSTALLATION appropriate Powertrain Diagnostics Procedures Man-
(1) Start the spark plug into the cylinder head by ual. If not using the DRB scan tool, disconnect
hand to avoid cross threading. the engine coolant temperature sensor electri-
(2) Tighten spark plugs to 28 Nzm (20 ft. lbs.) cal connector. The electric radiator fan will operate
torque. and the malfunction indicator lamp (Check Engine
(3) Install spark plug cables over spark plugs. A lamp) will turn on after disconnecting the engine
click will be heard and felt when the cable properly coolant sensor or starting the DRB scan tool proce-
attaches to the spark plug. dure.
(6) Aim Timing Light at timing scale (Fig. 7 or Fig.
IDLE RPM TEST—2.5L AND 3.0L ENGINES 8) or read magnetic timing unit. If flash occurs when
timing mark is before specified degree mark, timing
WARNING: APPLY PARKING BRAKE AND/OR is advanced. To adjust, turn distributor housing in di-
BLOCK WHEELS BEFORE PERFORMING IDLE rection of rotor rotation.
CHECK OR ADJUSTMENT, OR ANY TESTS WITH A If flash occurs when timing mark is after specified
RUNNING ENGINE. degree mark, timing is retarded. To adjust, turn dis-
tributor housing against direction of rotor rotation.
Engine idle set rpm should be tested and re- Refer to Vehicle Emission Control Information label
corded when the vehicle is first brought into for correct timing specification. If timing is within 6
Fig. 7 Timing Scale—2.5L Engine Fig. 10 Distributor Holddown—3.0L Engine

coolant temperature sensor was disconnected, con-
nect the sensor and erase diagnostic trouble
codes using the DRB scan tool. Refer to Group 14,
On Board Diagnostics.
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DISTRIBUTOR—2.5L ENGINE
REMOVAL
(1) Disconnect distributor pick-up connector from
wiring harness connector (Fig. 11).
Fig. 8 Timing Scale—3.0L Engine

2° of value specified on the label, proceed to step (8).
If outside specified tolerance, proceed to next step.
(7) Loosen distributor hold-down arm screw
enough to rotate the distributor housing (Fig. 9 or
Fig. 10). Turn distributor housing to adjust timing.
Tighten the hold-down arm screw and recheck tim-
ing.
Fig. 11 Distributor Pickup Connector—2.5L Engine

(2) Remove splash shield retaining screws (Fig.
12).
(3) Remove splash shield (Fig. 12).
Fig. 9 Distributor Holddown—2.5L Engine
(4) Loosen distributor cap retaining screws (Fig.
(8) Turn the engine off. Remove timing light or 13).
magnetic timing unit and tachometer. If the engine (5) Lift cap off of distributor (Fig. 14).
Fig. 14 Distributor Cap—2.5L Engine

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Fig. 12 Splash Shield—2.5L Engine

(a) Rotate the crankshaft until number one pis-
ton is at top of compression stroke. Pointer on
clutch housing should be in line with the O(TDC)
mark on flywheel.
(b) Rotate rotor to a position just ahead of the
number one distributor cap terminal.
(c) Lower the distributor into the opening, engag-
ing distributor drive with drive on auxiliary shaft.
With distributor fully seated on engine, rotor
should be under the cap number 1 tower.
(3) Install the distributor cap. Ensure all high ten-
sion wires snap firmly in the cap towers.
Fig. 13 Distributor Cap Retaining Screws—2.5L (4) Install hold-down arm screw and finger tighten.
Engine (5) Install splash shield.
(6) Rotate engine crankshaft until the distributor (6) Connect distributor pick-up connector lead wire
rotor is pointing toward the cylinder block. Use this at wiring harness connector.
as reference when reinstalling distributor. (7) Set ignition timing to specification. Refer to Ig-
(7) Remove distributor hold-down screw (Fig. 9). nition Timing.
(8) Carefully lift the distributor from the engine.
DISTRIBUTOR PICK-UP—2.5L ENGINE
INSTALLATION
(1) Position distributor in engine. Make certain REMOVAL
that the O-ring is properly seated on distributor. If (1) Remove splash shield and cap. Refer to Distrib-
O-ring is cracked or nicked, replace it with new one. utor Removal.
(2) Carefully engage distributor drive with auxil- (2) Remove rotor from shaft (Fig. 15).
iary shaft drive. When distributor is installed prop- (3) Remove Hall effect pick-up assembly (Fig.
16).
erly, rotor will be pointing toward cylinder block. If
engine has been cranked while distributor is INSTALLATION
removed, it will be necessary to establish (1) Place pick-up assembly into distributor housing
proper relationship between the distributor (Fig. 16).
shaft and Number 1 piston position as follows: The distributor pick-up wires may be dam-
aged if not properly reinstalled.
(2) Install rotor (Fig. 15).
Fig. 17 Distributor Electrical Connector—3.0L

Engine
(4) Rotate engine crankshaft until the distributor
rotor points the intake manifold plenum. Scribe a
mark on the plenum in line with the rotor. The scribe
line indicates where to position the rotor when rein-
Fig. 15 Ignition Rotor—2.5L Engine
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stalling the distributor.
Fig. 18 Distributor Cap—3.0L Engine

(5) Remove distributor hold down nut (Fig. 19).
(6) Carefully lift the distributor from the engine.
INSTALLATION
Fig. 16 Hall Effect Pickup Assembly—2.5L Engine (1) Position distributor in engine. Make certain
(3) Install cap and splash shield. Refer to Distrib- that the O-ring is properly seated on distributor. If
utor Installation. O-ring is cracked or nicked replace with new one.
(2) Carefully engage distributor drive with gear on
DISTRIBUTOR SERVICE—3.0L ENGINE camshaft. When the distributor is installed properly,
the rotor will be in line with previously scribe line on
REMOVAL air intake plenum. If engine was cranked while
(1) Disconnect distributor connector from wiring distributor was removed, it will be necessary to
harness connector (Fig. 17). establish proper relationship between the dis-
(2) Loosen distributor cap retaining screws. tributor shaft and Number 1 piston position as
(3) Lift cap of off distributor (Fig. 18). follows:
(3) Remove rotor screw (Fig. 21). Inspect rotor for

cracks or burned electrode. If any of these conditions
exist, replace rotor.
Fig. 19 Distributor Hold-Down—3.0L Engine

(a) Rotate the crankshaft until number one pis- Fig. 21 Rotor Screw
ton is at top of compression stroke. (4) Remove protective cover from distributor hous-
(b) Rotate rotor to number one rotor terminal ing (Fig. 22).
(Fig. 20).
(c) Lower the distributor into the opening, engag-
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ing distributor drive with drive on camshaft. With

distributor fully seated on engine, rotor should be
under the number 1 terminal (Fig. 20).
Fig. 22 Protective Cover

(5) Remove lead wire clamp screw and remove lead
wire (Fig. 23).
Fig. 20 Distributor Cap Terminal Routing, View from

Top of Cap—3.0L Engine
(3) Install the distributor cap (Fig. 18). Ensure sure
all high tension wires are firmly in the cap towers.
(4) Install hold-down nut and finger tighten (Fig. 19).
(5) Connect distributor electrical connector to wir-
ing harness connector (Fig. 17).
(6) Set ignition timing to specification. Refer to Ig-
nition Timing in this section.
DISASSEMBLY
(1) Remove distributor cap mounting screws (Fig. 18).
(2) Remove distributor cap and inspect for flashover,
cracked carbon button, cracked cap, or burned termi- Fig. 23 Lead Wire Clamp
nals. If any of these conditions exist, replace cap.
(6) Remove disk assembly screw (Fig. 24). (8) Remove bushing and photo optic sensing unit fas-
teners. Remove unit from distributor housing (Fig. 27).
Fig. 24 Disk Assembly Screw

(7) Remove disk spacers and disk (Fig. 25). Disk Fig. 27 Photo Optic Sensing Unit Assembly and
Bushing
and spacers are keyed. Check disk for warpage,
cracks or damaged slots (Fig. 26). (9) Remove bearing retainer screws (Fig. 28).
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Fig. 25 Disk and Spacers Installed Fig. 28 Bearing Retainer Screws
Fig. 26 Disk and Spacers

(10) Make reassembly alignment marks on gear and (12) Remove distributor drive gear (Fig. 32).
shaft (Figs. 29 and 30).
Fig. 32 Drive Gear

Fig. 29 Marking Drive Gear and Shaft (13) Remove distributor shaft and bearing assem-
bly (Fig. 33).
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Fig. 30 Marks on Drive Gear and Shaft

(11) With a pin punch drive out distributor drive Fig. 33 Distributor Shaft
gear roll pin (Fig. 31). (14) To reassemble, reverse preceding procedure.
Refer to Fig. 34.
Fig. 31 Drive Gear Roll Pin

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Fig. 34 Distributor—3.0L Engine

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
SERVICE—2.5L TBI AND 3.0L ENGINES
(1) Remove vacuum hose and remove mounting
screws from sensor (Fig. 35 and Fig. 36).
(2) Remove wiring harness and remove sensor.
(3) Reverse the above procedure for installation.
Fig. 36 Manifold Absolute Pressure (MAP) Sensor—

3.0L Engine
Check that vacuum hose is attached to vacuum
source.
Fig. 35 Manifold Absolute Pressure (MAP) Sensor—

2.5L TBI Engines
3.3L AND 3.8L DIRECT IGNITION SYSTEM—SYSTEM OPERATION
INDEX
page page
Automatic Shut Down (ASD) Relay and Fuel Pump Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . ..... . 29 Manifold Absolute Pressure (MAP) Sensor . . . . . . . 28
Camshaft Position Sensor . . . . . . . . . . . . . ..... . 26 Powertrain Control Module . . . . . . . . . . . . . . . . . . 23
Crankshaft Position Sensor . . . . . . . . . . . . ..... . 27 Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine Coolant Temperature Sensor . . . . . ..... . 28 Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . 26
General Information . . . . . . . . . . . . . . . . . ..... . 23 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
GENERAL INFORMATION
This section describes the ignition systems for the
3.3L and 3.8L engines.
On Board Diagnostics is described in the Fuel In-
jection Sections of Group 14.
Group 0, Lubrication and Maintenance, contains
general maintenance information for ignition related
items. The Owner’s Manual also contains mainte-
nance information.
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Both the 3.3L and 3.8L engines use a fixed ig-

nition timing system. Basic ignition timing is
not adjustable. All spark advance is determined
by the powertrain control module (PCM).
The distributorless ignition system used on 3.3L
and 3.8L engines is refereed to as the Direct Ignition
System. The system’s three main components are the
coil pack, crankshaft position sensor, and camshaft
position sensor. The crankshaft position sensor and
camshaft position sensor are hall effect devices.
FIRING ORDER
The firing order of 3.3L and 3.8L engines direct ig-
nition system is 1-2-3-4-5-6 (Fig. 1). Fig. 1 Spark Plug Wire Routing—3.3L Engine
POWERTRAIN CONTROL MODULE
The ignition system is regulated by the powertrain
control module (Fig. 2). The controller supplies bat-
tery voltage to the ignition coil through the Auto
Shutdown (ASD) Relay. The controller also controls
ground circuit for the ignition coil. By switching the
ground path for the coil on and off, the PCM adjusts
ignition timing to meet changing engine operating
conditions.
During the crank-start period the controller ad-
vances ignition timing a set amount. During engine
operation, the amount of spark advance provided by
the PCM is determined by three input factors:
• engine coolant temperature
• engine RPM
• available manifold vacuum
The PCM also regulates the fuel injection system. Fig. 2 Powertrain Control Module
Refer to the Fuel Injection sections of Group 14.
SPARK PLUG CABLES
Spark Plug cables are sometimes referred to as sec-
ondary ignition wires. The wires transfer electrical
current from the ignition coil pack to individual change in the spark plug gap. Tighten 3.3L engine
spark plugs at each cylinder. The spark plug cables spark plugs to 28 Nzm (20 ft. lbs.) torque.
are of nonmetallic construction and have a built in
resistance. The cables provide suppression of radio SPARK PLUG CONDITION
frequency emissions from the ignition system.
Check the spark plug cable connections for good NORMAL OPERATING CONDITIONS
contact at the coil and distributor cap towers and at The few deposits present will be probably light tan
the spark plugs. Terminals should be fully seated. or slightly gray in color with most grades of commer-
The nipples and spark plug covers should be in good cial gasoline (Fig. 4). There will not be evidence of
condition. Nipples should fit tightly on the coil and electrode burning. Gap growth will not average more
spark plug covers should fit tight around spark plug than approximately 0.025 mm (.001 in) per 1600 km
insulators. (1000 miles) of operation. Spark plugs that have nor-
mal wear can usually be cleaned, have the electrodes
SPARK PLUGS filed and regapped, and then reinstalled.
3.3L and 3.8L engines use resistor spark plugs.
They have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
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Replace spark plugs at the intervals recommended in

Group O.
Spark plugs that have low milage may be cleaned
and reused if not otherwise defective. Refer to the
Spark Plug Condition section of this group. After
cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the
electrodes (Fig. 3) to the dimensions specified in the
Fig. 4 Normal Operation and Cold (Carbon) Fouling
chart at the end of this section.
Some fuel refiners in several areas of the United
States have introduced a manganese additive (MMT)
for unleaded fuel. During combustion, fuel with MMT
may coat the entire tip of the spark plug with a rust
colored deposit. The rust color deposits can be misdi-
agnosed as being caused by coolant in the combustion
chamber. Spark plug performance is not affected by
MMT deposits.
COLD FOULING (CARBON FOULING)

Cold fouling is sometimes referred to as carbon
fouling because the deposits that cause cold fouling
are basically carbon (Fig. 4). A dry, black deposit on
one or two plugs in a set may be caused by sticking
valves or defective spark plug cables. Cold (carbon)
fouling of the entire set may be caused by a clogged
air cleaner.
Cold fouling is normal after short operating peri-
ods. The spark plugs do not reach a high enough op-
erating temperature during short operating periods.
FUEL FOULING
Fig. 3 Setting Spark Plug Electrode Gap—Typical A spark plug that is coated with excessive wet fuel
Always tighten spark plugs to the specified torque. is called fuel fouled. This condition is normally ob-
Over tightening can cause distortion resulting in a
served during hard start periods. Clean fuel fouled liquefy and bridge the gap between the electrodes
spark plugs with compressed air and reinstall them (Fig. 6). This short circuits the electrodes. Spark
in the engine. plugs with electrode gap bridging can be cleaned and
reused.
OIL FOULING
A spark plug that is coated with excessive wet oil is
oil fouled. In older engines, wet fouling can be caused
by worn rings or excessive cylinder wear. Break-in
fouling of new engines may occur before normal oil
control is achieved. Replace oil fouled spark plugs
with new ones.
OIL OR ASH ENCRUSTED

If one or more plugs are oil or ash encrusted, eval-
uate the engine for the cause of oil entering the com-
bustion chambers (Fig. 5). Sometimes fuel additives
can cause ash encrustation on an entire set of spark
plugs. Ash encrusted spark plugs can be cleaned and
reused.
Fig. 6 Electrode Gap Bridging

SCAVENGER DEPOSITS
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Fuel scavenger deposits may be either white or yel-

low (Fig. 7). They may appear to be harmful, but are
a normal condition caused by chemical additives in
certain fuels. These additives are designed to change
the chemical nature of deposits and decrease spark
plug misfire tendencies. Notice that accumulation on
the ground electrode and shell area may be heavy
but the deposits are easily removed. Spark plugs
with scavenger deposits can be considered normal in
condition, cleaned and reused.
Fig. 5 Oil or Ash Encrusted

HIGH SPEED MISS
When replacing spark plugs because of a high
speed miss condition; wide open throttle opera-
tion should be avoided for approximately 80 km
(50 miles) after installation of new plugs. This
will allow deposit shifting in the combustion chamber
to take place gradually and avoid plug destroying
Fig. 7 Scavenger Deposits
splash fouling shortly after the plug change.
CHIPPED ELECTRODE INSULATOR
ELECTRODE GAP BRIDGING A chipped electrode insulator usually results from
Loose deposits in the combustion chamber can bending the center electrode while adjusting the
cause electrode gap bridging. The deposits accumu- spark plug electrode gap. Under certain conditions,
late on the spark plugs during continuous stop- severe detonation also can separate the insulator
and-go driving. When the engine is suddenly from the center electrode (Fig. 8). Spark plugs with
subjected to a high torque load, the deposits partially chipped electrode insulators must be replaced.
ing, detonation and cooling system malfunctions also

can cause spark plug overheating.
Fig. 8 Chipped Electrode Insulator

PREIGNITION DAMAGE
Fig. 10 Spark Plug Overheating
Excessive combustion chamber temperature can
cause preignition damage. First, the center electrode SPARK PLUG SERVICE
dissolves and the ground electrode dissolves some- When replacing the spark plug and coil cables,
what later (Fig. 9). Insulators appear relatively de- route the cables correctly and secure them in the ap-
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posit free. Determine if the spark plug has the propriate retainers. Failure to route the cables prop-
correct heat range rating for the engine, if ignition erly can cause the radio to reproduce ignition noise,
timing is over advanced or if other operating condi- cross ignition of the spark plugs or short circuit the
tions are causing engine overheating. (The heat cables to ground.
Never Wire Brush Spark Plugs. The spark plug
range rating refers to the operating temperature of a
particular type spark plug. Spark plugs are designed
brushes. Bristles of wire brushes can leave a conduc-
to operate within specific temperature ranges de-
tive, metallic film on the insulator which could lead
pending upon the thickness and length of the center
to conductive deposits. Conductive deposits can cause
electrode and porcelain insulator.) spark plug failure and engine misfire. Use a jewelers
file to remove deposits from the electrode gap. Use a
spark plug cleaning machine to clean spark plugs.
CAMSHAFT POSITION SENSOR

The camshaft position sensor provides cylinder
identification to the powertrain control module
(PCM) (Fig. 11). The sensor generates pulses as
groups of notches on the camshaft sprocket pass un-
derneath it (Fig. 12). The PCM keeps track of crank-
shaft rotation and identifies each cylinder by the
pulses generated by the notches on the camshaft
sprocket. Four crankshaft pulses follow each group of
camshaft pulses.
Fig. 9 Preignition Damage

SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
10). The increase in electrode gap will be consider-
ably in excess of 0.001 in per 1000 miles of operation.
This suggests that a plug with a cooler heat range
rating should be used. Over advanced ignition tim-
Fig. 11 Camshaft Position Sensor
When the PCM receives two cam pulses followed by

the long flat spot on the camshaft sprocket, it knows
that the crankshaft timing marks for cylinder one
are next (on driveplate). When the PCM receives one
camshaft pulse after the long flat spot on the
sprocket, cylinder number two crankshaft timing
marks are next. After 3 camshaft pulses, the PCM
knows cylinder four crankshaft timing marks follow.
One camshaft pulse after the three pulses indicates
cylinder five. The two camshaft pulses after cylinder
5 signals cylinder six (Fig. 12). The PCM can syn-
chronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes
low (less than 0.3 volts). When a notch aligns with
the sensor, voltage spikes high (5.0 volts). As a group
of notches pass under the sensor, the voltage
switches from low (metal) to high (notch) then back Fig. 13 Camshaft Sensor Location
to low. The number of notches determine the amount
of pulses. If available, an oscilloscope can display the for a total of 12 slots (Fig. 15). Basic timing is set by
square wave patterns of each timing event. the position of the last slot in each group. Once the
Top dead center (TDC) does not occur when notches powertrain control module (PCM) senses the last slot,
on the camshaft sprocket pass below the cylinder. it determines crankshaft position (which piston will
TDC occurs after the camshaft pulse (or pulses) and next be at TDC) from the camshaft position sensor
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after the 4 crankshaft pulses associated with the par- input. The 4 pulses generated by the crankshaft po-
ticular cylinder. The arrows and cylinder call outs on sition sensor represent the 69°, 49°, 29°, and 9°
Figure 12 represent which cylinder the flat spot and BTDC marks. It may take the PCM one engine rev-
notches identify, they do not indicate TDC position. olution to determine crankshaft position.
Fig. 14 Crankshaft Position Sensor
Fig. 12 Camshaft Sprocket—3.3L and 3.8L Engines

The camshaft position sensor is mounted in the
front of the timing case cover (Fig. 13).
CRANKSHAFT POSITION SENSOR

The crankshaft position sensor detects slots cut
into the transmission driveplate extension (Fig. 14).
There are 3 sets of slots. Each set contains 4 slots, Fig. 15 Timing Slots
The PCM uses crankshaft position reference to de-

termine injector sequence and ignition timing. Once
the PCM determines crankshaft position, it begins
energizing the injectors in sequence.
The crankshaft sensor is located on the passengers
side of the transmission housing, above the differen-
tial housing (Fig. 16). The bottom of the sensor is po-
sitioned next to the drive plate.
Fig. 17 Coil Pack—3.3L Engine

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Fig. 16 Crankshaft Position Sensor Location

IGNITION COIL
WARNING: THE DIRECT IGNITION SYSTEM GENER-
ATES APPROXIMATELY 40,000 VOLTS. PERSONAL
INJURY COULD RESULT FROM CONTACT WITH
THIS SYSTEM.
The coil assembly consists of 3 coils independant

molded together (Fig. 17). The coil assembly is Fig. 18 Engine Coolant Temperature Sensor
mounted on the intake manifold. High voltage igni- When the engine is cold, the PCM will demand
tion cables route to each cylinder from the coil. The slightly richer air-fuel mixtures and higher idle
coil fires two spark plugs every power stroke. One speeds until normal operating temperatures are
plug is the cylinder under compression, the other cyl- reached.
inder fires on the exhaust stroke. The powertrain The engine coolant sensor input is also used for
control module (PCM) determines which of the coils cooling fan control.
to charge and fire at the correct time.
Coils one fires cylinders 1 and 4, coil two fires cyl- MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
inders 2 and 5, coil three fires cylinders three and The MAP sensor reacts to absolute pressure in the
six. intake manifold and provides an input voltage to the
powertrain control module (PCM). As engine load
changes, manifold pressure varies. The changes in
The engine coolant temperature (ECT) sensor is lo-
engine load cause the MAP sensors resistance to
cated next to the thermostat housing (Fig. 18). The
change. The change in MAP sensor resistance results
sensor provides an input voltage to the powertrain
control module (PCM). The sensor is a variable resis- in a different input voltage to the PCM.
tance (thermistor) with a range of -40°F to 265°F. As The input voltage level supplies the PCM with in-
coolant temperature varies, the sensors resistance formation relating to ambient barometric pressure
changes, resulting in a different input voltage to the during engine start-up (cranking) and engine load
PCM. while its operating. The PCM uses this input along
The PCM contains different spark advance sched- with inputs from other sensors to adjust air-fuel mix-
ules for cold and warm engine operation. The sched- ture.
ules reduce engine emission and improve driveability.
The MAP sensor (Fig. 19) is mounted to the side of The PCM turns the ground path off when the igni-
the intake manifold, below the positive crankcase tion switch is in the Off position. Both relays are off.
ventilation (PCV) valve. The sensor is connected to When the ignition switch is in the On or Crank po-
the PCM electrically. sition, the PCM monitors the distributor pick-up sig-
nal to determine engine speed and ignition timing
(coil dwell). If the PCM does not receive a distributor
signal when the ignition switch is in the Run posi-
tion, it will de-energize both relays. When the relays
are de-energized, battery voltage is not supplied to
the fuel injector, ignition coil, fuel pump and oxygen
The ASD and fuel pump relays are located in the
power distribution center (PDC). The PDC is located
in the engine compartment above the PCM (Fig. 20).
A label affixed to the underside of the PDC cover
identifies the relays and fuses in the PDC.
Fig. 19 Map Sensor

AUTOMATIC SHUT DOWN (ASD) RELAY AND FUEL
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PUMP RELAY
The powertrain control module (PCM) operates the
automatic shut down (ASD) relay and fuel pump re-
lay through one ground path. The PCM operates the
relays by switching the ground path on and off. Both
relays turn on and off at the same time.
The ASD relay connects battery voltage to the fuel
injector and ignition coil. The fuel pump relay con-
nects battery voltage to the fuel pump and oxygen
Fig. 20 Power Distribution Center
3.3L AND 3.8L DIRECT IGNITION SYSTEM—DIAGNOSTIC PROCEDURES
INDEX
page page
Check Coil Test—3.3L Engine . . . . . . . . . . . . . . . . 30 Failure to Start Test . . . . . . . . . . . . . . . . . . . . . . . . 31
Crankshaft Position Sensor and Camshaft Position Manifold Absolute Pressure (MAP) Sensor Test . . . 32
Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Testing for Spark at Coil . . . . . . . . . . . . . . . . . . . . 30
Engine Coolant Temperature Sensor Test . . . . . . . 31
TESTING FOR SPARK AT COIL Each coil tower is labeled with the number of the
corresponding cylinder.
WARNING: THE 3.3L AND 3.8L DIRECT IGNITION (1) Remove the ignition cables and measure the re-
SYSTEMS GENERATES APPROXIMATELY 40,000 sistance of the cables. Resistance must be between
VOLTS. PERSONAL INJURY COULD RESULT FROM 3,000 to 12,000 ohms per foot of cable. Replace any
CONTACT WITH THIS SYSTEM. cable not within tolerance.
(2) Disconnect the electrical connector from the coil
The coil pack contains 3 independent coils. Each pack (Fig. 2).
coil must be checked individually.
CAUTION: Spark plug wire damage may occur if the

spark plug is moved more than 1/4 inch away from
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the engine ground.
Remove the cable from number 2 spark plug. Insert

a clean spark plug into the spark plug boot, and
ground plug to the engine (Fig. 1).
Fig. 2 Ignition Coil Electrical Connection

(3) Measure the primary resistance of each coil. At
the coil, connect an ohmmeter between the B+ pin
and the pin corresponding to the cylinders in ques-
tion (Fig. 3). Resistance on the primary side of each
coil should be 0.45 - 0.65 ohm at 21° to 27°C (70° to
80°F). Replace the coil if resistance is not within tol-
erance.
Fig. 1 Testing For Spark
Crank the engine and look for spark across the
electrodes of the spark plug. Repeat the above test
for the five remaining cylinders. If there is no spark
during all cylinder tests, proceed to the failure to
start test.
If one or more tests indicate irregular, weak, or no
spark, proceed to Check Coil Test.
CHECK COIL TEST—3.3L ENGINE

Coils one fires cylinders 1 and 4, coil two fires
cylinders 2 and 5, coil three fires cylinders Fig. 3 Ignition Coil Terminal Identification
three and six.
(4) Remove ignition cables from the secondary tow- PCM grounded the auto shutdown (ASD) relay.
ers of the coil. Measure the secondary resistance of Proceed to step 5.
the coil between the towers of each individual coil (b) If the test light did not flash, the ASD relay
(Fig. 4). Secondary resistance should be 7,000 to did not energize. The cause is either the relay or
15,800 ohms. Replace the coil if resistance is not one of the relay circuits. Use the DRB scan tool to
within tolerance. test the ASD relay and circuits. Refer to the appro-
priate Powertrain Diagnostics Procedure Manual.
Refer to the wiring diagrams section for circuit in-
formation.
(5) Crank the engine. (If the key was placed in the
off position after step 4, place the key in the On po-
sition before cranking. Wait for the test light to flash
once, then crank the engine.)
(a) If the test light momentarily flashes during
cranking, the PCM is not receiving a crankshaft
position sensor signal. Use the DRB scan tool to
test the crankshaft position sensor and sensor cir-
cuits. Refer to the appropriate Powertrain Diagnos-
tics Procedure Manual. Refer to the wiring
diagrams section for circuit information.
(b) If the test light did not flash during cranking,
unplug the crankshaft position sensor connector.
Turn the ignition key to the off position. Turn the
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Fig. 4 Checking Ignition Coil Secondary Resistance

key to the On position, wait for the test light to
FAILURE TO START TEST momentarily flash once, then crank the engine. If
This no-start test checks the camshaft position sen- the test light momentarily flashes, the crankshaft
sor and crankshaft position sensor. position sensor is shorted and must be replaced. If
The powertrain control module (PCM) supplies 8 the light did not flash, the cause of the no-start is
volts to the camshaft position sensor and crankshaft in either the crankshaft position sensor/camshaft
position sensor through one circuit. If the 8-volt sup- position sensor 8-volt supply circuit, or the cam-
ply circuit shorts to ground, neither sensor will pro- shaft position sensor output or ground circuits. Use
duce a signal (output voltage to the PCM). the DRB scan tool to test the camshaft position
When the ignition key is turned and left in the On sensor and the sensor circuits. Refer to the appro-
position, the PCM automatically energizes the auto priate Powertrain Diagnostics Procedure Manual.
shutdown (ASD) relay. However, the controller de-en- Refer to the wiring diagrams section for circuit in-
ergizes the relay within one second because it has formation.
not received a camshaft position sensor signal indi-
cating engine rotation. ENGINE COOLANT TEMPERATURE SENSOR TEST
During cranking, the ASD relay will not energize (1) With key off, disconnect wire connector from
until the PCM receives a camshaft position sensor engine coolant temperature sensor (Fig. 5).
signal. Secondly, the ASD relay remains energized
only if the controller senses a crankshaft position
sensor signal immediately after detecting the cam-
shaft position sensor signal.
(1) Check battery voltage. Voltage should approxi-
mately 12.66 volts or higher to perform failure to
start test.
(2) Disconnect the harness connector from the coil
pack (Fig. 2).
(3) Connect a test light to the B+ (battery voltage)
terminal of the coil electrical connector and ground.
The wire for the B+ terminal is dark green with a
Fig. 5 Engine Coolant Temperature Sensor Test
black tracer.
(4) Turn the ignition key to the ON position. The (2) Connect one lead of ohmmeter to one terminal
test light should flash On and then Off. Do not turn of engine coolant temperature sensor.
the Key to off position, leave it in the On posi- (3) Connect the other lead of ohmmeter to remain-
tion. ing connector of engine coolant temperature sensor.
(a) If the test light flashes momentarily, the The ohmmeter should read as follows;
• Engine/Sensor hot at normal operating tempera- CRANKSHAFT POSITION SENSOR AND CAMSHAFT
ture around 200°F should read approximately 700 to POSITION SENSOR TESTS
1,000 ohms. Refer to the appropriate Powertrain Diagnostic
• Engine/Sensor at room temperature around 70°F,
Procedure manual.
ohmmeter should read approximately 7,000 to 13,000
ohms.
See On Board Diagnostics section of Group
14, or refer to the appropriate diagnostic man-
ual for further test procedures.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

TEST
Refer to the appropriate Powertrain Diagnostic
Procedure manual.
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3.3L AND 3.8L DIRECT IGNITION SYSTEMS—SERVICE PROCEDURES
INDEX
page page
Camshaft Position Sensor . . . . . . . ... . . . . . . . . . 35 Ignition Timing Procedure . . . . . . . . . . . . . . . . . . . 35
Crankshaft Position Sensor . . . . . . ... . . . . . . . . . 35 Manifold Absolute Pressure (MAP) Sensor . . . . . . . 36
Engine Coolant Temperature Sensor .. . . . . . . . . . 33 Powertrain Control Module . . . . . . . . . . . . . . . . . . 33
Idle RPM Test . . . . . . . . . . . . . . . . ... . . . . . . . . . 35 Spark Plug Cable Service . . . . . . . . . . . . . . . . . . . 34
Ignition Coil . . . . . . . . . . . . . . . . . ... . . . . . . . . . 36 Spark Plug Service . . . . . . . . . . . . . . . . . . . . . . . . 34
POWERTRAIN CONTROL MODULE

REMOVAL
(1) Remove air cleaner duct or air cleaner assem-
bly.
(2) Remove battery.
(3) Remove PCM mounting screws (Fig. 1).
(4) Remove 60-way connector from PCM. Remove
controller.
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Fig. 2 Engine Coolant Temperature Sensor

REMOVAL
(1) Drain cooling system until coolant level is be-
low sensor. Refer to Group 7, Cooling System.
(2) Remove electrical connector from coil (Fig. 3).
Fig. 1 Powertrain Control Module

INSTALLATION
(1) Connect 60-Way connector to PCM (Fig. 1).
(2) Install PCM on inside left front fender (Fig. 1).
Install and tighten mounting screws.
(3) Install the battery.
(4) Install air cleaner duct or air cleaner assembly.

The engine coolant temperature (ECT) sensor is lo-
cated below the ignition coil (Fig. 2).
Fig. 3 Ignition Coil Removal
(3) Remove coil mounting screws. Use an ohmmeter to check cables for opens, loose
(4) Rotate coil away from engine coolant tempera- terminals or high resistance.
ture sensor. (a) Remove cable from spark plug.
(5) Disconnect electrical connector from engine (b) Remove cable from the coil tower.
coolant temperature sensor. (c) Connect the ohmmeter between spark plug
(6) Remove sensor from engine. end terminal and the coil end terminal. Resistance
should be within tolerance shown in the cable re-
INSTALLATION sistance chart. If resistance is not within tolerance,
(1) Tighten the sensor to 7 Nzm (60 in. lbs.) torque. replace cable assembly. Test all spark plug cables
(2) Connect electrical connector to sensor. in same manner.
(3) Fill cooling system. Refer to Group 7, Cooling
CABLE RESISTANCE CHART
System.
(4) Install coil. Tighten coil mounting screws to 12
Nzm (105 in. lbs.) torque.
(5) Connect electrical connector to coil.
SPARK PLUG CABLE SERVICE

Clean high voltage ignition cables with a cloth
moistened with a non-flammable solvent. Wipe the
cables dry. Check for brittle or cracked insulation. SPARK PLUG SERVICE
When testing cables for punctures and cracks with When replacing the spark plug cables, route the ca-
an oscilloscope and an inductive voltage probe, follow bles correctly and secure them in the appropriate re-
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the instructions of the equipment manufacturers. tainers. Failure to route the cables properly can
cause the radio to reproduce ignition noise, cross ig-
CAUTION: Do not leave any one spark plug cable nition of the spark plugs or short circuit the cables to
disconnected any longer than necessary during test ground.
or possible heat damage to catalytic converter will Never Wire Brush Spark Plugs. The spark plug
occur. Total test time must not exceed ten minutes. insulator tip is harder than the bristles of wire
If an oscilloscope and inductive probe are not avail- brushes. Bristles of wire brushes can leave a conduc-
able, cables can be tested as follows: tive, metallic film on the insulator which could lead
(1) With the engine not running, connect one end to conductive deposits. Conductive deposits can cause
of a test probe (i.e. a piece of wire with insulated al- spark plug failure and engine misfire. Use a jewelers
ligator clips on each end) to a good ground, other end file to remove deposits from the electrode gap. Use a
free for probing. spark plug cleaning machine to clean spark plugs.
WARNING: THE DIRECT IGNITION SYSTEM GENER- SPARK PLUG REMOVAL
ATES APPROXIMATELY 40,000 VOLTS. PERSONAL Always remove the spark plug cable by grasping
INJURY COULD RESULT FROM CONTACT WITH at the spark plug boot, turning the boot 1/2
THIS SYSTEM. turn and pulling straight back in a steady mo-
tion.
(2) With the engine running, move test probe along (1) Prior to removing the spark plug spray com-
entire length of all cables (approximately 0 to 1/8 pressed air around the spark plug hole and the area
inch gap). If punctures or cracks are present there around the spark plug.
will be a noticeable spark jump from the faulty area (2) Remove the spark plug using a quality socket
to the probe. Cracked, leaking or faulty cables should with a rubber or foam insert.
be replaced. (3) Inspect the spark plug condition. Refer to
Use the following procedure when removing the Spark Plug Condition in this section.
high voltage ignition cable from the spark plug. First,
remove the cable from the retaining bracket. Then SPARK PLUG GAP ADJUSTMENT
grasp the terminal as close as possible to the Check the spark plug gap with a gap gauge. If the
spark plug. Rotate the cover (boot) slightly and gap is not correct, adjust it by bending the ground
pull straight back. Do not use pliers and do not electrode (Fig. 4).
pull the cable at an angle. Doing so will damage
the insulation, cable terminal or the spark plug insu- SPARK PLUG INSTALLATION
lator. Wipe spark plug insulator clean before re- (1) To avoid cross threading, start the spark plug
installing cable and cover. into the cylinder head by hand.
Resistance cables are identified by the words Elec- (2) Tighten spark plugs to 28 Nzm (20 ft. lbs.)
tronic Suppression. torque.
Fig. 5 Crankshaft Position Sensor

INSTALLATION
If the removed sensor is to be reinstalled,
clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor
Fig. 4 Setting Spark Plug Gap—Typical face before installation. If the sensor is being
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replaced, confirm that the paper spacer is at-

(3) Install spark plug cables over spark plugs. The tached to the face of the new sensor (Fig. 6).
cable will make a click sound whent the terminal end
properly attaches to the spark plug.
IDLE RPM TEST

WARNING: BE SURE TO APPLY PARKING BRAKE
AND/OR BLOCK WHEELS BEFORE PERFORMING
ANY ENGINE RUNNING TESTS.
Engine idle set rpm should be tested and re-

corded as it is when the vehicle is first brought
into shop for testing. This will assist in diagnosing
complaints of engine stalling, creeping and hard
shifting on vehicles equipped with automatic trans-
missions.
Proceed to the Throttle Body Minimum Airflow pro-
cedures.
Fig. 6 Crankshaft Position Sensor and Spacer
IGNITION TIMING PROCEDURE (1) Install sensor in transaxle and push sensor
The 3.3L and 3.8L engines use a fixed ignition sys- down until contact is made with the drive plate.
tem. Basic ignition timing is not adjustable. The pow- While holding the sensor in this position, and install
ertrain control module (PCM) regulates ignition and tighten the retaining bolt to 11.9 Nzm (105 in.
timing. lbs.) torque.
(2) Connect crankshaft position sensor electrical
CRANKSHAFT POSITION SENSOR connector to the wiring harness connector.
REMOVAL CAMSHAFT POSITION SENSOR

(1) Disconnect crankshaft position sensor electrical
connector from the wiring harness connector (Fig. 5). REMOVAL
(2) Remove crankshaft position sensor retaining (1) Disconnect camshaft position sensor electrical
bolt. connector from the wiring harness connector (Fig. 7).
(3) Pull crankshaft position sensor straight up out (2) Remove engine mount support bracket.
of the transaxle housing.
IGNITION COIL
(1) Remove spark plug cables from coil (Fig. 9).
Fig. 7 Camshaft Position Sensor

(3) Loosen camshaft position sensor retaining bolt
enough to allow slot in sensor to slide past the bolt.
(4) Pull sensor up out of the chain case cover. Do
not pull on the sensor lead. There is an O-ring on
the sensor case. The O-ring may make removal diffi-
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cult. A light tap to top of sensor prior to removal may

reduce force needed for removal.
Fig. 9 Ignition Coil Removal and Installation
INSTALLATION (2) Remove ignition coil electrical connector.
If the removed sensor is reinstalled, clean off (3) Remove ignition coil mounting screws.
the old spacer on the sensor face. A NEW (4) Remove ignition coil.
SPACER must be attached to the face before in- Reverse the above procedure for installation.
stallation. Inspect O-ring for damage, replace if nec- Tighten mounting screws to 12 Nzm (105 in. lbs.)
essary. If the sensor is being replaced, confirm that torque.
the paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor (Fig. 8). MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
(1) Disconnect electrical connector from MAP sen-
sor.
(2) Remove sensor by unscrewing from the intake
manifold (Fig. 10).
(3) Reverse the above procedure for installation.
Fig. 8 Camshaft Position Sensor and Spacer

(1) Apply a couple drops of clean engine oil to the
O-ring prior to installation. Install sensor in the
chain case cover and push sensor down until contact
is made with the camshaft gear. While holding the
sensor in this position, install and tighten the retain-
ing bolt 14 Nzm (125 in. lbs.) torque.
(2) Connect camshaft position sensor electrical con-
nector to harness connector. Position connector away
from the accessory belt.
Fig. 10 Manifold Absolute Pressure Sensor
(3) Install engine mount support bracket.
TSB 23-44-94 June 3, 1994
IGNITION SWITCH
IGNITION SWITCH AND KEY CYLINDER SERVICE

The ignition switch is located on the steering col-
umn. The Key In Switch is located in the ignition
switch module. For diagnosis of the Key In Switch,
refer to Section 8M.
IGNITION SWITCH DESIGNATIONS
Fig. 1 Ignition Switch Screw Removal

(b) Rotate the key clockwise to the OFF position.
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REMOVAL
(1) Disconnect negative cable from battery.
(2) If the vehicle has a tilt column, remove the tilt Fig. 2 Lock Cylinder with Retaining Pin Type I
lever by turning it counterclockwise. The lock cylinder will unseat from the ignition
(3) Remove upper and lower covers from steering switch (Fig. 3). When the lock cylinder is unseated,
column. it will be approximately 1/8 inch away from the ig-
(4) Remove ignition switch mounting screws. Use nition switch halo light ring. Do not attempt to
tamper proof torx bit Snap-on TTXR15A2, TTXR20A2 or remove the lock cylinder at this time.
equivalent to remove the screws (Fig. 1).
(5) Gently pull switch away from the column. Re-
lease connector locks on the 7 terminal wiring con-
nector, then remove the connector from the ignition
switch.
(6) Release connector lock on the 4 terminal con-
nector, then remove the connector from the ignition
switch.
TYPE I WITH RETAINING PIN

(7) To remove the lock cylinder with retaining pin
from the ignition switch:
(a) Insert key in the lock cylinder. Turn the key
to the LOCK position. Using a small screwdriver,
depress the lock cylinder retaining pin until it is
flush with the lock cylinder surface (Fig. 2).
Fig. 3 Unseated Key Cylinder
TSB 23-44-94 June 3, 1994
(b) Rotate key clockwise to the OFF position. Lock

cylinder will unseat from ignition switch (Fig. 4). When
lock cylinder is unseated, it will be approximately 1/8
inch away from ignition switch halo light ring. Do not
attempt to remove lock cylinder at this time.
(c) With lock cylinder in unseated position, rotate key
counterclockwise to the lock position and remove key.
(d) Remove lock cylinder from ignition switch (Fig. 7).
Fig. 4 Unseated Key Cylinder

(c) With the lock cylinder in the unseated posi-
tion, rotate the key counterclockwise to the lock po-
sition and remove the key.
(d) Remove lock cylinder from ignition switch (Fig. 5).
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Fig. 7 Key Cylinder Removal

INSTALLATION TYPE I
If the vehicle has a floor mounted gear shifter,
place the selector in the Park position.
(1) Connect electrical connectors to the ignition
switch. Make sure that the switch locking tabs are
fully seated in the wiring connectors.
(2) Before attaching the ignition switch to a tilt steering
column, the transaxle shifter must be in the Park position.
Also the park lock dowel pin and the column lock flag must
be properly indexed before installing the switch (Fig. 8).
(a) Place the transaxle shifter in the PARK position.
Fig. 5 Key Cylinder Removal
TYPE II WITH RETAINING SCREW
(7) To remove lock cylinder with retaining screw
from ignition switch:
(a) Insert key in ignition switch. Turn key to LOCK
position. Using a TTXR20A2 or equivalent torx bit, re-
move lock cylinder retaining screw and bracket (Fig 6).
Fig. 8 Ignition Switch View From Column

(b) Place the ignition switch in the lock position. The
switch is in the lock position when the column lock flag
is parallel to the ignition switch terminals (Fig. 8).
(c) Position ignition switch park lock dowel pin
so it will engage the steering column park lock
Fig. 6 Lock Cylinder with Retaining Screw Type II slider linkage (Fig. 9).
TSB 23-44-94 June 3, 1994
INSTALLATION TYPE II
(1) Connect electrical connectors to ignition switch.
Make sure that switch locking tabs are fully seated
in wiring connectors.
(2) Before attaching ignition switch to a tilt steer-
ing column, the transmission shifter must be in Park
position. Also the park lock dowel pin and column
lock flag must be properly indexed before installing
switch (Fig. 8).
(a) Place transmission shifter in PARK position.
(b) Place ignition switch in lock position. The
switch is in the lock position when column lock flag
is parallel to ignition switch terminals (Fig. 7).
(c) Position ignition switch park lock dowel pin
so it will engage steering column park lock slider
linkage (Fig. 8)
Fig. 8 Ignition Switch Mounting Pad (d) Apply a light coating of grease to column lock
(d) Apply a light coating of grease to the column flag and park lock dowel pin.
lock flag and the park lock dowel pin. (3) Place ignition switch against lock housing open-
(3) Place the ignition switch against the lock housing on steering column. Ensure that ignition switch
park lock dowel pin enters slot in park lock slider
ing opening on the steering column. Ensure ignition
linkage in steering column.
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switch park lock dowel pin enters the slot in the park
(4) Install retaining bracket and ignition switch
lock slider linkage in the steering column.
mounting screws. Tighten screws to 3±.5 Nzm (26±4
(4) Install ignition switch mounting screws.
in. lbs.) torque.
Tighten screws to 2 Nzm (17 in. lbs.) torque. (5) Install ignition lock cylinder:
(5) Install steering column covers. Tighten screws (a) With lock cylinder and ignition switch in
to 2 Nzm (17 in. lbs.) torque. Lock position, insert lock cylinder into ignition
(6) If the vehicle is equipped with a tilt steering switch until it bottoms.
column, install the tilt lever. (b) Insert ignition key into lock cylinder. While
(7) To install the lock in the lock cylinder with re- gently pushing lock cylinder in toward ignition
taining pin: switch, rotate ignition key to end of travel.
(a) With the lock cylinder and the ignition switch (6) Install retaining screw into bracket and lock
in the Lock position, insert the lock cylinder into cylinder. Tighten screw to 3±.5 Nzm (26±4 in. lbs.)
the ignition switch until it bottoms. torque.
(b) Insert ignition key into lock cylinder. While (7) Install steering column covers. Tighten screws
gently pushing the lock cylinder in toward the ig- to 2 Nzm (17 in. lbs.) torque.
nition switch, rotate the ignition key to the end of (8) If vehicle is equipped with a tilt steering col-
travel. umn, install tilt lever.
(c) Connect negative cable to battery. (9) Connect negative cable to battery.
(8) Check for proper operation of the halo light, (10) Check for proper operation of halo light, shift
shift lock (if applicable), and column lock. Also check lock (if applicable), and column lock. Also check for
for proper operation of the ignition switch accessory, proper operation of ignition switch accessory, lock,
lock, off, run, and start positions. off, run, and start positions.
8D - 39A IGNITION SYSTEMS .
TSB 23-44-94 June 3, 1994
SPECIFICATIONS
GENERAL INFORMATION SPARK PLUG WIRE ROUTING—3.3L AND 3.8L

The following specifications are published from the ENGINES
latest information available at the time of publica-
tion. If anything differs from the specifications on the
Vehicle Emission Control Information Label, use the
specifications on the label.
SPARK PLUG WIRE ROUTING—2.5L ENGINES
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SPARK PLUG WIRE ROUTING—3.0L ENGINE
3.3L ENGINE DIRECT IGNITION SYSTEM

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DISTRIBUTORS
IGNITION COILS
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SPARK PLUGS
TORQUE
. INSTRUMENT PANEL AND GAUGES 8E - 1
INSTRUMENT PANEL AND GAUGES
CONTENTS
page page
CLUSTER AND GAUGE SERVICE . . . . . . . . . . . . 2 INSTRUMENT PANEL COMPONENT REMOVAL . 17

GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SWITCH AND PANEL COMPONENT SERVICE . 12
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 WARNING LAMP SYSTEM TESTS . . . . . . . . . . 10
GENERAL INFORMATION
INSTRUMENT CLUSTERS
The mechanical cluster is an electronic cluster with
analog displays. The body control module sends the
mechanical cluster the gauge readings and warning
messages over the CCD Bus.
The electronic cluster receives most information
displayed from the body and powertrain control mod-
ule via the Chrysler Collision Detection (CCD) Serial
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Data Bus. The odometer memory is no longer re- Fig. 2 Mechanical Cluster With Tachometer
tained in the cluster it is retained in the body control • Digital speedometer and odometer
module. • Analog bar type gauges for, oil pressure, tempera-
The mechanical cluster without tachometer (Fig. 1) ture, voltage, tachometer and fuel
includes a 160 km/h (100 mph) speedometer, trip • Vehicle graphics showing door ajar, lift gate ajar,
odometer, fuel, temperature gauges and warning in- low washer fluid, malfunction indicator (check en-
dicators. The warning lamps include: low fuel, check gine) lamp, check gauges and low fuel
gauges, door ajar, low washer fluid, malfunction indi-
cator (check engine), gate ajar, volt and low oil pres-
sure.
Fig. 3 Electronic Cluster

MAGNETIC GAUGES
Fig. 1 Mechanical Cluster Without Tachometer
All the gauges on instrument clusters are the mag-
The mechanical cluster with tachometer (Fig. 2) netic type gauges. When the ignition switch is in the
will include a 160 km/h (100 mph) speedometer, trip OFF position each gauge should rest at or below the
odometer, gauges for fuel level, coolant temperature, low graduation.
oil pressure, and charging system voltage. Also, in-
cluded is a 7,000 rpm tachometer. The warning ELECTRONIC DIGITAL CLOCK
lamps may include: The electronic digital clock is in the radio. The
• Low fuel clock and radio each use the display panel built into
• Check gauges the radio. A digital readout shows the time in hours
• Door ajar and minutes whenever the ignition switch is in the
• Low washer fluid ON or ACC position.
• Malfunction indicator (check engine) When the ignition switch is in the OFF position, or
• Gate ajar when the radio frequency is being displayed, time
The electronic cluster (Fig. 3) contains: keeping is accurately maintained.
8E - 2 INSTRUMENT PANEL AND GAUGES .
The procedure for setting the clock varies slightly MECHANICAL CLUSTER SERVICE
with each radio. The correct procedure is described To test the gauges and mechanical cluster a DRB
under the individual radio operating instructions re- will be needed, and the Body Diagnostic Procedures
ferred to in the owner’s manual supplied with the ve- Manual.
hicle.
ELECTRONIC CLUSTER SERVICE
Refer to Body Diagnostic Procedures Manual when
SEAT BELT WARNING SYSTEM
using DRB.
For testing of this system refer to Group 8U,
Chime Warning/Reminder system. SELF DIAGNOSTIC SYSTEM
The electronic cluster has an internal diagnostic
SEAT BELT WARNING LAMP routing to isolate problems within the cluster.
The seat belt warning lamp is located in the hood Perform cluster Self-Diagnostic Test to decide
and message center assembly. Refer to Hood and whether problem is within cluster or outside of clus-
Message Center Removal or Lamp Replacement for ter. Start test by depressing and holding Trip and
lamp replacement. Trip Reset buttons while turning the ignition switch
ON, CHEC will appear in the odometer. Depressing
CLUSTER AND GAUGE SERVICE the US/M switch will perform the next test. Refer to
Figs. 5 and 6.
CAUTION: Disconnect battery negative cable, be- Successful completion of the SELF-DIAGNOSTIC
fore servicing instrument panel. When power is re- TEST shows that the problem is in the wiring, con-
quired for test purposes, connect battery negative nectors or sensors out side of the cluster.
cable for test only.
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CONDITION: MECHANICAL CLUSTER IS NOT

Disconnect battery negative cable after test and be- FUNCTIONAL WITH ENGINE RUNNING
fore continuing service procedures. The cluster is indicating that it is not receiving any
CCD Bus messages if:
Refer to Fig. 4 for cluster connector wire call out.
• Check gauge lamp is ON.
• Tachometer, speedometer and gauges are at low
scale.
(1) Perform self diagnostic test. If OK, go to step 3.
If not OK, go to step 2.
(2) Check for voltage and ground at the cluster. If
OK, replace cluster. If not OK, repair wiring as nec-
essary. Refer to Group 8W, Wiring Diagrams for ter-
minal information.
(3) Using the DRB, check if the bus is operational.
If OK, go to step 4. If not OK, identify the bus wiring
failure and/or module and repair as necessary.
(4) Disconnect the battery negative cable for at
least 30 seconds to reset modules. Connect battery
negative cable and go to step 5.
(5) Using a DRB, check body control module to see
if it is receiving data. If the module is on line and not
transmitting information to the cluster, replace the
body control module. If the module does not respond
check the following:
(a) Check the module connectors.
(b) Check for ignition feed and ground at the
Fig. 4 Cluster Connector body control module. Refer to Group 8W, Wiring Di-
agrams for terminal information.
(c) Check bus + and bus - terminals for 2.5 volts
at the module and cluster. If OK, replace body con-
trol module. If not OK, repair as necessary.
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Fig. 5 Electronic Cluster Self-Diagnostic Test

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Fig. 6 Electronic Cluster Self-Diagnostic Test—Continued

HOOD AND MESSAGE CENTER REMOVAL OR

LAMP REPLACEMENT
(1) To remove top cover use a flat blade tool. Pry
up on either end and continue across the full length
of the top cover.
(2) To remove cluster bezel grille use the removal
tool (Fig. 7). Using tool at either end pull up and re-
move grille (Fig. 8).
Fig. 8 Bezel Grille Removal

(3) Remove six mounting screws from the hood and
message center assembly. Using a flat blade tool pry
Fig. 7 Bezel Grille Removal Tool
up on either end and remove module and disconnect
(3) Remove six mounting screws from the assem- wire connector.
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bly. Using a flat blade tool pry up on either end and (4) Reach behind lower right corner of center bezel
remove assembly and disconnect wire connector. and pull to disconnect attaching clip. Repeat in all of
(4) Replace lamp and socket or lamp (Fig. 9). the corners and remove bezel. Disconnect ash re-
(5) For installation reverse above procedures. ceiver wire and lamp assembly if equipped.
(5) Remove three instrument cluster bezel screws
INSTRUMENT PANEL CLUSTER BEZEL on the bottom of bezel and three at the upper left.
REMOVAL Pulling up and rearward on the top edge of bezel re-
(1) To remove top cover use a flat blade tool. Pry move bezel (Fig. 10).
up on either end and continue across the full length (6) Disconnect POD switches wiring connectors.
of the top cover. (7) For installation reverse above procedures.
Fig. 9 Message Center Lamp Location

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Fig. 10 Instrument Cluster Bezel

INSTRUMENT PANEL CLUSTER LENS INSTRUMENT PANEL CLUSTER REMOVAL
REMOVAL (1) Refer to Instrument Panel Cluster Bezel Re-
(1) Refer to Instrument Panel Cluster Bezel Re- moval.
moval. (2) Remove left instrument panel silencer.
(2) Remove six screws securing lens to cluster (3) Disconnect parking hand brake linkage.
housing (Fig. 11). (4) Remove five cover attaching screws and lower
cover. Disconnect any wire connectors.
(5) Remove steering column cover.
(6) Remove two attaching over column cover
screws and cover.
(7) Remove four screws securing cluster. Carefully
rotate cluster and disconnect connector, to access
transmission range indicator attaching screws. Re-
move two screws attaching transmission range indi-
cator to cluster (Fig. 12).
(8) For electronic instrument cluster if equipped:
(a) Remove four screws securing cluster.
(b) Remove four screws attaching mask to hous-
ing.
(c) Rotate mask down then disconnect buttons
and transmission range indicator.
(d) Remove two screws attaching transmission
Fig. 11 Cluster Lens
range indicator to mask on electronic instrument
(3) Remove lens. cluster only.
(4) For installation reverse above procedures. (9) Remove cluster.

(3) Remove cluster.
(4) Remove six mounting screws and remove cover
(Fig. 14).
Fig. 12 Removal of Transmission Range Indicator

Fig. 14 Printed Circuit Board
• When installing cluster, do not kink or bind trans-
(5) Disconnect odometer connector and remove
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mission range indicator guide tube and position

guide tube in original location. screws attaching printed circuit board and housing.
• Move shift lever to Neutral (N) and note pointer (6) For installation reverse above procedures.
location. Move shift lever to D, L and P note pointer • When installing cluster, do not kink or bind trans-
location. Adjust, if necessary to center pointer on N. mission range indicator guide tube and position
guide tube in original location.
Refer to Fig. 13 for adjusting procedure.
• Move shift lever to Neutral (N) and note pointer
location. Move shift lever to D, L and P note pointer
location. Adjust, if necessary to center pointer on N.
CLUSTER LAMPS BULB REPLACEMENT

MECHANIAL CLUSTER ONLY
(1) Refer to Instrument Panel Cluster Bezel Re-
moval.
(2) Remove four cluster attaching screws.
(3) Carefully roll cluster out of instrument panel
without disconnecting transmission range indicator.
(4) Remove one piece integral bulb and socket from
rear of cluster (Fig. 15).
GAUGES
To test the gauges and mechanical cluster a DRB
will be needed and Body Diagnostic Procedures Man-
ual.
It is not necessary to remove instrument clus-
ter from vehicle for gauge replacement.
When removing gauge from cluster, gauge
Fig. 13 Adjusting Transmission Range Indicator must be pulled straight out, without twisting or
damage to gauge pins may result.
CLUSTER PRINTED CIRCUIT BOARD
REMOVAL FUEL GAUGE REPLACEMENT
(1) Refer to Instrument Panel Cluster Bezel Re- (1) Refer to Instrument Panel Cluster Bezel Re-
moval. moval.
(2) Remove cluster lens.

(3) Remove six screws attaching gauge to cluster
(Figs. 16 or 17).
(4) Remove voltmeter gauge.
TEMPERATURE GAUGE REPLACEMENT

moval.
(Figs. 16 or 17).
(4) Remove temperature gauge.
OIL PRESSURE GAUGE REPLACEMENT

moval.
(Figs. 16 or 17).
Fig. 15 Mechanical Cluster Lamp Location (4) Remove oil pressure gauge.
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(Figs. 16 and 17). TACHOMETER REPLACEMENT
moval.
(Figs. 16 or 17).
(4) Remove tachometer gauge.
SPEEDOMETER ASSEMBLY REPLACEMENT

moval.
Fig. 16 Gauge Assembly Without Tachometer (3) Remove six screws attaching gauge to cluster
(Figs. 16 or 17).
(4) Remove speedometer gauge.
ODOMETER ASSEMBLY REPLACEMENT

moval.
(3) Remove cluster.
Fig. 17 Gauge Assembly With Tachometer
(4) Remove six screws that attach cover (Fig. 14).
(4) Remove fuel gauge. (5) Disconnect odometer motor connector on rear of
(5) For installation reverse above procedures. cluster (Fig. 18).
VOLTMETER REPLACEMENT CAUTION: Do Not disconnect pancake connector

(1) Refer to Instrument Panel Cluster Bezel Re- on back side of motor (Fig. 19).
moval.
(6) Remove lens.
Fig. 18 Odometer
Fig. 20 Vehicle Speed Sensor and Connector

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Fig. 19 Odometer Motor and Connector

(7) Remove screws attaching gauge to cluster.
(8) Remove three screws and odometer.
• When installing cluster, do not kink or bind trans-
mission range indicator guide tube and position
guide tube in original location.
VEHICLE SPEED SENSOR REMOVAL

(1) Remove harness connector from sensor and
make sure weather seal is on harness connector (Fig.
Fig. 21 Vehicle Speed Sensor and Speedometer
20).
Pinion
(2) Remove sensor retaining bolt.
(3) Pull sensor and pinion gear assembly out of ELECTRONIC AUTOMATIC TRANSAXLE
transaxle. If necessary, carefully pry loose with a flat OUTPUT SPEED SENSOR REMOVAL
blade screwdriver (Fig. 21). The output vehicle speed sensor is located to the
(4) Remove pinion gear from sensor. left of the manual shift lever.
(5) For installation reverse above procedures and (1) Raise and support vehicle on safety stands.
seat sensor assembly by hand to insure proper gear (2) Remove vehicle speed sensor (Fig. 22).
engagement. Tighten retaining bolt to 7 Nzm (60 in. (3) For installation, reverse above procedures.
lbs.) torque.
(1) Sending units and wiring can be checked by

grounding the connector leads, at the sending unit,
in the vehicle.
(2) With the ignition in the ON position, a
grounded input will cause the fuel or temperature
gauge to read at or above maximum.
FUEL TANK SENDING UNIT TEST

Refer to Group 14, Fuel for the sending unit test
procedure.
WARNING LAMP SYSTEM TESTS

All warning lamps come on when the ignition
switch is first turn to the ON position. They will stay
on for a few seconds to see if lamps are working.
Fig. 22 Output Speed Sensor Removal MALFUNCTION INDICATOR LAMP

VEHICLE SPEED SENSOR TEST The Malfunction Indicator (Check Gages) lamp will
For testing of the vehicle speed sensor and related light for the following:
components refer to the Powertrain Diagnostics Test (1) Low oil pressure.
Procedure Manual. (2) High or low battery voltage.
(3) High coolant temperature.
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SENDING UNIT TEST (4) Charging system failure.

When a problem occurs with a cluster gauge, before Be sure the temperature gauge and voltage gauge,
disassembling the cluster to check the gauge, check if equipped, are reading normal and voltage lamp, if
for a defective sending unit wiring or body control equipped, is OFF. These can be monitored by using
module. the DRB to read the body control module.
Fig. 23 Brake System Warning Lamp Diagnosis

BRAKE SYSTEM WARNING LAMP TEST LOW OIL PRESSURE WARNING LAMP/CHECK
The brake warning lamp illuminates when parking GAGES TEST
brake is applied with ignition key turned ON. The The oil pressure/check gage warning lamp will illu-
same light will also illuminate should one of the two minate under any of the following conditions (Figs.
service brake systems fail when brake pedal is ap- 25 and 26):
plied. To test system turn ignition key ON and apply
parking brake. If lamp fails to light, inspect for a
broken or disconnected wire at switch. The lamp also
lights when the ignition switch is turned to start.
To test service brake warning system, raise vehicle
on a hoist and open a wheel cylinder bleeder while a
helper depresses brake pedal and observes warning
lamp. If lamp fails to light, inspect for a burned out
bulb, disconnected socket, a broken or disconnected
wire at switch (Figs. 23 and 24).
Fig. 25 Combination Oil Sending Unit

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Fig. 24 Brake Warning Lamp Switch

If lamp is not burned out and wire continuity is
proven, replace brake warning switch. The switch is
located in brake line Tee fitting mounted on frame
rail in engine compartment below master cylinder
(Fig. 24).
CAUTION: If wheel cylinder bleeder was opened Fig. 26 Combination Oil Sending Unit—3.0L Engine
check master cylinder fluid level. (1) Lamp check when the ignition key is turned to
the ON position for about two seconds.
(2) The oil pressure switch is closed to ground The
TEMPERATURE WARNING LAMP TEST
switch grounds the lamp and is in put to the body
To test the temperature warning lamp, turn the ig-
control module which turns on the lamp over the bus.
nition switch to the ON position. Disconnect the wire
(3) Oil pressure sending unit is high resistance,
from the temperature switch on the engine and mo-
low pressure. The body control module will turn on
mentarily touch the wire to ground. When the wire is
lamp over the bus. The lamp also illuminates when
grounded the bulb of the indicator should illuminate.
the engine oil pressure drops below a safe oil pres-
If the bulb fails to illuminate, indications are of a
sure level.
faulty circuit in the system, body control module is
To test the system, turn the ignition key to the ON
malfunctioning or possibly the indicator bulb is
position. If the lamp fails to light, during the two sec-
faulty. Repair or replace as necessary.
ond lamp, inspect for a burned out lamp or discon-
nected socket in the cluster.
CONDITION: WARNING LAMP DOES NOT

LIGHT
If the lamp goes out after the lamp check, inspect
the connection to the oil pressure switch and sensor.
Check that the wires are going to the correct termi-
nals of the sending unit. Both the switch and sensor
must fail to result in the light going out. If the con-
nector and wiring are OK, use the DRB to read the
oil pressure switch at the body control module. Dis-
connect the sending unit connector. Using an jumper
wire, connect one end to the switch terminal and the
other to ground. If the lamp fails to light check for Fig. 27 Combination Oil Sending Unit Terminals
continuity to the cluster and body control module
from the pressure switch. Check for short from pres- test pressure. For oil pressure specifications, refer to
sure sensor circuit to ground. Check the wiring go to Group 9, Engine. If OK, go to step 8.
the body control module connector for proper termi- (8) If the above results are not obtained, replace
nals. the switch.
CONDITION: LAMP STAYS ON WITH ENGINE SWITCH AND PANEL COMPONENT SERVICE
RUNNING
LEFT POD SWITCH
If the light stays on with engine running, perform
The left POD switch consist of the headlamp, park-
the combination sending unit tests. If the sending
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ing lamp and hazard switches operate with a push-

unit is OK perform the following:
on, push-off action. The interior lamp/dimming
(1) Using a DRB monitor the oil pressure switch
control switch has a horizontal sliding action with
with the sending unit connector disconnected. The
five clearly defined detent positions. The parking/
switch should read open. If it does not, there is a
headlamp lamp switches latch ON and use a cross
short in the wiring, repair as necessary. The circuit
cancelling mechanism to ensure the two systems are
goes from the switch to the body control module and
not ON at once (Fig. 28).
the cluster.
(2) Connect the sending unit. Start the engine. Us-
ing the DRB, read the oil pressure level. If the DRB
reads ignition voltage, there is a open circuit in the
sensor wiring circuit. Repair open circuit.
COMBINATION OIL SENDING UNIT TESTS

The combination oil unit has two functions (Figs.
25 and 26).
(1) The normally closed circuit keeps the oil pres-
sure warning lamp on until there is oil pressure.
(2) The sending unit provides a resistance that
varies with oil pressure.
(3) To test the normally closed oil lamp circuit, dis-
connect the locking connector and measure the resis-
tance between the switch terminal and the metal
housing (Fig. 27). The ohmmeter should read zero
ohms.
(4) Start the engine. If there is oil pressure, the
ohmmeter should read an open circuit.
(5) To test the sending unit, measure the resis-
tance between the sending unit terminal and the
metal housing. The ohmmeter should read open. Fig. 28 Headlamp POD Switch
(6) Start the engine. The ohmmeter should read RIGHT POD SWITCH
between 30 and 55 ohms, depending on engine speed, The right POD switch consist of one or more of the
oil temperature, and oil viscosity. following switches (Fig. 29).
(7) If the switch and sensor read low pressure with • Rear window wiper switch
the engine running, remove the sending unit. Con- • Rear window washer switch
nect a pressure gauge in place of the sending unit to • Rear window defogger switch
(b) The second detent from the left is the ON po-

sition. The ON position supplies power to the
switch in the rear passenger compartment. When
the switch is in any other position than ON, the
rear passenger compartment switch is over ridden.
(c) The third detent from the left is the Low po-
sition.
(d) The fourth detent at the full right is the High
position.
POD SWITCH REMOVAL TOOL

Use a 3/16 inch diameter metal rod approximately
10 inches long. Bent a 90 degree leg 1 1/2 inches long
on both ends as shown in Fig. 30.
Fig. 29 Right POD Switch

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• Over Drive lockout switch

• Rear A/C heater blower
(1) The rear wiper switch operates with a push-on
and push-off latching action. It provides a ground to Fig. 30 POD Switch Removal Tool
the rear wiper module for a fixed intermittent cycle. POD SWITCH REMOVAL
The indicator lamp on the button displays when the To remove POD switch the top and bottom tabs
wiper is ON. must be depressed (Fig. 31). Using the removal tool
(2) The rear washer switch operates with a push depress bottom tab and pull till bottom tab is free.
on momentary action. It provides a ground to the Move tool to top tab and pull down to release tab.
rear wiper module to turn rear window washer ON. Pull switch free and disconnect wire harness connec-
(3) The over drive switch operates with a push-on tor.
and push-off momentary action. The indicator lamp
on the button displays when the switch is ON. Once LEFT POD SWITCH REMOVAL
the switch is ON it will remain ON till one of the fol- (1) To remove left POD switch place tool in the
lowing occurs: hole right of the switch in the cluster bezel below the
(a) The switch is push again. POD switch (Fig. 32). Move tool to lower tab and de-
(b) Ignition is turn off. press. Pull switch out to free lower tab. Move tool up-
(c) Transmission control module will turn it off if ward along the right side of switch to place on the
transmission temperature becomes too high. top tab. Pull down on tab and pull switch out of be-
(4) The rear window defogger operates with a zel.
push-on and push-off momentary action. The switch (2) Disconnect wire connector.
portion of the POD consists of a timer circuit. An am- (3) To install connect wire connector and push
ber indicator on the button shows when the switch is switch into position till tab lock in place.
ON. Once the rear window defogger is ON, the sys-
tem shall remain on until one of the following occurs: RIGHT POD SWITCH REMOVAL
• The switch is actuated again by push-off action. (1) To remove right POD switch place tool in open-
• Ten minutes 62 minutes has elapsed since the ing in the cluster bezel below the POD switch (Fig.
switch has been actuated 33). Move tool to lower tab and depress. Pull switch
(5) Power to the rear passenger compartment out to free lower tab. Move tool upward along the
blower is controlled by the rear A/C header blower right side of switch to place on the top tab. Pull down
switch. The switch operates by a horizontal sliding on tab and pull switch out of bezel.
action. The switch has four clearly defined detent po- (2) Disconnect wire connector.
sitions: (3) For installation connect wire connector and
(a) The left most detent is OFF position. push switch into position till tab lock in place.
Fig. 33 Cluster Bezel Right Side

TEST 1 REAR WIPER SWITCH
(1) Using a voltmeter, with the POD switch wires
connected. Turn ignition switch to the ON position.
Check voltage at Pin G8, with the rear wiper switch
ON. The voltage should be less than 1 volt. If the
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voltage is more than 1 volt, check switch ground cir-

Fig. 31 POD Switch Removal cuit. Repair ground as necessary. If wires are OK, re-
place POD switch.
(2) Disconnect wire connector from POD switch.
Turn wiper switch OFF. Check for battery voltage at
Pin G8. If less than battery, disconnect switch and
test for voltage at Pin G8 of the connector. If voltage
is OK, replace POD switch. If not OK, check for a
open or short circuit in wiring. Repair as necessary.
TEST 2 INDICATOR LED

(1) Apply battery voltage to Pin G4 and ground Pin
G6. Turn rear wiper switch ON. If the indicator does
not light, replace POD switch.
(2) Apply battery voltage to Pin G4 and ground Pin
G3. Turn O/D lockout switch ON. If the indicator
does not light, replace POD switch.
(3) Apply battery voltage to Pin T2 and ground Pin
Fig. 32 Cluster Bezel Left Side G6. Turn front fog lamp switch ON. If the indicator
does not light, replace POD switch.
LEFT POD SWITCH TEST
(1) Remove pod switch, refer to Left POD Switch LIFTGATE RELEASE SWITCH
Removal. Liftgate release switch is located on the steering
(2) Using ohmmeter test continuity between termi- column cover. The liftgate release switch operates
nals, refer to Fig. 34. If no continuity or not within with a push-on momentary action. The switch oper-
limits, replace POD switch. ates a relay to provide power to the liftgate solenoid.
Vehicle must be in Park or Neutral and not moving
RIGHT POD SWITCH TEST for liftgate release switch to operate. The liftgate
(1) Remove switch, refer to Right POD Switch Re- latch switch must also be closed position.
moval
(2) Using a ohmmeter, refer to Fig. 35 for continu- REMOVAL
ity test. If no continuity replace POD switch. (1) Remove steering column cover. For removal
procedures refer to Steering Column Cover Removal.
(2) Disconnect wire connectors and remove cover.
(3) Remove switch.
Fig. 34 Headlamp POD Switch Continuity Test

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A/C AND HEATER CONTROL LAMP REMOVAL

moval.
(2) Remove cigar lighter element.
(3) Remove two screws and pull control assembly
rearward. Reach behind control and disconnect lamp.
REAR A/C-HEATER SWITCH REMOVAL

The rear A/C-heater switch assembly in the left
rear quarter trim panel (Fig. 36).
Fig. 35 Right POD Switch Test

TEST
Using ohmmeter, check for continuity with switch
depressed and no continuity when not depressed.
A/C AND HEATER CONTROL/BLOWER SWITCH

REMOVAL
moval.
(3) Remove two screws and pull control assembly
rearward. Reach behind control and disconnect the
wiring harnesses, vacuum lines and temperature con-
trol cable (Fig. 10). Remove switch.
Fig. 36 Rear A/C Heater Control Switch
(1) Using a trim stick pry switch from left quarter (3) Remove mounting screws from body control
trim panel. module.
(2) Disconnect wiring connector. (4) Pull to the left to release body control module
(3) For installation reverse above procedures. of S-clips and remove unit.
(5) For installation reverse above procedures. En-
CIGAR LIGHTER REMOVAL sure body control module is locked into the S-clips.
moval. DOOR COURTESY LAMP/REFLECTOR
(2) Remove cigar lighter element. REMOVAL
(3) Disconnect wire connectors and lamp/socket (1) Detach door trim panel and all wiring.
from rear of cigar lighter clamp. (2) Remove three screws to remove lamp or reflec-
(4) Hold outer clamp, while turning shell. Do not tor.
lose cigar lighter shield (Fig. 10). (3) For installation reverse above procedures.
DOOR COURTESY LAMP BULB
PREMIUM CONSOLE REMOVAL
REPLACEMENT
(1) Slide cup holder drawer out (Fig. 37).
(1) Use a flat edge tool to pry lens off the lamp as-
sembly. Start at top and bottom forward portion of
lamp lens and move rearward.
(2) Replace bulb.
(3) To install lens press until snap attachments en-
gage.
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DOME LAMP
(1) Pry the lens from bezel.
(2) Replace bulb.
(3) To install lens press until snap attachments en-
gage.
LIFTGATE LAMP BULBS REPLACEMENT

To service liftgate lamp bulb: The lens is part of
speaker grille and cannot be removed separately.
(1) Remove the speaker grille/lamp assembly from
the trim panel by prying with a screwdriver. There
are two slots provided at the lower corners of the
speaker grille.
(2) Disconnect wire connector.
(3) There is an insulator assembly on the back side
Fig. 37 Floor Console Removal of grille. Use a screwdriver in slot provided to pry the
(2) Remove two upper screws. insulator from the grille.
(3) Remove two lower screws at base of console (4) Replace bulb.
and pull unit out. (5) For installation reverse above procedures.
GLOVE BOX LIGHT SWITCH REMOVAL
ASH RECEIVER ASSEMBLY (1) Disconnect battery negative cable and isolate or
(1) Reach behind lower right corner of center bezel remove fuse 3 prior to removing switch or wires may
and pull to disconnect attaching clip. Repeat in of short to ground.
corners and remove bezel. Disconnect ash receiver (2) Pry glove box light switch from the glove box
wire and lamp assembly if equipped. (replace lamp if necessary).
(2) Depress the ash receiver/cupholder assembly (3) Disconnect wire connector.
stops and remove by sliding rearward. (4) For installation reverse above procedures.
BODY CONTROL MODULE REMOVAL TRANSMISSION RANGE INDICATOR

(1) Remove floor console or cover to gain access to REMOVAL
the body control module (Fig. 37). (1) Remove warning indicator grille by prying up
(2) Disconnect the two 25-way connectors from with a flat blade tool.
body control module.
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Fig. 38 Instrument Panel Steering Column Cover

(2) Remove three mounting screws from the warn-
ing indicator module assembly and disconnect wire
connector.
(3) Remove steering column cover (Fig. 38). Set
parking brake and shift gear selector into low.
(4) Remove cluster bezel and disconnect wire con-
nectors
(5) Remove four cluster mounting screws. Rotate
cluster and disconnect connector, to access transmis-
sion range indicator attaching screws. Remove two
screws attaching transmission range indicator to
cluster (Fig. 12).
(6) For electronic instrument cluster if equipped:
(a) Remove four screws securing cluster.
(b) Remove four screws attaching mask to hous-
ing.
(c) Rotate mask down then disconnect buttons
and transmission range indicator.
(d) Remove two screws attaching transmission
range indicator to mask.
(7) Remove cluster.
(8) Unhook transmission range indicator cable eye- Fig. 39 Transmission Range Indicator Release
let from column actuating arm (Fig. 39).
(9) Release column insert lock tab, squeeze legs to-
gether and lift insert from steering column, leave in-
sert free.
(10) Remove transmission range indicator assem-
bly. INSTRUMENT PANEL COMPONENT REMOVAL
• When installing cluster, do not kink or bind trans- STEERING COLUMN COVER REMOVAL
mission range indictor guide tube and position guide (1) Remove left instrument panel silencer.
tube in original location. (2) Disconnect parking hand brake linkage.
(3) Remove five cover attaching screws and lower

cover. Disconnect any wire connectors (Fig. 38).
UPPER RIGHT PANEL REMOVAL
WARNING: DISCONNECT AND ISOLATE THE BAT-

TERY NEGATIVE (GROUND) CABLE BEFORE BE-
GINNING ANY AIRBAG SYSTEM COMPONENT
REMOVAL OR INSTALLATION PROCEDURE. THIS
WILL DISABLE THE AIRBAG SYSTEM. FAILURE TO
DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY. ALLOW SYSTEM CAPACI-
TOR TO DISCHARGE FOR 2 MINUTES BEFORE
REMOVING ANY AIRBAG COMPONENTS. Fig. 40 Glove Box
CAUTION: Disconnect battery negative cable, in en-
gine compartment, before servicing instrument
moval.
panel.
(2) Refer to Lower Right Instrument Panel Re-
moval. (1) Refer to Instrument Panel Cluster Bezel Re-
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(3) Remove passenger airbag module. moval.

(4) Remove eight panel attaching screws. (2) Refer to Lower Right Instrument Panel Re-
(5) For installation reverse above procedures. moval.
(3) Remove lower left instrument panel silencer.
LOWER RIGHT INSTRUMENT PANEL
(4) Remove steering column cover (Fig. 38). Set
REMOVAL
parking brake and shift gear selector into low.
(5) Remove lower left reinforcement.
(2) Remove premium console.
(6) Disconnect transmission range indicator at col-
(3) Remove center trim bezel. Remove ash receiver
umn.
lamp and socket if a equipped. (a) Unhook transmission range indicator cable
(4) Remove A/C heater control (Fig. 10). eyelet from column actuating arm (Fig. 12).
(5) Disconnect cigar lighter. (b) Release column insert lock tab.
(6) Remove screw in air duct. (c) Squeeze legs together and lift insert from
(7) Remove attaching screws and right lower panel steering column, leave insert free.
(Fig. 10). Screw location: (d) Place cable on instrument panel to avoid
• One screw outboard right of lower panel transmission range indicator cable damage during
• Two screws in ash receiver/cupholder opening removal.
• Two screws bottom on the lower right (7) Remove steering column, refer to Group 19,
• One screw in heater duct above heater control Steering.
• Remove glove box attaching screws and disconnect (8) Remove lower right instrument panel silencer
check straps (Fig. 40) (Fig. 10).
• Disconnect glove box lamp (9) Remove premium console or module cover.
(8) For installation reverse above procedures. (10) Remove floor braces.
(11) Remove A-pillar intermediate and sill scuff
INSTRUMENT PANEL REMOVAL garnish moldings.
(12) Unfasten the hood release mechanism from
WARNING: CHOCK WHEELS WHEN INSTRUMENT the side cowl.
PANEL IS TO BE ROLLED DOWN. THE STEERING (13) Disconnect the brake light switch, parking
COLUMN IS REMOVED AND TRANSMISSION MAY brake switch and bulk head wiring connectors.
BE OUT OF PARK. RELEASE THE PARK BRAKE (14) Under the hood disconnect the ABS connector
BEFORE THE RELEASE CABLE IS DISCON- and resistor block. Unseat the grommet at the dash
NECTED. DISCONNECTING PARK BRAKE CABLE panel and feed wiring back into passenger compart-
WHILE PARK BRAKE IS ENGAGED MAY CAUSE ment.
PERSONAL INJURY. (15) Remove the two nuts securing the instrument
panel, at the steering column support brace.
(16) Loosen the instrument panel roll up bolts. (d) Disconnect the vacuum lines from the climate
(17) Remove the six screws securing the instru- control assembly.
ment panel at the fence line. (e) Disconnect the right side body wiring connec-
(18) Roll the instrument panel back and hang it tors.
from the short position of the roll up hook. (21) Remove instrument panel from vehicle.
(19) With instrument panel hanging in the short (22) For installation reverse above procedures.
position disconnect the left side body wiring connec- • When installing cluster, do not kink or bind trans-
tions. mission range indicator guide tube and position
(20) Roll the instrument panel to the long position guide tube in original location.
on the roll up hook and perform the following opera- • Move shift lever to Neutral (N) and note pointer
tions: location. Move shift lever to D, L and P note pointer
(a) Disconnect the antenna cable. location. Adjust, if necessary to center pointer on N.
(b) Disconnect the blower motor lead connection. Refer to Fig. 13 for adjusting procedure.
(c) Disconnect the temperature control cable
from the A/C or heater unit.
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. AUDIO SYSTEM 8F - 1
AUDIO SYSTEM
CONTENTS
page page
AUDIO DIAGNOSTIC TEST PROCEDURES . . . . . 1 MANUAL ANTENNAS . . . . . . . . . . . . . . . . . . . . . 12

CHOKE—INFINITY SPEAKERS . . . . . . . . . . . . . 14 RADIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
COMPACT DISC PLAYER . . . . . . . . . . . . . . . . . . 15 RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMPACT DISC PLAYER REPLACEMENT . . . . . 15 SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS TEST . . . . . . . . . . . . . . . . . . . . . . . 15
RADIOS These ground straps should be securely tightened

For operation of the factory installed standard and to assure good metal to metal contact. Ground straps
optional radios, refer to the Operating Instructions conduct very small high frequency electrical signals
Manual supplied with the vehicle. to ground and require clean large surface area con-
The vehicles is equipped with an Ignition-Off draw tact.
fuse which is removed when the vehicles are origi- Radio resistance type spark plug cables in the high
nally shipped from the factory. The fuse is located in tension circuit of the ignition system complete the in-
the power distribution center. The fuse being re- terference suppression.
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moved helps to prevent battery discharge during If radio noises are evident, be sure the capacitor
storage. For specific wires, connectors and locations, lead wires are making good contact on their respec-
refer to Wiring Diagrams. tive terminals and are securely mounted. Faulty or
This connector is part of the radio memory cir- deteriorated spark plug wires should be replaced.
cuitry and should be checked if the memory of time
or radio station programming is inoperative. AUDIO DIAGNOSTIC TEST PROCEDURES
Whenever a radio malfunction occurs:
INTERFERENCE ELIMINATION
Some components on the vehicle are equipped with (1) Check fuses 3, 6, 9 in the fuse block and IOD
a radio capacitor, to suppress radio frequency inter- fuse in the power distribution center.
ference (static). • Fuse 3, Power amplifier
Capacitors are mounted in various locations, on the • Fuse 6, Ignition feed
generator (either internal or external), internal to the • Fuse 9, Illumination
instrument cluster, and internal to the windshield • Fuse IOD, Memory feed
wiper motor. (2) Verify that the radio wire harness is properly
Ground straps are mounted from: connected to all connectors before starting normal di-
• Radio chassis to panel reinforcement bracket agnosis and repair procedures. Refer to Audio Diag-
• Engine to cowl nostic Charts and/or Radio Connector Circuit Chart
• Across engine mount on right hand side (Fig. 1).
• On vehicles with air conditioning there is a strap
from evaporator valve to cowl
8F - 2 AUDIO SYSTEM .
AM/FM STEREO—CASSETTE TAPE

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AM/FM STEREO CONTINUED

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INFINITY
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INFINITY CONTINUED
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INFINITY CONTINUED
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INFINITY CONTINUED
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INFINITY CONTINUED
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Fig. 1 Radio Connector Circuit

RADIO REMOVAL PROCEDURES

(1) To remove top cover use a flat blade tool. Pry
of the top cover.
Fig. 3 Bezel Grille Removal

(6) Remove two screws and pull radio rearward.
Fig. 2 Bezel Grille Removal Tool Reach behind radio and disconnect the wiring har-
(3) Remove six mounting screws from the hood and nesses and ground cable. Remove radio unit.
message center assembly. Using a flat blade tool pry (7) For installation reverse above procedures.
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up on either end and remove module and disconnect

wire connector. MANUAL ANTENNAS
(4) Reach behind lower right corner of center bezel
and pull to disconnect attaching clip. Repeat in all of TESTING
the corners and remove bezel. Disconnect ash re- Antenna performance may be tested by substitut-
ceiver wire and lamp assembly if equipped (Fig. 4). ing a known good antenna. It is also possible to
Fig. 4 Radio and Front Speaker Removal

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Fig. 5 Radio Antenna Cable

check short or open circuits with an ohmmeter or
continuity light once the antenna cable is discon-
nected from the radio as follows:
(1) Continuity should be present between the an-
tenna mast and radio end pin of antenna cable plug
(Fig. 5).
(2) No continuity should be observed between the
ground shell of the connector and radio end pin.
(3) Continuity should be observed between the
ground shell of the connector and the mounting hard-
ware on the vehicle fender.
REMOVAL
(1) Remove side cowl cover and disconnect antenna Fig. 6 Antenna Mast Removal & Installation
cable by pulling apart. (2) Install adapter and cap nut. Tighten cap nut to
(2) Remove antenna mast by unscrewing mast 14 Nzm (125 in. lbs.) torque with Antenna Nut Wench
from antenna body (Fig. 6). C-4816.
(3) Remove cap nut with Antenna Nut Wrench (3) Install antenna mast into antenna body until
C-4816 (Fig. 7). sleeve bottoms on antenna body.
(4) Remove antenna adapter (Fig. 7). (4) Route cable through body hole, make sure the
(5) From under fender remove antenna lead and grommet is seated to the body plug in cable to con-
body assembly (Fig. 5). nector.
INSTALLATION BENCH TEST FOR ANTENNA MALFUNCTION
(1) Install antenna body and cable from under- It is also possible to check short or open circuits
neath fender (Fig. 5). with an ohmmeter or continuity light once the an-
tenna has been removed from the vehicle.
FRONT DOOR SPEAKERS REPLACEMENT

(1) Carefully pry at top outboard corners of grille
with a blunt edge pry tool to disengage two clips.
(2) Pull top of grille rearward and lift up to disen-
gage two plastic hooks on grille from door trim panel.
(3) Remove four speaker mounting screws. Lift up
speaker and disconnect wire connector. Remove
speaker.
REAR SPEAKERS REPLACEMENT

(1) Carefully pry outward in two slots located
along bottom edge of grille to disengage two clips.
(2) Pull bottom edge away from trim and down to
disengage two plastic hooks on grille from trim
panel.
(3) Remove wire connector if grille is equipped
Fig. 7 Removing or Tightening Antenna Cap Nut with integral courtesy lamp.
(1) Continuity should be present between the tip of (4) Remove four screws attaching speaker to door
the mast and radio end pin (Fig. 8). (Fig. 9).
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Fig. 8 Antenna Bench Test Points

(2) No continuity should be observed between the
ground shell of the connector and radio end pin.
(3) Continuity should be observed between the
ground shell of the connector and the mounting hard-
ware.
Wiggle cable over its entire length to reveal
intermittent short or open circuits during steps
(1), (2) and (3).
SPEAKERS Fig. 9 Rear Speaker System

FRONT INSTRUMENT PANEL SPEAKER (5) Disconnect speaker wire connector and remove
REPLACEMENT speaker.
(1) To remove top cover use a flat blade tool. Pry (6) For installation reverse above procedures.
of the top cover (Fig. 4). RELAY
(2) Remove two screws that retain the speaker. Relay is located in the relay bank (Fig. 10). To test
(3) Remove the speaker and disconnect the wiring relay refer to Audio Diagnostic Test Procedures or
connector. use a known good relay.
When installing grille, ensure that all forward clips CHOKE—INFINITY SPEAKERS
engage before setting rear edge in to place. If the audio system is lacking bass response, check
for continuity across relay and choke connectors. If
no continuity Replace Radio Choke (Fig. 11). The
COMPACT DISC PLAYER
DIAGNOSIS TEST
Refer to Audio Diagnostic Test Procedures.
COMPACT DISC PLAYER REPLACEMENT

Refer to Radio Removal Procedures
Fig. 10 Relay Bank

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Choke is located under the left side of the Instru-

ment Panel on the relay bank and choke bracket.
Fig. 11 Choke—Infinity Speaker

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. HORNS 8G - 1
HORNS
CONTENTS
page page
DIAGNOSIS TESTING . . . . . . . . . . . . . . . . . . . . . 2 HORNS SOUND CONTINUOUSLY . . . . . . . . . . . . 1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 HORNS WILL NOT SOUND . . . . . . . . . . . . . . . . . 1
HORN SWITCH REPLACEMENT . . . . . . . . . . . . . 2
GENERAL INFORMATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
STEERING WHEEL OR COLUMN REMOVAL PROCE-
DURES.
The horn circuit consists of a horn switch, horn re-

lay, and horns (Fig. 1). On all models the relay plugs
into the relay bank. The horn circuit feed is from the
fuse box to the number 1 terminal on the horn relay.
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When the horn switch is depressed, this completes

the ground. A set of contacts in the horn relay closes,
which allows current to flow to the horn(s).
Fig. 2 Horn and Connector

relay in the circuit. If the test lamp illuminates when
depressing the horn switch, the original relay is de-
fective. Also, listen for the relay to click, when the
horn button is depressed. If the relay clicks the bat-
tery feed to the relay and horn switch circuit is OK.
If the lamp fails to illuminate with a known good re-
lay, unplug that relay. Connect a jumper wire from
the battery terminal to the horn terminal on the re-
Fig. 1 Horn System lay terminal board (Fig. 3). If the lamp connected in
place of the horns fails to illuminate, an open circuit
HORNS WILL NOT SOUND in the wiring between the relay terminal and the
If the horns do not sound, check for a blown horn horn or between the fuse and relay is at fault.
fuse in the fuse block. If the fuse is blown, replace it If the lamp illuminates, horn switch is defective or
with the same type fuse. If the fuse blows immedi- an open circuit in the wiring between the relay ter-
ately there is a short between the fuse and horn re-
minal and the horn switch is at fault.
lay. The fuse blows when depressing the switch, a
short circuit in the horn or wiring between the horn
HORNS SOUND CONTINUOUSLY
relay and the horn is responsible.
If the fuse is good, disconnect wire connector at CAUTION: Continuous sounding of horns may
horn. Using an test lamp, connect one lead to the cause relay to fail.
negative terminal and the other to the positive ter-
minal (Fig. 2). Depress the horn switch, the test If the horns sound continuously, unplug the horn
lamp should illuminate. If not, move the test lamp relay from the relay bank inside the passenger com-
ground wire to a good ground and depress the horn partment. Plug in a known, good relay. If the horns
switch. If test lamp lights inspect ground wire circuit stop blowing, relay is defective and must be replaced.
and repair as needed.
Should the horn’s still sound, proceed as follows:
If the test lamp fails to illuminate, check for a de-
fective horn relay. Substituting a known good horn
8G - 2 HORNS .
Fig. 3 Testing for an Open Circuit

Fig. 4 Testing for Short to Ground
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(1) Connect one voltmeter lead to battery terminal

on relay board and the other lead to switch terminal RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
(Fig. 4). AND POSSIBLE PERSONAL INJURY.
(2) Voltmeter will register battery voltage when
the wire to the horn switch is shorted to ground or (1) Disconnect isolate battery negative cable in en-
the horn switch is defective. gine compartment.
Remove steering wheel horn pad and disconnect (2) Remove four retaining nuts from back of steer-
wire from horn switch. Repeat the above test and if ing wheel. Remove airbag module (Figs. 6 and 7).
the test lamp still illuminates, wire is shorted and (a) Disconnect wire from rear of airbag module.
should be repaired. If test lamp does not illuminate, (b) Place airbag module on a clean level surface
horn switch is defective and must be replaced. with pad facing upward.
(3) Remove horn switch assembly from steering
DIAGNOSIS TESTING wheel.
Horn does not sound, horn sounds intermittently, (a) On high line steering wheel (Fig. 6), pry out
or horn sounds continuously go to Horn Diagnosis two trim cover buttons on back of steering wheel to
Chart (Fig. 5). access retaining screws for the horn switch. The
low line steering wheel (Fig. 7) the horn screws are
HORN SWITCH REPLACEMENT accessible after the Airbag is removed.
(b) Remove two screws and disconnect horn
WARNING: BEFORE BEGINNING ANY AIRBAG SYS- wires located in the lower portion of steering
TEM REMOVAL OR INSTALLATION PROCEDURES, wheel. Feed wires through the access ports and re-
REMOVE AND ISOLATE THE BATTERY NEGATIVE move horn switch.
CABLE (GROUND) FROM THE VEHICLE BATTERY. (4) For installation reverse the above procedures.
THIS IS THE ONLY SURE WAY TO DISABLE THE Use caution not to pinch wires.
AIRBAG SYSTEM. FAILURE TO DO THIS COULD
. HORNS 8G - 3
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Fig. 5 Horn Diagnosis

8G - 4 HORNS .
Fig. 6 High Line Steering Wheel

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Fig. 7 Low Line Steering

. VEHICLE SPEED CONTROL SYSTEM 8H - 1
VEHICLE SPEED CONTROL SYSTEM
CONTENTS
page page
CHECKING FOR MALFUNCTION CODE . . . . . . . . 5 SERVO ELECTRICAL TESTS . . . . . . . . . . . . . . . . 5

DIAGNOSIS PROCEDURES . . . . . . . . . . . . . . . . . 2 SERVO UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ELECTRICAL TEST: . . . . . . . . . . . . . . . . . . . . . . . 5 SERVO VACUUM TEST . . . . . . . . . . . . . . . . . . . . 8
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 SPEED CONTROL SWITCH . . . . . . . . . . . . . . . . . 8
INOPERATIVE SYSTEM . . . . . . . . . . . . . . . . . . . . 2 SPEED CONTROL SWITCH TEST . . . . . . . . . . . . 7
POWERTRAIN CONTROL MODULE ELECTRICAL STOP LAMP/VEHICLE SPEED CONTROL
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
The speed control system is electronically con-
trolled and vacuum operated. The electronic control
is integrated into the powertrain control module, lo-
cated next to battery. The controls are located on the
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steering wheel and consist of the ON/OFF, RESUME/

ACCEL and SET/DECEL buttons (Fig. 1). For identi-
fication and location of the major components (Figs. 2
through 4).
Fig. 2 Speed Control System—2.5L

TO ACTIVATE:
Place the ON/OFF button in the depressed latched
position ON. The speed control system is now ready
Fig. 1 Speed Control Switch for use.
The system is designed to operate at speeds above
35 mph (50 km/h). TO SET SPEED:
When the vehicle has reached the desired speed
WARNING: THE USE OF SPEED CONTROL IS NOT push the SET/DECEL button to engage system
RECOMMENDED WHEN DRIVING CONDITIONS DO which, will then automatically maintain the desired
NOT PERMIT MAINTAINING A CONSTANT SPEED, speed.
SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
ARE WINDING, ICY, SNOW COVERED, OR SLIP- TO DECELERATE:
PERY. When speed control is engaged, holding the SET/
DECEL button depressed allows the vehicle to coast
to a lower speed setting.
8H - 2 VEHICLE SPEED CONTROL SYSTEM .
TO RESUME:
After disengaging the speed control system by tap-
ping the brake pedal or clutch pedal, push the RE-
SUME/ACCEL button to return vehicle to the
previously set speed.
TO ACCELERATE:
While speed control is engaged, hold the RESUME/
ACCEL button depressed and release at a new de-
sired speed. This will allow the vehicle to accelerate
and set at a higher speed setting.
TAP-UP:
When the speed control system is engaged, tapping
the RESUME/ACCEL button will increase the speed
setting by 2 mph (3 km/h). The system will respond
to multiple tap-ups.
TO ACCELERATE FOR PASSING:

Depress the accelerator as you would normally.
When the pedal is released the vehicle will return to
the speed setting in memory.
Fig. 3 Speed Control System—3.0L
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DIAGNOSIS PROCEDURES
Whenever a speed control malfunction occurs, first
verify that the speed control wire harness is properly
connected to all connectors before starting normal di-
agnosis and repair procedures. Refer to Electronic
Speed Control System Diagnosis Chart or Speed Con-
trol Circuit (Fig. 5).
A poor connection can cause a complete or intermit-
tent malfunction and is also the only connection in
the circuit, that cannot be tested. For this reason, a
loose connection may be misdiagnosed as a compo-
nent malfunction.
Also, check all vacuum connections for tightness
and cracked hoses.
ROAD TEST
Road test vehicle to verify reports of speed control
system malfunction. The road test should include at-
tention to the speedometer. Speedometer operation
should be smooth and without flutter at all speeds.
Flutter in the speedometer shows a problem which,
might cause surging in the speed control system. The
cause of any speedometer deficiencies should be cor-
Fig. 4 Speed Control System—3.3L rected before proceeding.
TO DEACTIVATE:
A soft tap of the brake pedal, normal brake appli- INOPERATIVE SYSTEM
cation or depressing the clutch pedal while the sys- If road test verifies an inoperative system with a
tem is engaged will disengage speed control without correct speedometer operation:
erasing memory. A sudden increase in engine rpm • Inspect fuse
may be experienced if the clutch pedal is depressed • Check for loose electrical and vacuum connections
at the servo
while the speed control system is engaged. Pushing
• Check for correct position of the vacuum check
the ON/OFF button to the unlatched position or turn-
valve in the hose from servo to vacuum source. The
ing off the ignition erases the memory.
word VAC on the valve must point toward the vac-
uum source.
SYSTEM DIAGNOSIS
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SYSTEM DIAGNOSIS—CONTINUED
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nents refer to the Powertrain Diagnostics Test Proce-

dure Manual.
(4) Correct any problems found when performing
these tests and recheck for Malfunction Code if
changes were made.
(5) If no problems were found above, replace pow-
ertrain control module.
ELECTRICAL TEST:
Electronic speed control systems may be tested us-
ing two different methods. One involves use of a
DRB. If this test method is desired, please refer to
the Powertrain Diagnostic Test Procedures for charg-
ing and speed control system manual.
The other test method uses a volt/ohm meter and is
described in the following tests.
If any information is needed concerning wiring, re-
fer to Group 8W, Wiring Diagrams.
CAUTION: When test probing for voltage or conti-

nuity at electrical connectors, care must be taken
Fig. 5 Speed Control Circuit not to damage connector, terminals, or seals. If
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these components are damaged, intermittent or

• Inspection also should be made to verify that both
complete system failure may occur.
ends of the speed control cable are securely attached.
If either end is loose, the speed control system will be
inoperative. SERVO ELECTRICAL TESTS
CHECKING FOR MALFUNCTION CODE WARNING: ON VEHICLES EQUIPPED WITH AIR-
(1) When trying to verify a speed control system BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
electronic malfunction: AIRBAG, STEERING WHEEL OR COLUMN RE-
(a) Connect a DRB if available. MOVAL PROCEDURES.
(b) Plug DRB into the diagnostic connector in the
engine compartment. (1) Turn ignition switch to the ON position. With
(c) Check that either a Function Code 34 or 15 is the speed control switch in the ON position, set up a
shown. voltmeter to read battery voltage and connect the
(d) An inoperative speed control may still occur negative lead to a good chassis ground.
without either malfunction code being shown. (2) Disconnect the four-way connector going to the
(e) If DRB is not available perform steps f and g. servo (Fig. 6). Test pin 3 of the main harness four-
(f) With key inserted in ignition switch, cycle way connector for battery voltage. If not OK go to
switch to ON position three times. On third cycle, step 3. If voltage is OK go to step 4.
leave switch in ON position. (3) Perform the following tests.
(g) After switch has been cycled three times, ob- (a) Disconnect the six-way connector at the stop
serve Malfunction Indicator (CHECK ENGINE) lamp switch and test pin 3 of the main harness for
lamp on instrument cluster. If a Malfunction Code battery voltage. If voltage is OK perform the stop
is present, the indicator will flash (blink) in a se- lamp switch test. Refer to Stop Lamp Speed Con-
ries and will show which Malfunction Code is the trol Switch Test.
problem. EXAMPLE: A series of three flashes in (b) If the stop lamp switch tests OK; repair wire
rapid succession, a slight pause, then four flashes between the servo and the stop lamp switch.
in rapid succession would show a Malfunction Code (c) If no voltage at pin 3 at the 6-way stop lamp
34. connector, remove the speed control switch and dis-
(2) If no Malfunction Code appears, or Malfunction connect the four-way connector. Test pin 1 of main
Code 34 is observed, refer to: harness for battery voltage.
• The Servo Electrical Test. (d) If voltage is OK perform the speed control
• The Powertrain Control Module Electrical Test. switch test. Refer to Stop Lamp Speed Control
(3) If a malfunction code 15 is observed, test vehi- Switch Test.
cle speed sensor. (e) If speed control switch is OK, test continuity
For testing vehicle speed sensor and related compo- across the clockspring.
Fig. 7 Powertrain Control Module and Connector

Location
Fig. 6 Servo Harness Connector
(3) Using an ohmmeter test continuity between pin
(f) If clockspring OK, repair as required, wire be- 23 of powertrain control module and pin 4 of the
tween stop lamp switch and clockspring. speed control switch harness. Refer to Fig. 8 for mod-
(g) If no voltage at pin 1 of the 4-way speed con- ule terminal locations.
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trol switch connector.

• Test for battery voltage between the ignition and
the fuse
• If voltage OK, check fuse
• If fuse OK, repair wire between fuse and clock-
spring
(4) Connect a jumper wire between pin 3 of the
four-way servo connector of the main harness and
pin 3 of the speed control servo (Fig. 6). The other
three pins from the servo should show battery volt-
age. If not, replace the servo.
(5) Using an ohmmeter, connect one lead to a good Fig. 8 Powertrain Control Module 60-Way Connector
body ground. With the other lead touch pin 4 in the Shown from Terminal End
four-way servo connector of the main harness.The (a) If no continuity, repair wire circuit as neces-
meter should show continuity. If not, repair the sary.
ground circuit as necessary. (b) Continuity OK, refer to Speed Control Switch
Test.
POWERTRAIN CONTROL MODULE ELECTRICAL (4) Connect the 4-way connector to speed control
TEST switch.
(5) Connect negative lead of voltmeter to a good
WARNING: ON VEHICLES EQUIPPED WITH AIR- body ground near the powertrain control module.
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR (6) Turn ignition switch ON.
AIRBAG, STEERING WHEEL OR COLUMN RE- (7) Place speed control switch in the OFF position.
MOVAL PROCEDURES. Touch the positive lead of the voltmeter to pin 53, the
voltmeter should read 0 volts.
(1) Unplug 60-way connector from the powertrain
(8) Place speed control switch in the ON position.
control module, located next to the battery (Fig. 7).
Touch the positive lead of the voltmeter to pin 53, the
(2) Remove speed control switch. Refer to Speed
voltmeter should read battery voltage.
Control Switch Removal. Disconnect the 4-way con-
(9) If voltage is OK go to step 10. If no voltage,
nector.
check for voltage at pin 2 of the speed control servo
(Fig. 6). If no voltage perform servo electrical test. If
voltage OK, repair wire between pin 5 of powertrain
control module and pin 2 of the servo.
(10) Place speed control switch in the OFF posi-

tion. Touch the positive lead of the voltmeter to pin
33, voltmeter should read 0 volts.
(11) Place speed control switch in the ON position.
Touch the positive lead of the voltmeter to pin 33, the
voltmeter should read battery voltage.
(12) If voltage is OK go to step 13. If no voltage,
check for voltage at pin 1 of the servo. If no voltage,
perform servo electrical test. If voltage OK, repair
the wire between pin 33 and pin 1 of the speed con-
trol servo (Fig. 6).
(13) Using an ohmmeter, connect one lead to a
good body ground and touch the other lead to pin 29.
With the brake pedal released, the meter should
show continuity. When the pedal is depressed, the
meter should show no continuity. If no continuity
perform the following test:
(a) Using an ohmmeter test continuity between
pin 29 of powertrain control module and pin 1 of
the stop lamp switch connector.
(b) If no continuity, repair as necessary.
(c) If continuity, refer to Stop Lamp Switch Test. Fig. 9 Speed Control Switch Continuity
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(d) If stop lamp switch test OK, Test continuity

between pin 2 of stop lamp switch and ground.
(14) Using an ohmmeter, touch one lead to a good
body ground and touch the other lead to pin 30. The
meter should show no continuity when transmission
is in DRIVE and continuity when in PARK or NEU-
TRAL. If not test Neutral Start and Back-Up switch
using DRB.
SPEED CONTROL SWITCH TEST

WARNING: IF REMOVAL OF AIRBAG MODULE IS
NECESSARY, REFER TO GROUP 8M, RESTRAINT
SYSTEMS.
(1) Remove the switch and disconnect 4-way con-

nector.
(2) Using an ohmmeter, test continuity at the four Fig. 10 Stop Lamp and Vehicle Speed Control
pins of the speed control switch. Refer to Speed Con- Switch Wiring
trol Switch Continuity (Fig. 9). (2) If the above results are not obtained, the stop
(3) If there is no continuity or incorrect continuity lamp switch is defective or out of adjustment.
at any one of the switch positions, replace the switch. (3) Stop lamp switch adjustment is detailed in
Group 5, Brakes.
STOP LAMP/VEHICLE SPEED CONTROL SWITCH
TEST VACUUM SUPPLY TEST
(1) Remove the stop lamp/speed control switch. (1) Disconnect vacuum hose at the servo and in-
Disconnect connector from stop lamp switch (Fig. 10). stall a vacuum gauge in the hose (Fig. 11).
Using an ohmmeter, switch continuity may be (2) Start engine and observe gauge at idle. Vacuum
checked as follows: gauge should read at least ten inches of mercury.
(a) With switch plunger released, there should be Shut off engine, the vacuum should continue to hold
continuity between pin 5 and pin 6. 10 inches of mercury.
(b) With switch plunger depressed, there should (3) If vacuum does not meet this requirement,
be continuity: check and correct the following vacuum leaks:
• Between pin 1 and pin 2. • Vacuum lines
• Between pin 3 and pin 4. • Check valve
(5) Pull cable away from servo to expose retaining

clip and remove clip attaching cable to servo.
INSTALLATION
(1) With throttle in full open position align hole in
speed control cable sleeve with hole in servo pin and
install retaining clip.
(2) Connect vacuum hose to servo.
(3) Connect electrical connector.
(4) Position mounting bracket and install screws
attaching bracket. Tighten screws to 12 Nzm (105 in.
lbs.) torque, if mounted to shock tower 5 Nzm (45 in.
lbs.) torque.
(5) Insert servo studs through holes in speed con-
trol cable and mounting bracket.
(6) Install nuts, tighten to 7 Nzm (60 in. lbs.)
torque.
SPEED CONTROL SWITCH

The speed control switch is mounted in the steering
Fig. 11 Vacuum Gauge Test wheel and wired through the clock spring device un-
der the steering wheel hub (Fig. 1).
• Vacuum reservoir
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• Servo Vacuum, refer to Servo Vacuum Test WARNING: IF REMOVAL OF AIRBAG MODULE IS
• Poor engine performance.
NECESSARY, REFER TO GROUP 8M, RESTRAINT
SYSTEMS.
SERVO VACUUM TEST
(1) Remove the speed control cable at the throttle
body end. REMOVAL
(2) Disconnect the 4-way electrical connector and (1) Turn off ignition.
the vacuum harness at the servo (Refer to Fig. 6). (2) Remove two (2) screws from back side of steer-
(3) Connect battery voltage to pin 2 of the servo. ing wheel.
(4) Ground the remaining three servo pins 1, 3 and (3) Rock switch away from airbag or horn pad
4. while lifting switch out of steering wheel.
(5) Connect a hand held vacuum pump to the servo
(4) Disconnect 4-way electrical connector.
vacuum nipple and apply 10 to 15 inches of vacuum.
(6) The cable should pull in and hold for as long as INSTALLATION
vacuum is applied. (1) Turn off ignition.
(2) Connect 4-way electrical connector from clock
SERVO UNIT spring to switch.
REMOVAL (3) Place switch in steering wheel, sliding the for-
(1) Remove two nuts attaching speed control cable ward edge of switch under airbag or horn pad. Line
and mounting bracket to servo. up locating pins on switch with holes in steering
(2) Remove screws attaching servo mounting wheel frame.
bracket. (4) Attach switch to wheel with two screws start-
(3) Remove servo mounting bracket. ing with the screw at the left end of the switch.
(4) Disconnect electrical connectors and vacuum
hose.
. TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 1
TURN SIGNALS AND HAZARD WARNING FLASHER
CONTENTS
page page
CHIME FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

ELECTRONIC COMBINATION FLASHER . . . . . . . 3 HAZARD WARNING SWITCH . . . . . . . . . . . . . . . 1
FLASHER SYSTEM DIAGNOSIS . . . . . . . . . . . . . 3 MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION HAZARD WARNING SWITCH

Refer to Group 8E, Instrument Panel, Headlamp
WARNING: ON VEHICLES EQUIPPED WITH AIR- Switch.
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
AIRBAG REMOVAL PROCEDURES. CHIME FUNCTION
If the turn signals are left ON, the chime will
The turn signals are apart of the multi-function
sound after the vehicle has traveled a distance of 1.0
switch. The switch contains the turn signal, head-
miles at a speed above 15 miles per hour.
lamp beam select, headlamp optical horn, windshield
wiper, pulse wipe and windshield washer controls.
The integrated switch is mounted on the left side of
MULTI-FUNCTION SWITCH
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the steering column. The driver moves the lever up- The multi-function switch contains:
ward for the right signal and downward for the left • Electrical circuitry for turn signal
signal to flash. After completion of a turn the system • Headlamp beam select
is canceled automatically. • Headlamp optical horn
If only momentary signaling such as indication of a • Windshield wiper
lane change is desired, the switch is actuated to a • Pulse wipe
left or right intermediate detent position. In this po- • Windshield washer switching
sition the signal lamps flash as described above, but This integrated switch assembly is mounted to the
the switch returns to the OFF position as the lever is left hand side of the steering column. If any function
released. of the switch fails, the entire switch assembly must
Activate the system and the indicator lamps will be replaced. Refer to Fig. 1 for diagnosis.
flash in unison with the turn signal lamps. This
shows that the system is operating.
8J - 2 TURN SIGNALS AND HAZARD WARNING FLASHER .
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Fig. 1 Turn Signal and Hazard Warning Flasher Diagnosis

. TURN SIGNALS AND HAZARD WARNING FLASHER 8J - 3
SWITCH TEST
(1) Disconnect the battery negative cable.
(2) Remove the upper and lower column covers to
gain access to the switch connector.
(3) Remove switch connector.
(4) Using an ohmmeter, test for continuity between
the terminals of the switch as shown in the following
continuity charts (Figs. 2 and 3).
Fig. 4 Multi-Function Switch

INSTALLATION
(1) Install wiring connector to switch and tighten
connector retaining screw to 2 Nzm (17 in. lbs.)
torque.
(2) Mount multi-function switch to column and
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tighten retaining screws to 2 Nzm (17 in. lbs.) torque.

(3) Install steering column covers. Tighten retain-
Fig. 2 Turn Signal Continuity ing screws to 2 Nzm (17 in. lbs.) torque.
(4) Tilt column only, install the tilt lever.
(5) Connect battery negative cable.
(6) Check the switch functions for proper opera-
tion.
ELECTRONIC COMBINATION FLASHER

The module provides both turn signal and hazard
flasher operation. The flasher plugs into the lower
left corner of relay bank to the left of the fuse block.
To gain access to the flasher, remove the lower steer-
ing column cover. The flash rate for the turn signal
and hazard warning flasher for any number of lamps
is constant with all lamp working. Depending on ex-
act current draw of lamps, there should be between
60 and 120 flashes per minute. If a lamp or circuit to
a lamp is open, the flash rate for that side of the ve-
Fig. 3 Beam Select Switch Continuity hicle will double for the turn signal. The turn signal
(5) If reading are incorrect, replace switch. and hazard warning functions are on separate fuses
and cartridge fuses (Fig. 5).
REMOVAL
(1) Disconnect battery negative cable. FLASHER SYSTEM DIAGNOSIS
(2) Tilt column only remove tilt lever. (1) Hazard warning and turn signal flasher are not
(3) Remove both upper and lower steering column working (Fig. 6):
covers. • Check electronic combination flasher
(4) Remove multi-function switch tamper proof • Check both fuses
mounting screws (Fig. 4). • Check cartridge fuse
(5) Gently pull switch away from column and • Check Hazard warning switch in the left POD
loosen connector screw. The screw will remain in the • Check multi-function switch
connector. • Check wiring
(6) Remove wiring connector from multi-function • Repair as necessary
switch. • Confirm proper operation
8J - 4 TURN SIGNALS AND HAZARD WARNING FLASHER .
• Identify any non-flashing lamp

• Check and replace any defective lamp. If lamp is
OK, repair wiring to lamp as required.
• Hazard warning flasher is not operating at all,
check fuse or wiring. Repair as necessary.
• Confirm proper operation. If OK, go to step 3.
(3) The hazard warning flasher system is operating
properly:
• Turn OFF hazard warning flasher switch
• Turn ignition switch ON
• Actuate the turn signal lever to both right and left
sides to confirm proper operation of lamps for each
side.
• Check and replace any defective lamp. If lamp is
OK, repair wiring to lamp as required.
• Confirm proper operation. If not go to step 4.
(4) If hazard warning flasher system is OK and the
turn signal is not operating properly:
• Turn signal appears to be defective to the front
lamps, problem maybe in the turn signal, hazard
warning switch or wiring.
Fig. 5 Relay Bank • Turn signal is not operating at all, check the turn
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signal, hazard warning switch, fuses or wiring. Re-

(2) Actuate hazard warning flasher switch, located
pair as necessary.
in headlamp POD switch.
• Confirm proper operation
• Observe lamps for proper operation
Fig. 6 Combination Flasher Schematic Diagram

. WINDSHIELD WIPER AND WASHER SYSTEMS 8K - 1
WINDSHIELD WIPER AND WASHER SYSTEMS
CONTENTS
page page
INTERMITTENT WINDSHIELD WIPER MOTOR WINDSHIELD WASHERS . . . . . . . . . . . . . . . . . . . 9

AND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 8 WINDSHIELD WIPER BLADE AND ARM . . . . . . . 1
REAR WINDOW WIPER/WASHER SYSTEM . . . 11 WINDSHIELD WIPER MOTOR AND LINKAGE . . . 4
WINDSHIELD WIPER BLADE AND ARM
INDEX
page page
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1 Wiper Blade Element Change Replacement . . . . . . . 3
Wiper Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . . 3
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Wiper Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiper Arm Replacement . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION The wiper motor has permanent magnetic fields.

The speeds are determined by current flow to the ap-
WARNING: ON VEHICLES EQUIPPED WITH AIR- propriate set of brushes.
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR The intermittent wipe system has a low and high
STEERING WHEEL OR COLUMN REMOVAL PROCE- speed with a delay mode. The delay mode has a
DURES. range of 2 to 20 seconds. This is done by a variable
resistor in wiper switch and is controlled electrically
The windshield wipers can be operated with the
by a relay in the body control module.
windshield wiper switch only when the ignition
The wiper system completes the wipe cycle when
switch is in the ACCESSORY or IGNITION position.
the switch is turned OFF. The blades park in the
A fuse located in the fuse block protects the circuitry
lowest portion of the wipe pattern (Fig. 1).
of the wiper system and the vehicle.
8K - 2 WINDSHIELD WIPER AND WASHER SYSTEMS .
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Fig. 1 Windshield Wiper System

WIPER BLADES • Check each release point for positive locking when
Wiper blades exposed to the weather for a long pe- installing blade element and blade assembly on vehi-
riod of time tend to lose their wiping effectiveness. cle.
Periodic cleaning of the wiper blade is suggested to
remove the accumulation of salt and road film. The WIPER ARM REPLACEMENT
wiper blades, arms and windshield should be cleaned (1) Lift the arm to permit the latch (Fig. 4) to be
with a sponge or cloth and a mild detergent or non- pulled out to the holding position then release the
abrasive cleaner. If the blades continue to streak or arm. The arm will remain off the glass in this posi-
smear, they should be replaced. tion.
WIPER BLADE ELEMENT CHANGE REPLACEMENT

(1) Turn wiper switch ON, position blades to a con-
venient place by turning the ignition switch ON and
OFF.
(2) Lift wiper arm to raise blade off glass.
(3) Remove blade assembly from arm. Insert a
small screwdriver tip between the latch and arm to
depress latch (Fig. 2). Pull blade assembly toward
the wiper pivot to release from J hook attachment.
Fig. 4 Removing Wiper Arm
(2) Remove the arm from the pivot by using a rock-
ing motion.
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(3) Set arm on pivot and push down.

(4) Lift arm and push latch in to release arm to
windshield.
• Short wiper arm is on the driver side
• Longer wiper arm is on the passenger side
(5) For proper alignment of wiper arm, refer to
Wiper Arm Adjustment.
Fig. 2 Wiper Blade and Element WIPER ARM ADJUSTMENT

(1) Cycle the wiper motor into the PARK position.
(4) Remove wiping element from blade assembly.
(2) Check the tips of the blades in blackout area
(a) Grasp rubber element where channel is rub-
(Fig. 5). The arms should positioned so that the blade
ber.
is:
(b) Pull rubber element and vertibra out for re-
• left side is 50 to 90 mm (2 to 2 1/2 in.)
placement (Fig. 3).
Right side is 20 to 60 mm (3/4 to 2 3/8 in.)
Fig. 3 Wiper Blade and Element Fig. 5 Windshield Wiper Arm Adjustment
(5) For installation reverse above procedures. (3) Operate the wipers if the requirements are not
• Driver side blade assembly is 22 inches long met, check linkage and pivot assembly for worn
• Passenger side blade assembly is 18 inches long parts.
WINDSHIELD WIPER MOTOR AND LINKAGE
INDEX
page page
Motor Tests .............................. 4 Wiper Motor Replacement . . . . . . . . . . . . . . . . . . . . 7
WARNING: ON VEHICLES EQUIPPED WITH AIR- (c) If no noticeable increase greater than 3 volts
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR is observed, the problem is a faulty motor assem-
STEERING WHEEL OR COLUMN REMOVAL PROCE- bly.
DURES. (5) Disconnect motor wiring connector and replace
fuse. Place wiper switch in all positions.
The following is a list of general wiper motor sys- (a) If fuse does not blow, motor is defective.
tem problems. The tests are to be performed to locate (b) If fuse blows, switch or wiring is at fault.
the faulty part and the corrective action to be taken.
These tests will cover both two speed and intermit- CONDITION: MOTOR RUNS SLOWLY AT ALL
tent wipe functions, refer to Windshield Wiper Motor SPEEDS
Diagnosis (Fig. 6).
REPAIR
MOTOR TESTS (1) Disconnect wiring harness connector at motor.
Remove wiper arms and blades. Connect an ammeter
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CONDITION: MOTOR WILL NOT RUN IN ANY

SWITCH POSITION between battery (B+) and terminal 3 on motor (Fig.
8).
REPAIR (a) If motor runs and average ammeter reading
(1) Check for a blown fuse in the fuse block. is more than 6 amps, go to step 2.
(a) If fuse is good, go to step 2. (b) If motor runs and average ammeter reading
(b) If fuse is defective, replace and check motor is less than 6 amps, go to step 3.
operation in all switch positions. (2) Check to see if wiper linkage or pivots are bind-
(c) If motor is still inoperative and the fuse does ing or caught. Disconnect drive link from motor.
not blow, go to step 2. (a) If motor now runs and draws less than 3
(d) If replacement fuse blows, go to step 5. amps, repair linkage system.
(2) Place switch in LOW speed position. (b) If motor continues to draw more than 3 amps,
(3) Listen to motor. If you cannot hear it running, replace motor assembly.
go to Step No. 4. If you hear it running, check motor (3) Check motor wiring harness for shorting be-
output shaft. If output shaft is not turning, replace tween high and low speed wires as follows:
motor assembly. If it is turning, drive link to output (a) Connect a voltmeter or test lamp to motor
shaft or linkage is not properly connected. Replace ground strap.
worn parts and/or properly connect drive link to the (b) Set wiper switch to LOW position.
motor output shaft. (c) Connect other lead of voltmeter to terminal 4
(4) Connect a voltmeter between motor terminal 3 of the wiring harness.
and ground strap (Fig. 7). If there is no voltage or (d) If voltage is present, there is a short in the
very little voltage (less than one volt) present, move wiring or wiper switch.
negative test lead from the ground strap to battery (e) If no voltage is present set wiper switch to
negative terminal. HIGH position.
(a) If an increase in voltage is noticed, the prob- (f) Move voltmeter lead from terminal 4 to termi-
lem is a bad ground circuit. Make sure the motor nal 3 of the wiring harness.
mounting is free of paint and that nuts or bolts are (g) If voltage is present, there is a short in the
tight. wiring or wiper switch.
(b) If there is still no indication of voltage, the (h) If no voltage is present, check the ground
problem is an open circuit in the wiring harness or strap for a good connection. If ground is OK, re-
wiper switch. place motor.
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Fig. 6 Windshield Wiper Motor Diagnosis

Fig. 9 Test Lamp Between Terminal 4 and Ground

Fig. 7 Voltmeter Between Terminal 3 and Ground
Connect second jumper from Terminal 2 to battery
(B+). If motor runs to PARK position and stops, go to
step 2. If motor keeps running and does not park, re-
place motor assembly.
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Fig. 8 Ammeter Between Terminal 3 and Battery

CONDITION: MOTOR WILL RUN AT HIGH
SPEED, BUT NOT AT LOW SPEED OR MOTOR
WILL RUN AT LOW SPEED, BUT NOT AT HIGH
Fig. 10 Jumper Wire Between Terminal 1 and 3
SPEED.
(2) Turn ignition switch OFF, connect wiring to
REPAIR motor. Disconnect blue connector from the body con-
(1) If motor will not run on high speed, put switch trol module. Using an ohmmeter, check continuity be-
in HIGH position and connect a test lamp between tween terminal 22 and 24 of the body control module
motor Terminal 4 and ground (Fig. 9). (Fig. 11).
(2) If motor will not run on low speed, put switch (a) If there is continuity, replace body control
in LOW position and connect a test lamp between module.
motor Terminal 3 and ground. (b) If no continuity, check wires between multi-
(3) If test lamp does not light at motor terminal, function switch and terminal 22 and 24 of the mod-
there is an open in wiring or switch. If test lamp ule for a short circuit. Repair as necessary. If
lights at motor terminal, replace motor assembly. wiring OK, refer to Multi-Function Switch
Test—Wiper
CONDITION: MOTOR KEEP RUNNING WITH
SWITCH IN OFF POSITION
REPAIR
(1) Remove wiring harness. Connect jumper from
Terminal 1 to Terminal 3 of wiper motor (Fig. 10).
(4) Ignition OFF, disconnect body control module.

Check for continuity between pin 20 and 24 of the
module blue connector (Fig. 11). If no continuity, re-
place body control module.
(5) If continuity OK, disconnect the multi-function
switch connecter. The switch in the OFF position,
check continuity between terminal 6 and 7 of the
switch. If no continuity, replace multi-function
switch. If continuity OK, a open in the wiring exist,
repair as necessary.
WIPER MOTOR REPLACEMENT

(1) Remove windshield wiper arms (Fig. 4).
(2) Open hood assembly.
(3) Remove cowl top plenum grille.
(4) Remove hoses from hose connectors.
Fig. 11 Body Control Module 25-Way Connectors (5) Remove cowl plenum chamber plastic screen.
CONDITION: MOTOR WILL STOP, WHEN (6) Remove wiper pivot retaining screws.
SWITCH IS SET IN OFF POSITION. WIPERS DO (7) Push pivots down into plenum chamber.
NOT CONTINUE RUNNING TO PARK (8) Remove nut from wiper motor output shaft and
POSITION. remove linkage assembly.
(9) Disconnect wiper motor wiring harness.
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REPAIR (10) Remove mounting screw and nuts from wiper

(1) Remove motor wiring connector and clean ter- motor.
minals. Connect connector and test motor. If problem (11) Remove wiper motor.
persists, go to Step 2. (12) Perform disassembly and service on pieces as
(2) Set wiper switch to OFF position. Disconnect necessary.
motor wiring connector. Connect a voltmeter or test (13) For installation reverse above procedures. Ex-
lamp to the motor ground strap. Connect the other
cept the following torque specifications:
lead to terminal 2 of wiring connector. Turn ignition
(a) Tighten motor mounting screw and nuts 7 to
switch ON.
8 Nzm (60 to 70 in. lbs.) torque.
(a) If voltage is not present, check for an open
(b) Tighten pivot screws 7 to 8 Nzm (60 to 70 in.
circuit in the wiring harness.
(b) If voltage is present, go to step 3. lbs.) torque.
(3) Using an ohmmeter, check continuity between (c) Position wiper motor drive crank on motor
terminals 3 and 1 of the motor wire harness connec- shaft and tighten retaining nut 10 to 11 Nzm (90 to
tor. 100 in.lbs.) torque.
(a) If there is continuity between these termi- (d) Refer to Wiper Arm Adjustment for proper
nals, the problem is a defective motor. alignment.
(b) If there is no continuity, the problem is an
open circuit in the wiper control switch, body con-
trol module or wiring harness.
INTERMITTENT WINDSHIELD WIPER MOTOR AND SWITCH

INTERMITTENT WIPER MOTOR TEST The intermittent wipe function is controlled by the
Intermittent Wiper Motor Service Procedures for body control module, located behind the center stack.
diagnosis of problems which, do not involve the delay If the body control module is determined to be the
function, refer to the Motor Tests. The two-speed problem, refer to Group 8E, Instrument Panels and
functions of all wiper motors are identical. Gauges, for replacement procedures.
If a problem occurs, only in the DELAY mode, the To test the intermittent wipe functions a DRB will be
following tests are to be performed. needed, and the Body Diagnostic Procedures Manual.
The DRB is used to monitor the intermittent wipe
CONDITION: EXCESSIVE DELAY OF MORE input, washer input and the dwell switch input.
THAN 30 SECONDS OR INADEQUATE To test the switch, first disconnect the switch wires
VARIATION IN DELAY from the body wiring in the steering column. Using
REPAIR an ohmmeter, test for continuity between the termi-
nals of the switch, as indicated in the following con-
Variations in delay should be as follows:
(1) Minimum delay, control to the extreme counter- tinuity chart. The identity of each terminal is shown
clockwise position before first detent, should be one in Fig. 12.
half to two seconds.
(2) Maximum delay, control to extreme clockwise
position before off detent, should be fifteen to twenty
five seconds.
(3) If there is excessive delay or no variations in
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delay go to intermittent wipe switch test.

(4) If not within specification, replace body control
module.
CONDITION: IN DELAY MODE WIPERS RUN

CONTINUALLY WHEN WASH IS OPERATED
BUT DO NOT PROVIDE AN EXTRA WIPE
WHEN THE WASH CONTROL IS RELEASED
REPAIR
Replace the body control module.
CONDITION: WIPERS START ERRATICALLY

DURING DELAY MODE
REPAIR
(1) Check that the ground connection at the instru-
ment panel is making good connection, free from Fig. 12 Multi-Function Switch Continuity Test
paint and is tight.
(2) Check that the motor ground strap is making good For test purposes, the first position is the OFF po-
contact and that the motor mounting bolts are tight. sition, next is the slide for the DELAY wipe. LOW is
(3) Check body control module for proper ground the next detent position and HIGH is the full coun-
connections. terclockwise detent position.
(4) Using an DRB, check the intermittent wipe In any wiper mode, if the knob is pushed all the
level input to body control module. way in, the washer circuit will be completed.
(5) If condition is not corrected, replace body con- The wiper switch is part of the multi-function
trol module. switch assembly. If the wiper switch fails, the multi-
function switch must be replaced. Refer to Group 8J,
MULTI-FUNCTION SWITCH TEST—WIPER Turn Signals and Hazard Warning Flasher for multi-
function switch service procedure.
WARNING: ON VEHICLES EQUIPPED WITH AIRBAG,
SEE GROUP 8M, RESTRAINT SYSTEMS FOR STEER-
ING WHEEL OR COLUMN REMOVAL PROCEDURES.
WINDSHIELD WASHERS
INDEX
page page
General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 Washer Reservoir Pump Replacement . . . . . . . . . . . 9
Washer Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Washer Reservoir Removal . . . . . . . . . . . . . . . . . . . 9
GENERAL INFORMATION WASHER RESERVOIR REMOVAL

All models are equipped with electric operated (1) Unlock and open the hood.
windshield washer pumps. (2) Remove screws attaching the reservoir in ple-
The wash function can be accessed in the OFF po- num.
sition of the wiper control switch. Holding the wash (3) Disconnect the wiring harness from the reser-
button depressed when the switch is in the OFF po- voir pump and sensor, if equipped.
sition will operate the wipers and washer motor (4) Disconnect the washer hose and block the liq-
pump continuously until the washer button is re- uid outlet to prevent the liquid from running out
leased. Releasing the button will stop the washer while removing the reservoir from engine compart-
pump. The wipers will complete the current wipe cy- ment.
cle followed by an average of two more wipe cycles (5) For installation reverse above procedures.
(61) before the wipers park and the module turns Tighten attaching screws to 3 Nzm (26 in. lbs.)
off. torque.
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Whenever a windshield washer malfunction occurs,

verify that the windshield washer wire harness is WASHER RESERVOIR PUMP REPLACEMENT
properly connected before starting normal diagnosis (1) Remove washer reservoir and pump assembly,
and repair procedures. Refer to Windshield Washer refer to Reservoir Removal.
Diagnosis Chart (Fig. 13).
Fig. 13 Windshield Washer Diagnosis

(2) Notice position of pump, then using a 19mm

(3/4 in.) socket through the liquid filler opening,
loosen the pump filter and nut.
(3) Disconnect the outside portion of the pump.
(4) Remove inner and outer portions of the pump.
(a) Install rubber grommet into place in bottom
of reservoir.
(b) Refer to Washer Reservoir Removal for instal-
lation of reservoir.
WASHER NOZZLE Fig. 14 Windshield Washer Nozzle

These models are equipped with two hood mounted
washer nozzles. Each nozzle emits two streams into
the wiper pattern (Fig. 14). If nozzle performance is
unsatisfactory they can be adjusted. To adjust insert-
ing a pin into the nozzle ball and move to proper pat-
tern (Fig. 15). The right and left nozzles are
identical.
To replace nozzle, disconnect washer fluid hose. Us-
ing a needle nose pliers, squeeze together the locking
tabs on the nozzle. When installing make sure that
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both locking tabs are securely snapped into position.

Connect washer fluid hose
Fig. 15 Windshield Washer Pattern
REAR WINDOW WIPER/WASHER SYSTEM
INDEX
page page
Liftgate Motor Replacement . . . . . . . . . . . . . . . . . . 12 Rear Arm Adjustment . . . . . . . . . . . . . . . . . . . . . . 11
Liftgate Washer Reservoir Pump Replacement . . . . 12 Rear Window Intermittent Wipe Module Location . . 11
Liftgate Washer Reservoir Removal . . . . . . . . . . . . 12 Rear Wiper/Washer Control Pod Switch . . . . . . . . . 12
Liftgate Wiper Motor Test . . . . . . . . . . . . . . . . . . . 12 Washer Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Module Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
For wiper blade service, refer to windshield Wiper

Blades.
REAR ARM ADJUSTMENT

(1) With the motor in park position, mount the
arm on the motor shaft. Choose a serration engage-
ment that properly locates tip of the blade about 90
mm (3 1/2 inch) parallel, with lower edge of liftgate
glass (Fig. 16).
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Fig. 17 Intermittent Wipe Module Location
MODULE TEST
(1) Remove liftgate trim panel. Refer to Group 23,
Body.
(2) Using a volt/ohmmeter test each pin and repair
as necessary.
(a) Pin 1, test for module output battery voltage
to wiper motor, with the ignition switch in the ON
position and the rear wiper switch ON (Fig. 18).
The intermittent mode will have a eight second de-
Fig. 16 Installing Liftgate Wiper Arm
lay between wipes.
(2) Operate the wiper on dry glass with the engine (b) Pin 2, test for battery voltage from ignition
off. The tip of the wiper blade should be within 60 switch, with the ignition in the ON position.
mm (2 3/8 inch) to 120 mm (4 3/4 inch) above lower (c) Pin 3, test for continuity to ground.
edge of liftgate glass. (d) Pin 4, ignition switch ON and the rear win-
dow washer switch ON, test for battery voltage.
REAR WINDOW INTERMITTENT WIPE MODULE (e) Pin 5, ignition switch ON and wiper switch
LOCATION ON, test for continuity to ground.
The intermittent wipe module is located inside the (f) Pin 6, ignition switch ON and washer switch
lift gate on the right van side (Fig. 17). pushed-in, test continuity to ground.
(4) With ignition switch in ON position, and wiper

switch in OFF position, check for battery voltage be-
tween both wires. If battery voltage is not present
check ground wire to wiper module.
(5) If battery voltage is present in steps 2 and 3,
replace motor.
LIFTGATE MOTOR REPLACEMENT

(1) Remove liftgate wiper arm assembly, refer to
Wiper Arm Replacement.
(2) Unlock and open the liftgate.
(3) Remove liftgate trim panel, refer to Group 23,
Liftgate Trim Panel Removal.
(4) Remove five liftgate motor mounting screws
(Fig. 19).
(5) Disconnect wiring harness from liftgate motor
Fig. 18 Rear Wipe Module connector.
(6) Remove motor assembly from liftgate.
REAR WIPER/WASHER CONTROL POD SWITCH
Refer to Group 8E Instrument Panel and gauges, (a) Install five liftgate motor mounting screws.
for service of right POD Switch. Tighten 3 to 5 Nzm (25 to 45 in. lbs.) of torque.
(b) Install wiper arm assembly, refer to Wiper
LIFTGATE WIPER MOTOR TEST Arm Adjustment.
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The following test is used to locate and then repair

liftgate wiper motor defects. Refer to Group 8W, Wir- LIFTGATE WASHER RESERVOIR REMOVAL
ing Diagrams for liftgate wiper motor wiring sche- (1) Unlock and open the liftgate.
matic. (2) Remove two side aperture panel and reservoir
(1) Disconnect feed wire connector from wiper mo- mounting screws (Fig. 20).
tor (Fig. 19). (3) Disconnect the wiring harness from the washer
pump.
(4) Disconnect the washer hose from reservoir sys-
tem, block the liquid outlet to prevent the liquid from
running out while removing the reservoir.
(5) Remove one upper reservoir screw.
(6) Remove reservoir and pump assembly through
the side aperture panel access hole. Work filler tube
off reservoir. Empty the reservoir outside of vehicle.
(a) Fill reservoir and test system.
LIFTGATE WASHER RESERVOIR PUMP

REPLACEMENT
(1) Remove washer reservoir and pump assembly,
refer to Washer Reservoir Removal.
(2) With mechanical fingers, loosen pump filter
Fig. 19 Liftgate Wiper Motor and Bracket Assembly and nut through liquid filler opening.
(3) Disconnect the outside portion of the pump.
(2) With ignition switch in ON position, check for (4) Remove inner and outer portions of the pump,
battery voltage at the brown wire with pink tracer. and remove pump.
(3) With ignition switch in ON position and wiper (5) For installation reverse above procedures.
switch ON, check for battery voltage at both wires. If
battery voltage is not present in steps 2 and 3, check WASHER NOZZLE
fuse, liftgate wiper switch and wiring and wiper mod- To replace unsnap nozzle from wiper arm and dis-
ule. The wiper circuit will have eight seconds be- connect hose. When installing make sure that both
tween the wipe cycles. the nozzle and the hose guard are securely snapped
into position.
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Fig. 20 Liftgate Washer System

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. LAMPS 8L - 1
LAMPS
CONTENTS
page page
BULB APPLICATION . . . . . . . . . . . . . . . . . . . . . 10 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1

EXTERIOR LAMPS, SWITCHES AND SYSTEMS . . . . . 2 ILLUMINATED ENTRY SYSTEM . . . . . . . . . . . . . 8
GENERAL INFORMATION
Each vehicle is equipped with lamps used for illu- CAUTION: Do not touch the glass of halogen bulbs
minating and indicating purposes. A circuit must with fingers or any possibly oily surface, reduced
have a good ground to be complete. Circuit ground bulb life will result.
occurs when the lamp socket makes contact with the
metal body. On vehicles with plastic lamps, a wire
between the socket and the body makes the grounds. DIAGNOSTIC PROCEDURES
When changing lamp bulbs, check the socket for Begin electrical system failure diagnosis by testing
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corrosion. If corrosion is present, clean contacts with all related fuses and circuit breakers in the fuse
a wire brush and coat the inside of the socket with block and engine compartment. Also refer to Group
Mopart Multi-purpose Grease or equivalent. 8W, Wiring Diagrams for component location and cir-
cuit information.
HEADLAMP DIAGNOSIS
8L - 2 LAMPS .
EXTERIOR LAMPS, SWITCHES AND SYSTEMS
INDEX
page page
Center High-Mounted Stop Lamp (CHMSL) . . .... . 7 Headlamp Dimmer Switch . . . . . . . . . . .. . . . . . . . . 2
Daytime Running Lamps—Canada Only . . . . .... . 7 Headlamp Housing . . . . . . . . . . . . . . . .. . . . . . . . . 4
Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .... . 6 Headlamp Switch . . . . . . . . . . . . . . . . .. . . . . . . . . 2
Headlamp Adjustment Using Alignment Screen ... . 2 Headlamp Time Delay System . . . . . . .. . . . . . . . . 7
Headlamp Alignment . . . . . . . . . . . . . . . . . . . .... . 2 License Plate Lamp . . . . . . . . . . . . . . .. . . . . . . . . 6
Headlamp Alignment Preparation . . . . . . . . . . .... . 2 Park/Turn Signal and Side Marker Lamp . . . . . . . . . 5
Headlamp Bulb . . . . . . . . . . . . . . . . . . . . . . . .... . 3 Tail Lamp . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 6
HEADLAMP SWITCH (3) From the floor up 1.27 meters (5 ft), tape a line
Service procedures for the headlamp switch can be on the wall at the centerline of the vehicle. Sight
found in Group 8E, Instrument Panel and Gauges. More along the centerline of the vehicle (from rear of vehi-
information can be found in Group 8W, Wiring Dia- cle forward) to verify accuracy of the line placement.
grams. (4) Rock vehicle side-to-side three times to allow
suspension to stabilize.
HEADLAMP DIMMER SWITCH (5) Jounce front suspension three times by pushing
The headlamp dimmer switch is incorporated into the downward on front bumper and releasing.
(6) Measure the distance from the center of head-
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turn signal switch. Proper procedures can be found in

Group 8J, Turn Signal and Flashers. More information lamp lens to the floor. Transfer measurement to the
can be found in Group 8W, Wiring Diagrams. alignment screen (with tape). Use this line for up/
down adjustment reference.
HEADLAMP ALIGNMENT (7) Measure distance from the centerline of the ve-
Headlamps can be aligned using the screen method hicle to the center of each headlamp being aligned.
provided in this section. Alignment Tool C4466-A or Transfer measurements to screen (with tape) to each
equivalent can also be used. Refer to instructions side of vehicle centerline. Use these lines for left/
provided with the tool for proper procedures. The right adjustment reference.
preferred headlamp alignment setting is 0 for
the left/right adjustment and 0 for the up/down HEADLAMP ADJUSTMENT (FIG. 2 OR 3)
adjustment. A properly aimed low beam headlamp will project
the top edge of low beam hot spot on the alignment
HEADLAMP ALIGNMENT PREPARATION screen from 50 mm (2 in.) above to 50 mm (2 in.) be-
(1) Verify headlamp dimmer switch and high beam low the headlamp centerline. The side-to-side left
indicator operation. edge of low beam hot spot should be from 50 mm (2
(2) Inspect and correct damaged or defective com- in.) left to 50mm (2 in.) right of headlamp centerline
ponents that could interfere with proper headlamp (Fig. 1). The preferred headlamp alignment is 0
alignment. for the up/down adjustment and 0 for the left/
(3) Verify proper tire inflation. right adjustment. The high beams on a vehicle
(4) Clean headlamp lenses. with aero headlamps cannot be aligned. The high
(5) Verify that luggage area is not heavily loaded. beam pattern should be correct when the low beams
(6) Fuel tank should be FULL. Add 2.94 kg (6.5 are aligned properly.
lbs.) of weight over the fuel tank for each estimated To adjust headlamp alignment, rotate alignment
gallon of missing fuel. screws to achieve the specified low beam hot spot
pattern (Fig. 2 or 3).
HEADLAMP ADJUSTMENT USING ALIGNMENT
SCREEN FOG LAMP ALIGNMENT (FIG. 4)
Prepare a alignment screen. Refer to Alignment
ALIGNMENT SCREEN PREPARATION (FIG. 1) Screen Preparation paragraph in this section. A prop-
(1) Position vehicle on a level surface perpendicu- erly aligned fog lamp will project a pattern on the
lar to a flat wall 7.62 meters (25 ft) away from front alignment screen 100 mm (4 in.) below the fog lamp
of headlamp lens. centerline and straight ahead.
(2) If necessary, tape a line on the floor 7.62
meters (25 ft) away from and parallel to the wall.
. LAMPS 8L - 3
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Fig. 1 Headlamp Alignment Screen—Typical
Fig. 2 Headlamp Alignment Screws—AS/C-H-P-Y Fig. 3 Headlamp Alignment Screws—AS/D-K Vehicle

Vehicle (3) Rotate the bulb retaining ring counterclockwise
HEADLAMP BULB one quarter turn and remove the retaining ring
(4) Pull bulb from back of lamp.
REMOVAL (FIG. 5)
(1) Open hood. INSTALLATION
(2) Disconnect wire connector from behind head- (1) Align the guide notches on the bulb base with
lamp in the engine compartment. the guides in lamp receiver hole.
(2) Push the socket into the lamp until it seats.
CAUTION: Do not touch the bulb with fingers or any (3) Install retaining ring.
possibly oily surface, reduced bulb life will result. (4) Connect wire connector to back of lamp and
test operation.
8L - 4 LAMPS .
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Fig. 4 Fog Lamp Alignment

(7) Turn headlamp retainer blocks one quarter
turn in either direction to align the retainer to the
hole in the headlamp housing. There is one retainer
on top of headlamp and two on the bottom (Fig. 6).
(8) Separate lamp from vehicle.
INSTALLATION
Reverse the preceding operation.
Fig. 5 Headlamp Bulb

HEADLAMP HOUSING
REMOVAL
Lens fogging is a normal condition and does
not require service. Moisture will vent from
tubes behind the lens.
(1) Open hood.
(2) Remove grill, refer to Group 23, Body.
(3) Remove screws holding grille extension molding
to headlamp housing, on AS/H-Y vehicles.
(4) Separate grille extension molding from vehicle.
(5) Disconnect wire connector from back of head- Fig. 6 Headlamp Retaining Blocks
lamp.
(6) Remove Park/Turn Signal Lamp.
. LAMPS 8L - 5
PARK/TURN SIGNAL AND SIDE MARKER LAMP

LAMP OR BULB REMOVAL
(1) Open hood and support on prop rod.
(2) Remove screw holding grille lower corner and
lamp mounting to reinforcement bracket (Fig. 7).
(3) Remove screw holding park/turn signal lamp to
headlamp housing (Fig. 8).
(4) Remove vertical screw holding park/turn lamp
to closure panel (Fig. 9).
(5) Separate park/turn lamp from headlamp hous-
ing (Fig. 10).
(6) Twist sockets counterclockwise and separate
sockets from lamp (Fig. 11).
(7) Pull bulb straight out of socket.
LAMP OR BULB INSTALLATION Fig. 9 Vertical Mounting Screw

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Fig. 10 Park/Turn Signal and Side Marker Lamp

Fig. 7 Grille/Lamp Mounting Screw
Fig. 11 Park/Turn Signal and Side Marker Lamp

Fig. 8 Outer Mounting Screw Sockets
8L - 6 LAMPS .
FOG LAMP TAIL LAMP

The tail lamp includes back-up, side marker, stop
BULB REMOVAL and turn signal lamps.
(1) Remove screws holding fog lamp to mounting
fixture (Fig. 12). BULB REPLACEMENT (FIG. 14)
(2) Separate fog lamp from mounting fixture. (1) Raise lift gate to the open position.
(3) Disconnect wire connector. (2) Remove screws holding top of tail lamp to quar-
ter panel opening.
CAUTION: Do not touch the bulb with fingers or any (3) Tilt top of tail lamp away from quarter panel
possibly oily surface, reduced bulb life will result. enough to gain access to bulb sockets.
(4) Twist socket counterclockwise and separate
(4) Pinch together and hinge spring retainer to one
socket from lamp.
side (Fig. 13) to release bulb from lamp assembly.
(5) Pull bulb from socket.
BULB INSTALLATION To install, reverse the preceding operation.
TAIL LAMP REMOVAL (FIG. 14)
(1) Raise lift gate to the open position.
(2) Remove screws holding top of tail lamp to quar-
ter panel opening.
(3) Tilt top of tail lamp away from quarter panel
enough to gain access to bulb sockets.
(4) Twist sockets counterclockwise and separate
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sockets from lamp.

(5) Disengage tail lamp from lower mounting
bracket.
LAMP INSTALLATION
Fig. 12 Fog Lamp Mounting Screws
Fig. 14 Tail lamp

LICENSE PLATE LAMP
BULB OR LAMP REMOVAL (FIG. 15)
(1) Remove screws holding license plate lamp to
lift gate.
(2) Separate license plate lamp lens from socket
base.
(3) Pull bulb from socket base.
BULB OR LAMP INSTALLATION

Fig. 13 Fog Lamp Bulb Removal and Installation
. LAMPS 8L - 7
DRLR allows the high beam headlamps to illuminate

at 50% of the switched ON brightness when the en-
gine is running with the headlamp switch OFF. The
Daytime running lamps will go out when the head-
lamp switch is pulled out. The passing light feature
will flash bright high beams while the daytime run-
ning lamps are activated.
DAYTIME RUNNING LAMP DIAGNOSTICS

The daytime running lamp system shears fuse 24,
in the fuse panel, with the back-up lamp circuit. The
DRLR is controlled by inputs received from the
Fig. 15 License Plate Lamp
Speed Sensor, Headlamp Switch and the Engine Con-
CENTER HIGH-MOUNTED STOP LAMP (CHMSL) troller (SBEC). Refer to Group 8W, Wiring Diagrams
for component location and circuit information.
BULB OR LAMP REMOVAL (FIG. 16)
To replace CHMSL bulb, remove socket from lamp DAYTIME RUNNING LAMP RELAY REMOVAL
and pull bulb from socket. (FIG. 17)
(1) Raise lift gate to the open position. (1) Raise hood to open position and support hood
(2) Remove plugs and screws holding CHMSL ac- on prop-rod.
cess cover to lift gate trim panel. (2) Disconnect wire connector from DRLR.
(3) Separate access cover from lift gate. (3) Remove screw holding DRLR to engine com-
(4) Twist sockets counterclockwise and separate partment dash panel.
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sockets from lamp. (4) Separate DRLR from dash panel.

(5) Remove screws holding CHMSL to lift gate and
separate lamp from vehicle. DAYTIME RUNNING LAMP RELAY
INSTALLATION
BULB OR LAMP INSTALLATION Reverse the preceding operation.
Fig. 17 Daytime Running Lamp Relay (DRLR)

Fig. 16 Center High-Mounted Stop Lamp
HEADLAMP TIME DELAY SYSTEM
DAYTIME RUNNING LAMPS—CANADA ONLY The optional Headlamp Time Delay system is con-
The daytime running lamps are controlled by the trolled by the Body Controller (BC). The BC is lo-
Daytime Running Lamp Relay (DRLR). The DRLR is cated behind the instrument panel on the left side of
located in the engine compartment near the right the center console. The headlamp time delay system
strut tower attached to the dash panel (Fig. 17). The can be activated by turning ON the headlamps when
8L - 8 LAMPS .
the engine is running, turn OFF the ignition switch, DIAGNOSTIC PROCEDURES
then turn OFF the headlamp switch. The BC will al- Refer to Group 8W, Wiring Diagrams for compo-
low the headlamps to remain ON for 60 seconds be- nent location and circuit information. Refer to the
fore they automatically turn off. Refer to Owner’s Body Systems Diagnostic Procedures Manual for
Manual for more information. more information.
ILLUMINATED ENTRY SYSTEM
GENERAL INFORMATION
The optional Illuminated Entry System turns ON
the courtesy lamps (except ignition switch lamp)
when the exterior front door handles are lifted. Front
door handle switches (Fig. 18) and the Body Control-
ler (Fig. 19) are used to control the system. Courtesy
lamps will turn on for 30 seconds (6 1 second) and
turn OFF. The courtesy lamps will stay ON for 6 sec-
onds after the engine has started then the Body Con-
troller will turn the courtesy lamps OFF. After the
engine has started, the courtesy lamps will go OFF
as soon as:
• The parking lamps are turned ON.
• The vehicle is in motion.
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• The transaxle is shifted out of PARK on vehicles

Fig. 19 Body Controller
with Ultradrive Transaxle.
The Illuminated Entry System cannot be activated Refer to Group 8W, Wiring Diagrams for compo-
unlit 30 seconds after the system has timed out or nent location and circuit information. Refer to Body
the ignition switch has been turned OFF. Systems Diagnostic Procedures Manual for more in-
formation.
BODY CONTROLLER
BODY CONTROLLER REMOVAL (FIG. 19)
The Body Controller is located behind the instru-
ment panel, left of center console. Refer to Group 8E,
Instrument Panel and Gauges for proper procedures.
ILLUMINATED ENTRY SWITCH

ILLUMINATED ENTRY SWITCH REMOVAL
(FIG. 18)
(1) Disconnect Fusible Link connector located rear-
ward of the battery in the engine compartment.
(2) Remove door trim panel and weather shield, re-
fer to Group 23, Body.
Fig. 18 Door Latch Switches (3) Disconnect illuminated entry actuator switch
wire connector.
DIAGNOSTIC PROCEDURES (4) Disengage push-in fasteners holding switch to
When testing the system, all doors must be closed outside door handle.
to prevent courtesy lamps from lighting. The Illumi- (5) Separate switch from door.
nated Entry Diagnosis Chart provides a step by step
procedure. The instrument cluster lamp dimmer ILLUMINATED ENTRY SWITCH INSTALLATION
switch must be ON for the Illuminated Entry Reverse the preceding operation.
System to operate. If switch is OFF it will not
operate. INSTRUMENT PANEL LAMPS AND SWITCHES
For replacement of instrument panel lamps and
switches, refer to Group 8E, Instrument Panel and
Gauges.
. LAMPS 8L - 9
ILLUMINATED ENTRY DIAGNOSIS

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8L - 10 LAMPS .
BULB APPLICATION
GENERAL INFORMATION Heater Control .......................................................158
The following Bulb Applications list the lamp title Instrument Cluster (MIC)................................PC194
on the left side of the column and trade number or Radio ......................................................................ASC
part number on the right. Rear Defogger Switch....................................4685005
Rear Wiper Switch.........................................4685004
CAUTION: Do not use bulbs that have a higher can-
dle power than the bulb listed in the Bulb Applica- INDICATOR LAMPS
tions. Damage to lamp can result. Service procedures for most of the lamps in the in-
Do not touch halogen bulbs with fingers or other strument panel, instrument cluster and switches are
possibly oily surfaces. Bulb life will be reduced. located in Group 8E, Instrument Panel and Gauges.
Air Bag (MIC) ...................................................PC194
Anti-lock Brake (MIC)......................................PC194
EXTERIOR LAMPS
Brake Warning (MIC).......................................PC194
Back-up ...................................................................921
Check Engine (MIC) .........................................PC194
Center High Mounted Stop ..................................921
Check Gauges (MIC) ........................................PC194
Fog............................................................................H3
Front Side Marker.................................................168 Door Open..........................................................PC194
Headlamp..............................................................9004 Engine Oil Pressure .........................................PC194
License Plate ..........................................................168 High Beam (MIC) .............................................PC194
Park/Turn Signal W/O Side Marker ..................3157 Lift Gate Open ..................................................PC194
Park/Turn Signal With Side Marker .................2057 Low Fuel ............................................................PC194
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Tail/Stop/Turn Signal...........................................3157 Low Washer Fluid.............................................PC194

Maintenance Required......................................PC194
INTERIOR LAMPS Seat Belt (MIC).................................................PC194
Turn Signal (MIC) ............................................PC194
DIMMER CONTROLLED LAMPS
Service procedures for most of the lamps in the in- NON-DIMMING LAMPS
strument panel, Instrument cluster and switches are Service procedures for most of the lamps in the fol-
located in Group 8E, Instrument Panel and Gauges. lowing list can be found in Group 23, Body. Some
Some components have lamps that can only be ser- components have lamps that can only be serviced by
viced by a Authorized Service Center (ASC) after the a Authorized Service Center (ASC) after the compo-
component is removed from the vehicle. Contact local nent is removed from the vehicle. Contact local
dealer for location of nearest ASC. When illumination dealer for location of nearest ASC.
goes out in the Electronic Instrument Cluster (EIC) Door Courtesy ........................................................562
the complete button module must be replaced. The Dome ....................................................................212-2
Mechanical Instrument Cluster (MIC) uses PC194 Engine Compartment ............................................105
bulbs for illumination. Glove Compartment.............................................1891
A/C Heater Control..................................................37 Ignition Lock.........................................................ASC
Ash Receiver.............................................................37 Lift Gate .................................................................562
Auxiliary Heater Control ........................................37 Overhead Console ...............................................212-2
Cigar Lighter..........................................................161 Reading Lamp ........................................................906
Fog Lamp Switch Symbol .............................4685005 Rear Cargo...........................................................211-2
Gear Shift Selector ..................................................73 Under Seat Storage Bin........................................194
Headlamp Switch...........................................4685003 Visor Vanity ....................................................6501966
Headlamp Dimmer Switch............................4685003
. RESTRAINT SYSTEMS 8M - 1
RESTRAINT SYSTEMS
CONTENTS
page page
AIRBAG CONTROL MODULE (ACM) . . . . . . . . . . 5 DRIVER AIRBAG MODULE . . . . . . . . . . . . . . . . . 3

AIRBAG SERVICE AND TEST PROCEDURES . . . 1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
AIRBAG SYSTEM CHECK . . . . . . . . . . . . . . . . . . 3 PASSENGER AIRBAG MODULE . . . . . . . . . . . . . . 4
CLOCKSPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STEERING COLUMN SWITCHES . . . . . . . . . . . . . 7
CLOCKSPRING CENTERING PROCEDURE . . . . . 6 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 7
AIRBAG SERVICE AND TEST PROCEDURES

WARNING: THIS SYSTEM IS A SENSITIVE, COM-
PLEX ELECTRO-MECHANICAL UNIT. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE
BEFORE BEGINNING ANY AIRBAG SYSTEM COM-
PONENT REMOVAL OR INSTALLATION PROCE-
DURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
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FAILURE TO DISCONNECT THE BATTERY COULD

RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY. ALLOW SYS-
TEM CAPACITOR TO DISCHARGE FOR 2 MINUTES
BEFORE REMOVING ANY AIRBAG COMPONENTS.
If the Driver/Passenger Airbag Module Assembly is

defective and non-deployed, refer to Chrysler Motors
current return list for proper handling procedures. Fig. 1 Driver Airbag System
The inflator assembly is mounted to the back of the
WARNING: REPLACE AIRBAG SYSTEM COMPO- module housing. When supplied with the proper elec-
NENTS WITH CHRYSLER MOPART SPECIFIED RE- trical signal the inflator assembly will produce a gas
PLACEMENT PARTS. SUBSTITUTE PARTS MAY and discharges it directly into the cushion. A protec-
VISUALLY APPEAR INTERCHANGEABLE, BUT IN- tive cover is fitted to the front of the airbag module
TERNAL DIFFERENCES MAY RESULT IN INFERIOR and forms a decorative cover in the center of the
OCCUPANT PROTECTION. steering wheel. The airbag module is mounted di-
rectly to the steering wheel.
THE FASTENERS, SCREWS AND BOLTS, ORIG-
INALLY USED FOR THE AIRBAG COMPONENTS, PASSENGER AIRBAG MODULE
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIRBAG SYSTEM. WARNING: NEVER DISASSEMBLE THE PASSEN-
THEY MUST NEVER BE REPLACED WITH ANY GER AIRBAG MODULE, THERE ARE NO SERVICE-
SUBSTITUTES. ANYTIME A NEW FASTENER IS ABLE PARTS WITHIN THE MODULE.
NEEDED, REPLACE WITH THE CORRECT FAS-
TENERS PROVIDED IN THE SERVICE PACKAGE The passenger inflator assembly is within the mod-
OR FASTENERS LISTED IN THE PARTS BOOKS. ule housing. The module is attached to the instru-
ment panel mounting bracket. When supplied with
GENERAL INFORMATION the proper electrical signal the inflator will produce a
gas and discharge it directly into the airbag. A pro-
DRIVER AIRBAG MODULE tective covered door is part of the airbag module.
The airbag module is the most visible part of the This door will pivot out of the way and allow the air-
system (Fig. 1). It contains the airbag cushion and its bag to fully inflate.
supporting components. The airbag module contains
a housing to which the cushion and inflator are at-
tached and sealed.
8M - 2 RESTRAINT SYSTEMS .
AIRBAG CONTROL MODULE DEPLOYED MODULE

The Airbag Control Module (ACM) contains the im- The vehicle interior may contain a very small
pact sensor and energy reserve capacitor. The ACM amount of sodium hydroxide powder, a byproduct of
monitors the system to determine the system readi- the driver airbag deployment. Since this powder can
ness. The ACM contains on-board diagnostics and irritate the skin, eyes, nose or throat, be sure to wear
will illuminate the AIRBAG warning lamp in the safety glasses, rubber gloves and long sleeves during
message center when a fault occurs. cleanup (Fig. 2).
IMPACT SENSOR
The driver and passenger airbag system is a safety
device designed to reduce the risk of fatality or seri-
ous injury, caused by a frontal impact of the vehicle.
The impact sensor provides verification of the di-
rection and severity of the impact. One impact sensor
is used. It is located inside the Airbag Control Mod-
ule (ACM) which is mounted on a bracket, just for-
ward of the center console. The impact sensor is an
accelerometer that senses deceleration. The decelera-
tion pulses are sent to a microprocessor which con-
tains a decision algorithm. When an impact is severe
enough to require airbag protection, the ACM micro
processor sends a signal that completes the electrical
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circuit to the driver and passenger airbags. The sen-

sor is calibrated for the specific vehicle and reacts to Fig. 2 Wear Safety Glasses and Rubber Gloves
the severity and direction of the impact.
If you find that the cleanup is irritating your skin,
CLOCKSPRING run cool water over the affected area. Also, if you ex-
The clockspring is mounted on the steering column perience nasal or throat irritation, exit the vehicle for
behind the steering wheel and is used to maintain a fresh air until the irritation ceases. If irritation con-
continuous electrical circuit between the wiring har- tinues, see a physician.
ness and the driver’s airbag module. This assembly
consists of a flat ribbon-like electrically conductive CLEANUP PROCEDURE
tape which winds and unwinds with the steering Roll or fold the passenger airbag towards the in-
wheel rotation. strument panel surface and close the door over the
folded bag. Then tape the door shut.
STORAGE Use a vacuum cleaner to remove any residual pow-
The airbag module must be stored in its original der from the vehicle interior. Work from the outside
special container until used for service. Additionally, in so that you avoid kneeling or sitting in an un-
it must be stored in a clean, dry environment, away cleaned area (Fig. 3).
from extreme heat, sparks and sources of high elec-
trical energy. Always place or store the module on a
surface with the;
• Driver airbag trim cover
• Passenger airbag door
facing up to minimize movement in case of acciden-
tal deployment.
HANDLING OF MODULE
At no time should any source of electricity be per-
mitted near the inflator on the back of the module.
When carrying or handling a live module;
• The trim cover of the driver airbag module
• The door of the passenger airbag module
should be pointed away from the body to minimize
injury in the event of accidental deployment. In ad-
dition, if the module is placed on a bench or other
surface, the door should face up to minimize move- Fig. 3 Seal the Airbag Exhaust Vents
ment in case of accidental deployment.
Be sure to vacuum the heater and A/C outlets as (5) After checking that no one is inside the vehicle,
well (Fig. 4). In fact it’s a good idea to run the blower connect the battery negative cable.
on low and to vacuum up any powder expelled from (6) Using the DRB, read and record active diagnos-
the plenum. You may need to vacuum the interior of tic data.
the car a second time to recover all of the powder. (7) Read and record any stored diagnostic codes.
(8) Refer to the Airbag (CCD Communications) Di-
agnostic Manual if any diagnostic codes are found in
steps 6 and 7.
(9) Erase stored diagnostic codes if there are no ac-
tive diagnostic codes. If problems remain, diagnostic
codes will not erase.
(10) Turn the ignition key to OFF then ON and ob-
serve the message center airbag lamp. It should go
on for six to eight seconds, then go out; indicating
system is functioning normally.
If airbag warning lamp either fails to light,
blinks on and off or goes on and stays on, there
is a system malfunction. Refer to the Airbag
(CCD Communications) Diagnostic Manual to
diagnose the problem.
Fig. 4 Vacuum Heater and A/C Outlets DRIVER AIRBAG MODULE

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Place the deployed bag and module in your automo-

tive scrap. TERY NEGATIVE CABLE BEFORE BEGINNING ANY
AIRBAG SYSTEM COMPONENT REMOVAL OR IN-
SERVICE OF DEPLOYED AIRBAG MODULE
STALLATION PROCEDURE. THIS WILL DISABLE
After a driver airbag has been deployed, the airbag
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT
module and clockspring assembly must be replaced
THE BATTERY COULD RESULT IN ACCIDENTAL
because they cannot be reused. Other driver airbag AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
system components are replaced if damaged. After a INJURY. ALLOW SYSTEM CAPACITOR TO DIS-
PASSENGER airbag module has been deployed the CHARGE FOR 2 MINUTES BEFORE REMOVING ANY
module must be replaced because it cannot be re- AIRBAG COMPONENTS.
used. The upper right trim pad may also be required
to be replaced if damaged.
REMOVAL
AIRBAG SYSTEM CHECK When removing a deployed module, rubber gloves,
eye protection and long sleeve shirt should be worn,
WARNING: DISCONNECT AND ISOLATE THE BAT- as there may be deposits on the surface which could
TERY NEGATIVE CABLE BEFORE BEGINNING ANY irritate the skin and eyes.
AIRBAG SYSTEM COMPONENT REMOVAL OR IN- (1) Disconnect the battery negative cable and iso-
STALLATION PROCEDURE. THIS WILL DISABLE late.
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT (2) Wait two minutes for the reserve capacitor to
THE BATTERY COULD RESULT IN ACCIDENTAL discharge before removing non deployed module.
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL (3) Remove four nuts attaching airbag module to
INJURY. ALLOW SYSTEM CAPACITOR TO DIS- steering wheel (Fig. 5).
CHARGE FOR 2 MINUTES BEFORE REMOVING ANY (4) Lift module and disconnect electrical connector
from rear of module.
AIRBAG COMPONENTS.
(5) Remove module.
(1) Disconnect the battery negative cable and iso- (6) When replacing a deployed module, the clock-
late. spring must also be replaced. Refer to Clockspring
(2) Remove forward console or cover as necessary. Removal and Installation for proper procedure.
(3) Connect DRB to ACM data link 6-way connec- INSTALLATION
tor, located at right of steering column. (1) Connect clockspring squib connector to the
(4) Turn the ignition key to ON position. Exit ve- module, by pressing straight in on the connector.
hicle with DRB. Use the latest version of the proper Push connector past the secondary latching fingers
cartridge. until it is FULLY SEATED into the module squib.
Fig. 6 Remove or Install Battery Cable
Fig. 5 Driver Airbag Module

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(2) Install four nuts and tighten to 9 to 11 Nzm (80

to 100 in. lbs.) torque.
(3) Do not connect battery negative cable. Refer to
Airbag System Check for proper procedure.
PASSENGER AIRBAG MODULE

Fig. 7 Passenger Airbag Module
TERY NEGATIVE CABLE BEFORE BEGINNING ANY
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. ALLOW SYSTEM CAPACITOR TO DIS-
CHARGE FOR 2 MINUTES BEFORE REMOVING ANY
AIRBAG COMPONENTS.
NON DEPLOYED REMOVAL

(1) Disconnect and isolate the battery negative ca-
ble (Fig. 6).
(2) Disconnect glove box door check straps and al-
low door to open fully. Fig. 8 Passenger Airbag Module Removal
(3) Remove the four screws attaching the module two connectors and remove module. Use a shop towel
to the bracket (Fig. 7). to protect trim pad before placing module on it.
(4) Using a large flat tipped screwdriver by hand, (6) For installation, reverse above procedures.
pry module up to unsnap door from the trim pad and Tighten module attaching screws to 6 Nzn (50 in. lbs.)
lift away from snaps. The access hole for the screw- torque.
driver is located at the center of the module mount-
ing bracket (Fig. 8). DEPLOYED MODULE
(5) Hold on to the door and raise module from When removing a deployed module:
opening. Rest module on trim pad and disconnect the • Rubber gloves
• Eye protection
• Long-sleeved shirt should be worn. There may be
deposits on the surface which could irritate the skin
and eyes.
(1) Disconnect and isolate the battery negative ca-
ble (Fig. 6).
(2) Roll/fold airbag towards instrument panel.
(3) Close door over folded airbag and tape door
closed.
(4) Refer to Cleanup Procedure above.
(5) Disconnect glove box door check straps and al-
low door to open fully.
(6) Remove the four screws attaching the module
to the bracket (Fig. 8).
(7) Using a large flat tipped screwdriver or by
hand, pry module up to unsnap door from the trim
pad and lift away from snaps. The access hole for the
screwdriver is located at the center of the module
mounting bracket (Fig. 8).
(8) Hold on to the door and raise module from
opening. Rest module on trim pad and disconnect the
two connectors and remove module. Use a shop towel Fig. 9 ACM with Center Console
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to protect trim pad before placing module on it.

(4) Remove the two upper console attaching screws
(9) Check trim pad for any cracking or surface
behind the cupholder.
marks and replace as necessary. Refer to Group 8E
(5) Slide console rearward and up to remove.
Instrument Panel and Gauges for replacement proce-
(6) Disconnect wiring at ACM and remove module.
dures.
(7) Remove the four ACM mounting screws.
(8) Slide the ACM off the mounting bracket toward
Check door for fit and finish while tightening module
the drive side and remove module.
screws. Tighten module attaching screws to 6 Nzn (50
in. lbs.) torque. CAUTION: USE CORRECT SCREWS
AIRBAG CONTROL MODULE (ACM) (9) For installation, reverse above procedures. At-
tach module and bracket with screws and tighten to
WARNING: THE ACM CONTAINS THE IMPACT SEN- 10.7 Nzn (95 in. lbs.) torque.
SOR WHICH ENABLES THE SYSTEM TO DEPLOY Do not connect battery negative cable. Refer to Air-
THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOY- bag System Check for proper procedure.
MENT, NEVER CONNECT ACM ELECTRICALLY TO
THE SYSTEM WHILE VEHICLE BATTERY IS CON- CLOCKSPRING
NECTED. DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE CABLE BEFORE BEGINNING ANY WARNING: DISCONNECT AND ISOLATE THE BAT-
AIRBAG SYSTEM COMPONENT REMOVAL OR IN- TERY NEGATIVE CABLE BEFORE BEGINNING ANY
STALLATION PROCEDURE. THIS WILL DISABLE AIRBAG SYSTEM COMPONENT REMOVAL OR IN-
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT STALLATION PROCEDURE. THIS WILL DISABLE
THE BATTERY COULD RESULT IN ACCIDENTAL THE AIRBAG SYSTEM. FAILURE TO DISCONNECT
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL THE BATTERY COULD RESULT IN ACCIDENTAL
INJURY. ALLOW SYSTEM CAPACITOR TO DIS- AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
CHARGE FOR 2 MINUTES BEFORE REMOVING ANY INJURY. ALLOW SYSTEM CAPACITOR TO DIS-
AIRBAG COMPONENTS. CHARGE FOR 2 MINUTES BEFORE REMOVING ANY
AIRBAG COMPONENTS.
REMOVAL
(1) Disconnect the battery negative cable and iso- REMOVAL
late cable. (1) Place the front wheels in the straight ahead po-
(2) Remove the two screws attaching lower console sition before starting the repair.
to instrument panel support brackets (Fig. 9). (2) Disconnect the battery negative cable and iso-
(3) Slide cupholder out. late.
(3) Wait two minutes for the reserve capacitor to THE BATTERY COULD RESULT IN ACCIDENTAL
discharge before removing non deployed module. AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
(4) Remove the airbag module. INJURY. ALLOW SYSTEM CAPACITOR TO DIS-
(5) Remove Speed Control switch and connector if CHARGE FOR 2 MINUTES BEFORE REMOVING ANY
so equipped or cover. AIRBAG COMPONENTS.
(6) Disconnect horn terminals.
(7) Remove the steering wheel. (1) Place front wheels in the straight ahead posi-
(8) Remove upper and lower steering column tion.
shrouds to gain access to clockspring wiring. (2) Wait two minutes for the reserve capacitor to
(9) Disconnect the 2-way connector between the discharge before removing non deployed module.
clockspring and the instrument panel wiring harness (3) Refer to Steering Wheel procedures for removal
on top of the fuse block. of airbag module and steering wheel.
(10) To remove, pull clockspring assembly from the (4) Depress the two plastic locking pins to disen-
steering column by lifting locating fingers as neces- gage locking mechanism (Fig. 10).
sary. The clockspring cannot be repaired and must be
replaced if faulty.
INSTALLATION
(1) Snap clockspring onto the steering column. If
the clockspring is not properly positioned, follow the
clockspring centering procedure before installing
steering wheel.
(2) Connect the clockspring to the instrument
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panel harness, ensure wiring locator clips are prop-

erly seated on wiring trough. Ensure harness locking
tabs are properly engaged.
(3) Install steering column shrouds. Be sure airbag
wire is inside of shrouds.
(4) Front wheels should still be in the straight-
ahead position. Install steering wheel, ensure the
flats on hub align with clockspring. Pull the horn
lead through the smaller upper hole. Pull the airbag
and speed control leads through the larger bottom
hole. Ensure leads are not pinched under the steer-
ing wheel.
(5) Connect the horn lead wire, then the airbag
lead wire to the airbag module.
(6) Install the airbag module and tighten nuts to 9 Fig. 10 Clockspring (Auto-Locking)
to 11 Nzm (80 to 100 in. lb.) torque. (5) Keeping locking mechanism disengaged, rotate
(7) Install vehicle speed control switch and connec- the clockspring rotor in the CLOCKWISE DIREC-
tor or cover.
TION to the end of travel. Do not apply excessive
(8) Do not connect battery negative cable. Refer to
torque.
Airbag Systems Check for proper procedure.
(6) From the end of travel, rotate the rotor two full
CLOCKSPRING CENTERING PROCEDURE turns and a half in the counterclockwise direction.
If the rotating tape within the clockspring is not The horn wire should end up at the top and the
positioned properly with the steering wheel and the squib wire at the bottom. Engage clockspring locking
front wheels, the clockspring may fail during use. mechanism.
The following procedure MUST BE USED to center (7) Refer to Steering Wheel procedures for installa-
the clockspring if it is not known to be properly po- tion of steering wheel and airbag module.
sitioned, or if the front wheels were moved from the (8) Do not connect battery negative cable. Refer to
straight ahead position. Airbag System Check for proper procedure.

STEERING WHEEL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY. ALLOW SYSTEM CAPACITOR TO DIS-
CHARGE FOR 2 MINUTES BEFORE REMOVING ANY
AIRBAG COMPONENTS.
REMOVAL
(1) Make sure front wheels are straight and steer-
ing column is locked in place. Fig. 11 Steering Wheel Wiring
(2) Disconnect the battery negative cable and isolate.
(3) Wait two minutes for the reserve capacitor to WARNING: DISCONNECT AND ISOLATE THE BAT-
discharge before removing non deployed module. TERY NEGATIVE CABLE BEFORE BEGINNING ANY
(4) Remove four nuts attaching airbag module AIRBAG SYSTEM COMPONENT REMOVAL OR IN-
from the back side of steering wheel. STALLATION PROCEDURE. THIS WILL DISABLE
(5) Lift module and disconnect connector from rear THE AIRBAG SYSTEM. FAILURE TO DISCONNECT
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of module. THE BATTERY COULD RESULT IN ACCIDENTAL

(6) Remove vehicle speed control switch and con- AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
nector if so equipped or cover. INJURY. ALLOW SYSTEM CAPACITOR TO DIS-
(7) Remove steering wheel retaining nut. CHARGE FOR 2 MINUTES BEFORE REMOVING ANY
(8) Remove steering wheel with steering wheel AIRBAG COMPONENTS.
puller Tool C-3428B.
INSTALLATION REMOVAL
(1) If the clockspring is not properly positioned or (1) Disconnect the battery negative cable and isolate.
if front wheels were moved, follow the clockspring (2) Wait two minutes for the reserve capacitor to
centering procedure before installing steering wheel. discharge before removing non deployed module.
With the front wheels in the straight ahead position. (3) Remove four nuts attaching airbag module
Position the steering wheel on the steering column. from the back side of steering wheel.
Making sure to fit the flats on the hub of the steering (4) Lift module and disconnect connector from rear
wheel with the formations on the inside of the clock- of module.
spring. Pull the airbag and speed control wires (5) Remove vehicle speed control switch and con-
through the lower, larger hole in the steering wheel nector if so equipped or cover.
and the horn wire through smaller hole at the top. (6) Remove steering wheel.
Make sure not to pinch wires (Fig. 11). (7) Unsnap clockspring and remove it.
(2) Install retaining nut and tighten it to 61 Nzm (8) Refer to the appropriate section for switch re-
(45 ft. lbs.) torque. placement.
(3) Connect horn wiring lead.
(4) Connect 4-way connector to vehicle speed con- INSTALLATION
trol switch and attach switch to steering wheel. (1) Snap clockspring on to steering column. Assure
(5) Connect airbag lead wire to airbag module and the 4-way connector is still seated.
secure module to steering wheel. (2) Install steering wheel.
(6) Do not connect battery negative cable. Refer to (3) Install vehicle speed control switch and connec-
Airbag System Check for proper procedure. tor or cover.
(4) Connect clockspring wiring connector to the
STEERING COLUMN SWITCHES module.
This procedure covers the removal and installation (5) Install four nuts to module and tighten to 9 to
of the steering wheel and clockspring. Once the steer- 11 Nzm (80 to 100 in. lbs.) torque.
ing wheel and clockspring have been removed, refer (6) Do not connect battery negative cable. Refer to
to the appropriate section of this service manual for Airbag System Check for proper procedure.
switch replacement.
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. REAR WINDOW DEFOGGER 8N - 1
REAR WINDOW DEFOGGER
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 RIGHT POD SWITCH . . . . . . . . . . . . . . . . . . . . . . 1

REAR WINDOW GRID LINES TEST . . . . . . . . . . . 2 RIGHT POD SWITCH TEST . . . . . . . . . . . . . . . . . 2
REPAIR GRID LINES, TERMINALS AND SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PIGTAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION the right POD switch. An indicator illuminates when

The electrically heated rear window defogger (Fig. the switch is activated. The switch energizes the tim-
1) is available on wagons and vans. ing circuit and activates the rear window defogger re-
lay. The relay allows current to flow to the grid. The
defogger relay may be on for approximately 10 min-
utes or until the control switch or ignition is turned
off.
SYSTEM TEST
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Electrically heated rear window defogger operation

can be checked on the vehicle in the following man-
ner:
(1) Turn the ignition ON.
(2) Turn rear window defogger control switch ON.
(3) Using a ammeter on the battery, turn the de-
fogger control switch to the ON position, a distinct
increase in amperage draw should be noted.
(4) The rear window defogger operation can be
checked by feeling the glass. A distinct difference in
temperature between the grid lines and adjacent
clear glass can be detected in 3 to 4 minutes of oper-
ation.
(5) Using a DC voltmeter (Fig. 2) contact terminal
B with the negative lead, and terminal A with the
positive lead. The voltmeter should read 10-14 volts.
Fig. 1 Rear Window Defogger Wiring
The system consists of two vertical bus bars and a
series of electrically connected grid lines on the in-
side surface of the rear window.
When the switch is activated, current is directed to
the rear window grid lines. The heated grid lines in
turn heat the rear window to clear the outside sur-
face of the glass.
CAUTION: Since grid lines can be damaged or

scraped off with sharp instruments, care should be
taken in cleaning the glass or removing foreign ma-
terials, decals or stickers. Normal glass cleaning
solvents or hot water used with rags or toweling is
recommended.
RIGHT POD SWITCH Fig. 2 Grid Line Test

The rear window defogger switch is integrated into
8N - 2 REAR WINDOW DEFOGGER .
(6) Only steps (3) and (4) or (5) above will confirm (4) Connect negative lead of voltmeter to terminal
system operation. Indicator light illumination means A on passenger side bus bar and touch each grid line
that there is power available at the switch only and at Mid-Point with positive lead. A reading of approx-
does not necessarily verify system operation. imately 6 volts indicates a line is good. A reading of 0
(7) If turning the switch ON produced no distinct volts indicates a break in line between Mid-Point C
current draw on the ammeter the problem should be and terminal B. A reading of 10-14 volts indicates a
isolated in the following manner: break between Mid-Point C and ground terminal A.
(a) Confirm that ignition switch is ON. Move toward break and voltage will change as soon
(b) Ensure that the heated rear window feed pig- as break is crossed.
tail is connected to the wiring harness and that the
ground pigtail is in fact grounded. RIGHT POD SWITCH TEST
(c) Ensure that the fuse 20 in power distribution Refer to Group 8E Instrument Panel and Gauges
center is operational. for removal and test procedures.
(8) When the above steps have been completed and
REPAIR GRID LINES, TERMINALS AND PIGTAILS
the system is still inoperative, one or more of the fol-
The repair of grid lines and replacement of the ter-
lowing is defective:
minal is possible using the Mopar Repair Package or
(a) Right POD switch.
equivalent.
(b) Rear window defogger relay in relay bank. (1) Clean area surrounding grid line or terminal by
(c) Check for loose connector or a wire pushed gently rubbing area with steel wool.
out of connector. (2) Wipe area with clean cloth soaked in alcohol or
(d) Rear window grid lines (all grid lines would similar solvent. It is necessary that all contaminants
have to be broken, or one of the feed pigtails not be removed from repair area.
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connected to the bus bar, for no ammeter deflec- (3) Remove package separator clamp and mix plas-
tion). tic conductive epoxy thoroughly.
(9) If turning the switch ON produces severe volt- (4) For grid line, mark off area to be repaired with
meter deflection, the circuit should be closely checked masking tape (Fig. 3).
for a shorting condition.
(10) If the system operation has been verified but
indicator LED does not light, replace switch.
(11) For detailed wiring information, refer to
Group 8W, Wiring Diagrams.
REAR WINDOW GRID LINES TEST

The horizontal grid lines and vertical bus bar lines
printed and baked on inside surface of rear window
glass makes up an electrical parallel circuit. The
electrically conductive lines are composed of a silver
ceramic material which when baked on glass be-
comes bonded to the glass and is highly resistant to
abrasion. It is possible, however, that a break may Fig. 3 Grid Line Repair—Typical
exist or occur in an individual grid line resulting in
(5) Apply conductive epoxy through slit in masking
no current flow through the line. To detect breaks in
tape. Overlap both ends of the break.
grid lines, the following procedure is required:
(6) For a terminal replacement, apply a thin layer
(1) Turn ignition and rear window defogger control
of epoxy to area where terminal was fastened.
switch ON. The indicator light should come on. (7) Apply a thin layer of epoxy on terminal and
(2) Using a DC voltmeter with 0-15 volt range, place terminal on desired location. To prevent termi-
contact vertical bus bar connecting grid lines on pas- nal from falling off use a wooden wedge to secure it.
senger side of vehicle at terminal A with negative (8) Carefully remove masking tape from grid line.
lead of voltmeter (Fig. 2). With positive lead of volt-
meter, contact vertical bus bar on driver side of vehi- CAUTION: Do not allow the glass surface to exceed
cle at terminal B. The voltmeter should read 10-14 204°C (400°F), glass may fracture.
volts.
(3) With negative lead of voltmeter, contact a good (9) Allow epoxy to cure 24 hours at room tempera-
body ground point. The voltage reading should not ture or use heat gun with a 260°-371°C (500°-700°F)
change. A different reading indicates a poor ground range for 15 minutes. Hold gun approximately 254
connection. mm (10 inches) from repaired area.
. REAR WINDOW DEFOGGER 8N - 3
(10) After epoxy is properly cured remove wedge NALLY, INDUCE VOMITING; CALL A PHYSICIAN IM-
from terminal and check the operation of the rear MEDIATELY. IF IN CONTACT WITH EYES, FLUSH
window defogger. WITH PLENTY OF WATER. USE WITH ADEQUATE
VENTILATION. DO NOT USE NEAR FIRE OR FLAME.
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE CONTENTS CONTAINS 3
IRRITATION. CONTAINS EPOXY RESIN AND AMINE FLAMMABLE SOLVENTS.
TYPE HARDENER, HARMFUL IF SWALLOWED.
AVOID CONTACT WITH SKIN AND EYES. FOR SKIN,
WASH AFFECTED AREAS WITH SOAP AND WATER. WARNING: KEEP OUT OF REACH OF CHILDREN.
DO NOT TAKE INTERNALLY. IF TAKEN INTER-
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. POWER LOCKS 8P - 1
POWER LOCKS
CONTENTS
page page
AUTOMATIC DOOR LOCKS . . . . . . . . . . . . . . . . . 2 LOCK MOTOR REPLACEMENT SLIDING DOOR

CIRCUIT BREAKER TEST . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CIRCUIT TEST SLIDING DOOR . . . . . . . . . . . . . . 2 POWER DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . 1
DOOR LATCH WITH INTEGRAL LOCK—FRONT RELEASE SOLENOID REPLACEMENT LIFTGATE
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DOOR LOCK INHIBIT . . . . . . . . . . . . . . . . . . . . . . 1 REMOTE KEYLESS ENTRY . . . . . . . . . . . . . . . . . 4
DOOR LOCK SYSTEM TEST . . . . . . . . . . . . . . . . 2 REMOTE KEYLESS ENTRY SYSTEM (RKE) . . . . 1
ELECTRIC MOTOR TEST . . . . . . . . . . . . . . . . . . . 2 REMOTE KEYLESS MODULE REPLACEMENT . . . 7
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LIFT GATE OPERATION . . . . . . . . . . . . . . . . . . . . 3 SWITCH VOLTAGE TEST . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION POWER DOOR LOCKS

Both front doors and sliding side door, when elec- When vehicle is equipped with power door locks,
trically equipped, can be locked or unlocked electri- the system includes an automatic door locking fea-
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cally by operating the switch on a front door panel. ture. Which is actuated through the vehicle’s body
All doors can be locked or unlocked mechanically control module.
with the locking knob. The vehicle is built with the system disabled.
Both front doors and sliding door can be locked or When the system is disabled the door locks will
unlocked mechanically from the outside with the key work by use of the door lock switches only. When this
or electrically as described above. Both front doors system is enabled the automatic door locks will work
can also be unlocked by actuation of their respective automatically.
inside remote door handle. The body control module controls the power locks
The lift gate release consists of a latch with inter- when the door lock switch is activated. If the door
nal solenoid, A relay and push button switch. The so- lock switch is pressed for longer than eight consecu-
lenoid is energized only when the push button is tive seconds, the body control module will de-energize
depressed. the door lock relay. Also, the body control module will
automatically lock all doors when all of the condi-
DOOR LOCK INHIBIT tions below are met:
When the key is in the ignition switch in the ON or • All doors are closed
OFF position with the driver’s door open, the body • The vehicle speed exceeds 15 6 1 MPH
control module will ignore the command to lock the • The throttle position sensor tip-in is greater than
power door locks. Once the key is removed, or the 10 6 2 degrees
The automatic door lock can be enable/disable.
driver’s door is closed, the body control module will
The body control module will automatically re-lock
allow the power door locks to lock.
all doors if the above conditions are met and if any of
the doors become ajar. The body control module does
REMOTE KEYLESS ENTRY SYSTEM (RKE)
not control the door unlock function. The switch is
The system allows locking and unlocking of vehicle
wired directly to the unlock relay.
doors and lift gate by remote control using a hand The power lock motors are also equipped with a
held radio transmitter. The ignition switch must be thermal protection system which prevents the motors
OFF before the lift gate can be unlocked with the from burning out. The motors may chatter if they are
transmitter. continuously activated.
The receiver may receive signals from two trans- The sliding door can be locked or unlocked electri-
mitters. Each transmitter has its own code, and the cally when the door is closed. The sliding door can
code has been stored in memory. If the transmitter is also be locked electrically when the door is open as
replaced or a second transmitter is add, the code on follows: By activating the power lock switch to the
both units have to be placed in memory. lock position while the sliding door is open and the
key is not in the ignition switch. The front doors will
lock and send a signal to the body control module to
8P - 2 POWER LOCKS .
relock all doors upon the sliding door closing. Activat-

ing the power lock switch to the unlock position be-
fore the sliding door is closed will cancel the lock
request.
AUTOMATIC DOOR LOCKS

The vehicle comes with two options for automatic
door locks:
• Rolling automatic lock, enable approximately at 16
mph.
• No automatic lock, disable.
To change the automatic door lock selection, do the
following:
(1) Close all doors.
(2) Place the ignition key in the OFF position for Fig. 1 Door Lock Switch Continuity
20 seconds or more. ter, refer to (Fig. 1) to determine if continuity is
(3) Turn ignition key to the run position and to the correct in the Lock and Unlock switch positions. If
OFF position without cranking the engine four times. these results are not obtained, replace the switch.
The malfunction lamp will come on each time the key
is in the run position. CIRCUIT TEST SLIDING DOOR
(4) Press the power door lock button to lock the Connect one lead of a test light to the upper con-
doors. This procedure selects the next possible auto- tact on the B— pillar and the other lead to the lower
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matic door lock option. If the present option is unde- contact. If the test light comes on when the lock
sirable, repeat to arrive at the desired option. switch is depressed, the wiring circuit to the contacts
is good. If the test light does not come on:
DOOR LOCK SYSTEM TEST
• Check fuse
For complete testing of the automatic door lock sys-
• Check connectors at the right side cowl
tems, refer to the Body Diagnostic Procedures Man-
• Check for a broken wire
ual.
The sliding door partially open, connect jumper
SWITCH VOLTAGE TEST wires from contacts on door to contacts on B—pillar.
The following wiring test sequence determines Connecting these contacts should lock or unlock door
whether or not voltage is continuous through the when switch is depressed.
body harness to switch. If lock and unlock occurs, the fault is at the door
After removing switch from trim panel for testing and pillar switch contacts. Check for proper shim at
purposes, carefully separate multiple terminal block door contact plate. If lock and unlock does not occur,
on wiring harness from switch body. Connect one remove door trim panel and check for voltage at mo-
lead of test light to terminal 3 and touch other test tor connector.
light lead to ground (Fig. 1). If the test light comes
on, the wiring circuit between the battery and switch ELECTRIC MOTOR TEST
is functional. If light does not come on, check 30 amp Make certain battery is in normal condition before
circuit breaker or for a open circuit. circuits are tested.
To determine which motor is faulty, check each in-
CIRCUIT BREAKER TEST dividual door for electrical lock and unlock or discon-
Find correct circuit breaker on fuse block. Pull out nect the motor connectors one at a time, while
slightly but be sure that circuit breaker terminals operating the door lock switch. In the event that
still contact terminals in fuse block. Connect ground none of the motors work, the problem may be caused
wire of voltmeter to a good ground. With probe of by a shorted motor, a relay or a bad switch. Discon-
voltmeter positive wire, check both terminals of cir- necting the defective motor will allow the others to
cuit breaker for 12 volts. If only one terminal checks work.
at 12 volts, circuit breaker is defective and must be To test an individual door lock motor, disconnect
replaced. If neither terminal shows 12 volts, check the electrical connector from the motor. To lock the
for open or shorted circuit to circuit breaker. door, connect a 12 volt power source to the positive
pin of the lock motor and a ground wire to the other
SWITCH TEST pin (Figs. 2 and 3). To unlock the door reverse the
For switch testing, remove the switch and bezel as- wire connections at the motor pin terminals. If these
sembly from its mounting location. Using an ohmme- results are NOT obtained, replace the motor.
Fig. 4 Lift Gate Release Assembly

(2) Provide proper ground through latch mounting
screws.
(3) Remove latch and examine plunger, to insure it
is undamaged and properly attached, the plunger
Fig. 2 Sliding Door lock Motor should spring back when pressed.
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(4) Insure that solenoid plunger travel is adequate

approximately 16 mm (5/8 in.).
ADJUSTMENT
Adjust lift gate latch and striker so that liftgate
latches with a moderate slam. Should latch fail to
lock, replace latch assembly.
With ignition switch in ON or ACCESSORY posi-
tion, push lift gate switch to a ensure proper opera-
tion.
DOOR LATCH WITH INTEGRAL LOCK—FRONT

DOOR
REMOVAL
(1) Remove inside door release handle, window
regulator handle and door trim panel.
(2) Roll door water shield away from lower rear
corner of door to reveal inside panel access opening.
(3) Disconnect latch links and remove door latch
with integral lock motor (Fig. 5).
(4) Disconnect motor from wiring harness.
Fig. 3 Front Door Lock Motor (5) Remove motor mounting bracket screws and re-
LIFT GATE OPERATION move motor assembly from mounting.
The lift gate is controlled by a push button switch
INSTALLATION
in the steering column cover. The switch control a re-
(1) Connect motor link at latch and connect wires.
lay in the relay bank. The body control module pro-
(2) Attach motor to door inside panel and install
vides the ground for this relay only when the vehicle
screws.
is not moving. Automatic Transaxle must be in park
(3) Reset water shield at lower rear corner of door.
or neutral.
(4) Install window regulator handle, door inside re-
TEST lease handle bezel and door trim panel.
(1) Confirm solenoid lead wire is connected and 10
volts or more are available at solenoid (Fig. 4).
Fig. 5 Front Door Assembly Fig. 6 Latch Control Assembly

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LOCK MOTOR REPLACEMENT SLIDING DOOR (2) Connect solenoid link to locking lever and con-
REMOVAL nect solenoid power connector.
(1) Remove inside handle bezel screws. (3) Install door trim panel.
(2) Remove plastic button, in upper right corner of
door trim panel. Remove screw behind button and a
REMOTE KEYLESS ENTRY
second screw down towards the right middle of panel. OPERATION
(3) Remove three plastic retainers along bottom The transmitter has three buttons for operation
edge of panel. (Fig. 7).
(4) Using a trim stick, start at top left side of
panel and disengage trim clips.
(5) Remove complete door trim panel.
(6) Remove latch control assembly mounting bolts
(Fig. 6).
(7) To remove assembly, slide assembly to the
right, pull outward slightly and let it hang towards
the inside of vehicle.
(8) Remove motor link at locking lever.
(9) Disconnect motor power connector.
(10) Remove motor mounting screws and motor
from door.
RELEASE SOLENOID REPLACEMENT LIFTGATE

DOOR Fig. 7 Transmitter
(1) Remove liftgate trim panel
• UNLOCK driver’s door, enable illuminated entry.
(2) Remove solenoid link at locking lever.
Pushing and releasing the button once will unlock
(3) Disconnect solenoid power connector.
the driver’s door. Two times within five seconds all
(4) Remove solenoid mounting screws and motor
from door. doors will unlock.
• LOCK all doors and chirp horn. The chirp of horn
INSTALLATION verifies the lock signal was received.
(1) Install solenoid and tighten screws to 3 Nzm (25 • Unlock Lift Gate
in. lbs.) torque.
• The receiver is capable of retaining the transmit- (9) To reinstate the Horn Chirp feature refer to
ters in memory even when power is removed. Program Remote Keyless Entry.
• Each receiver must have at least one and no more
than two transmitters. TESTING
CONDITION: When trying to program the receiver
CONTROL RANGE module in the vehicle with a new transmitter and
Operation range is within 7 meters (23 ft.) of the there is no response from the module, Example: the
receiver. door locks do not cycle through a lock/unlock routine.
Refer to Fig. 8 for a block wiring diagram or to
TRANSMITTER BATTERY Group 8W, Wiring Diagrams.
The battery can be removed without special tools (1) Be sure that the module has a battery feed
and are readily available at local retail stores. The from the 15 amp fuse in cavity 1 of the black connec-
recommended battery is Duracell DL 2016 or equiva- tor. Also affected would be:
lent. Battery life is about one to two years. • Interior lights
• Power mirrors
PROGRAM REMOTE KEYLESS ENTRY • Radio memory
(1) Open and lower glove box door.
• Body control module
(2) Locate program line a dark green wire with a
(2) Be sure that the module has an ignition feed
molded insulator on the end. Located behind and
from 10 Amp fuse in cavity 7 of the blue connector.
lower end of the glove box.
Also affected would be the body computer, instru-
(3) Turn ignition switch to the ON position.
ment cluster and message center.
(4) Connect the program line from the Remote
(3) Be sure that the module has a ground to the
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Keyless Entry Module to ground. The door locks will

cavity 5 of the black connector.
lock and unlock to indicate the receiver is ready to
(4) Be sure that you are supplying a good ground
receive transmitter code. Lift gate solenoid will not
to the programming wire.
cycle.
(5) If the above circuits are good, replace the Re-
(5) Press any button on the transmitter to set code.
ceiver Module.
If there is a second transmitter it has to be set at CONDITION: Doors can be locked or unlocked with
this time. The locks will cycle to confirm program- the Keyless Entry transmitter. But the doors will not
ming. lock from the switch.
(6) Disconnect the program line from ground. This Check the connection from door lock switch to RKE
returns the system to its normal operation mode. module.
(7) Install glove box to original position CONDITION: All doors except driver’s door will
lock with the transmitter.
HORN CHIRP CANCELLATION (1) Test the driver’s door output of the Receiver
During the programming operation the horn chirp Module for a battery voltage.
can be disabled using the following procedures: (2) If there is no voltage at the pin, replace the Re-
(1) Open and lower glove box door. ceiver module.
(2) Locate program line a dark green wire with a (3) If there is a battery voltage at the output,
molded insulator on the end. Located behind and check the motor for battery voltage. If voltage OK,
lower end of the glove box. replace the door lock motor. If not OK, repair as nec-
(3) Turn ignition switch to the ON position. essary.
(4) Connect the program line from the Remote CONDITION: Only driver’s door will lock with the
Keyless Entry Module to ground. The door locks will transmitter.
lock and unlock to indicate the receiver is ready to • Repair ground circuit to unlock relay or the circuit
receive transmitter code. Lift gate solenoid will not from the motors to the relay.
cycle. • Replace unlock relay
(5) Press any button on the transmitter to set code. CONDITION: Doors do not lock with transmitter
If there is a second transmitter it has to be set at but lock using switch and still has horn CHIRP indi-
this time. The locks will cycle to confirm program- cating they did lock.
ming. Check circuit from remote keyless entry module to
(6) Press LOCK then UNLOCK transmitter but- the body control module. Check for proper connection
tons repeat three times. and that terminals are fully seated. If circuits are
(7) Door locks and rear release will cycle three OK replace receiver module.
times as feedback of Horn Chirp lockout. CONDITION: Doors will lock with the transmitter
(8) Remove ground from program line to restore but there is no horn CHIRP.
normal system operation. (1) Press horn button, listen horn sound.
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Fig. 8 Block Wiring Diagram

Fig. 9 Bezel Grille Removal Tool

(2) If the horn sounded, check continuity between
horn relay and RKE module. If no horn, check the
horn relay operation and wiring to horns.
(3) Still no CHIRP, check continuity between the Fig. 10 Bezel Grille Removal
horn relay and the receiver output pin. Repair as (2) To remove cluster bezel grille use the removal
necessary. tool (Fig. 9). Using tool at either end pull up and re-
(4) Still no horn CHIRP, replace the receiver mod- move grille (Fig. 10).
ule. (3) Remove six mounting screws from the hood and
(5) If using a DRB, refer to Body Diagnostic Proce- message center assembly. Using a flat blade tool pry
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dures. up on either end and remove module and disconnect

wire connector.
REMOTE KEYLESS MODULE REPLACEMENT (4) Remove two screws attaching the Remote Key-
(1) To remove top cover use a flat blade tool. Pry less Entry Module to instrument panel (Fig. 11).
up on either end and continue across the full length (5) To installation reverse above procedures.
of the top cover.
Fig. 11 RKE Module Removal

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. POWER SEATS 8R - 1
POWER SEATS
CONTENTS
page page
ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 MOTOR CABLE AND HOUSING . . . . . . . . . . . . . . 2

CIRCUIT BREAKER TEST . . . . . . . . . . . . . . . . . . . 1 MOTOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 2
HARNESS VOLTAGE TEST . . . . . . . . . . . . . . . . . . 1 SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORIZONTAL AND VERTICAL TRANSMISSIONS . . . . . 2 TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . 1
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION If only one terminal has battery voltage check for a
Driver’s power seat can be adjusted in six different short to ground between the circuit breaker and the
directions up, down, forward, back, tilt forward, or switch. If no short is found than, circuit breaker is
tilt rearward. defective and must be replaced. If neither terminal
A three armature permanent magnet reversible shows battery voltage, check for open or shorted cir-
motor is coupled through cables to worm gear box as- cuit to circuit breaker.
semblies located in the seat tracks, providing the var-
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ious seat movements. MOTOR TESTS

The electrical circuit is protected by a 20 amp cir- (1) Remove switch from mounting position and dis-
cuit breaker located in the micro relay bank. connect from harness (Fig. 1).
TEST PROCEDURES
Before any testing is attempted the battery should
be carefully charged and all connections and termi-
nals cleaned and tightened to insure proper continu-
ity and grounds.
With dome lamp on, apply switch in direction of
failure. If dome lamp dims the seat motion is trying
to work indicating mechanical jamming. If dome
lamp does not dim, then proceed with the following
electrical tests.
HARNESS VOLTAGE TEST

The following test will determine whether or not
voltage is continuous through the body harness to
the switch.
(1) Remove power seat switch from mounting posi-
tion and disconnect switch from wiring harness.
(2) Connect one lead of test light to ground termi-
nal, black wire (BK) of center section, and touch Fig. 1 Power Seat Switch Connector
other test light lead to red wire (RD) terminal.
(3) If test light comes on, harness to switch is (2) To check the front motor, connect a covered
good. If test light does not come on, perform circuit jumper wire between cavity number 2 and cavity
breaker test. number 12. Connect a second jumper wire between
cavity number 1 and cavity number 11. If the motor
CIRCUIT BREAKER TEST does not operate, reverse the jumpers (2 to 11 and 1
Find correct circuit breaker in the micro relay to 12). If motor still does not operate check wiring be-
bank. Pull out slightly but be sure that circuit tween switch connector and motor assembly. If wiring
breaker terminals still contact terminals in fuse checks good replace motor assembly.
block. Connect ground wire of voltmeter to a good (3) To check the center motor, connect a covered
ground. With probe of voltmeter positive wire, check jumper wire between cavity number 2 and cavity
both terminals of circuit breaker for battery voltage. number 9. Connect a second jumper wire between
8R - 2 POWER SEATS .
cavity 1 and cavity number 10. If the motor does not INSTALLATION
operate, reverse the jumpers (2 to 10 and 1 to 9). If (1) Position seat assembly in vehicle.
motor still does not operate check wiring between (2) Connect wiring harness.
switch connector and motor assembly. If wiring (3) Install and tighten mounting bolts and nuts.
checks good replace motor assembly. (4) Connect battery negative cable and check seat
(4) To check the rear motor, connect a covered operation.
jumper between cavity number 2 and cavity number
8. Connect a second jumper wire between cavity MOTOR CABLE AND HOUSING
number 1 and cavity number 4. If the motor does not
operate, reverse the jumpers (2 to 4 and 1 to 8). If REMOVAL
motor still does not operate, check wiring between It is recommended that anytime a cable is to be re-
switch connector and motor assembly. If wiring placed that the motor assembly be removed also for
checks good replace motor assembly. ease of replacement.
(5) If all motors and the seat operate properly, per- (1) After motor has been disconnected, remove
form Switch Test. corbin clamp from cable housing.
(2) Remove cables from motor by removing two
SWITCH TEST screws from bracket, then slide cables out of motor.
To check the switch, remove the switch from its
mounting position. Using an ohmmeter, and referring INSTALLATION
to the Switch Continuity, determine if continuity is (1) Insert cable and housing into bracket and in-
correct. If there is no continuity at any one of the stall corbin clamp.
switch positions, replace the switch. (2) Synchronize left and right hand adjuster posi-
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tions.
SEAT ASSEMBLY (3) Position cables in motor with bracket in posi-
tion, then secure with two screws.
REMOVAL (4) Install motor assembly.
(1) Remove adjuster attaching bolts and nuts from
floor pan. Move adjuster as required for access. HORIZONTAL AND VERTICAL TRANSMISSIONS
(2) Disconnect battery negative cable. Transmissions are not removable and no mainte-
(3) Disconnect wiring harness power lead at car- nance is required. If transmission fails replace entire
pet. seat adjuster assembly.
(4) Remove assembly from vehicle.
Fig. 2 Switch Continuity

. POWER SEATS 8R - 3
ADJUSTER (1) Remove seat assembly from vehicle following

procedure outlined under Seat Assembly Removal.
REMOVAL (2) Lay seat on its back on a clean surface.
(1) Remove seat assembly from vehicle following (3) Remove motor mounting screws.
procedure outlined under Seat Assembly Removal. (4) Carefully disconnect housing and cables from
(2) Lay seat on its back on a clean surface. motor assembly.
(3) Remove bolts attaching adjuster to seat assem-
bly. INSTALLATION
(4) Disconnect wiring harness at switch if seat (1) Place motor assembly into position.
mounted switch is used. (2) Carefully connect cables and housings to motor
assembly.
INSTALLATION
(3) Install mounting screws.
(1) Lay seat on its back on a clean surface.
(4) Install bolt holding motor assembly to adjuster.
(2) Position adjuster to seat assembly and install
attaching bolts. (5) Install seat assembly following procedure out-
(3) Connect wiring harness at switch. lined under Seat Assembly Installation.
(4) Install seat assembly following procedure out-
lined under Seat Assembly Installation.
MOTOR
REMOVAL
Anytime the motor, cable and housing assemblies
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require maintenance, the assemblies must be syn-

chronized to insure easy and proper operation.
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. POWER WINDOWS 8S - 1
POWER WINDOWS
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 SWITCH VOLTAGE TEST . . . . . . . . . . . . . . . . . . . 1

MOTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . 2 VENT CABLE AND CRANK MECHANISM . . . . . . 4
POWER VENT WINDOWS . . . . . . . . . . . . . . . . . . 3 VENT WINDOW MOTOR REPLACEMENT . . . . . . 5
POWER WINDOW CABLE HOUSING/MOTOR VENT WINDOW MOTOR TEST . . . . . . . . . . . . . . 3
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 2 VENT WINDOW SWITCH TEST . . . . . . . . . . . . . . 3
SWITCH CONTINUITY TEST . . . . . . . . . . . . . . . . 2 WINDOW MOTOR TEST . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION SWITCH VOLTAGE TEST

Window lift motors are of the permanent magnet The following wiring test sequence determines
type. A battery positive and negative connection to ei- whether or not voltage is continuous through the
ther of the two motor terminals will cause the motor body harness to switch (Fig. 2).
to rotate in one direction. Reversing current through
these same two connections will cause the motor to
rotate in the opposite direction.
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Each individual motor is grounded through the

master switch by a black wire attached to the left
cowl panel.
It is necessary that the window be free to slide up
and down in the glass channels or tubes and tracks.
If the window is not free to move up and down, the
window lift motor will not be able to move the glass.
To determine if the glass is free, disconnect the
electric window regulator lift plate from the glass
(Fig. 1). Then slide the window up and down by
hand.
Fig. 2 Mirror/Window Switch
(1) After removing switch from trim panel for test-

ing purposes, carefully separate multiple terminal
block on wiring harness from switch body.
(2) Turn ignition switch to the ON or ACCESSORY
position.
(3) Connect one lead of test light to black wire ter-
minal and touch other test light lead to tan wire ter-
minal.
(4) If the test light comes on, the wiring circuit be-
tween the battery and switch is functional.
(5) If light does not come on:
• Check 20 amp circuit breaker in the micro relay
bank
Fig. 1 Power Window Regulator • A broken feed or ground wire
8S - 2 POWER WINDOWS .
SWITCH CONTINUITY TEST (a) If window happens to be already in full UP

To check the switch, remove the switch from its position and motor is connected so to rotate in UP
mounting position. Using an ohmmeter, and referring direction no movement will be observed.
to the Switch Continuity (Figs. 3 and 4), determine if (b) Also, the motor connected to DOWN direction
continuity is correct. If there is no continuity at any rotation, no movement will be observed if window
one of the switch positions, replace the switch. is already in full down position.
(4) Reverse battery leads (steps 1 and 2) and win-
dow should now move. If window does not move, re-
move motor. See below for motor removal from
vehicle.
(5) If window moved completely up or down, motor
should be reversed one more time (step 4) to com-
plete a full window travel inspection.
(6) If switch voltage, continuity and motor test are
OK, check for open circuit the between motor and
switch.
POWER WINDOW CABLE HOUSING/MOTOR

REPLACEMENT
(1) Remove front door trim panel. Refer to group
23, Body.
(2) Disconnect window lift plate from glass (Fig. 5).
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(3) Disconnect window track from door.
Fig. 3 Master Switch Continuity
Fig. 5 Cable and Housing/Motor

(4) Disconnect window lift motor and drive cables.
(5) Disconnect electrical connections.
(6) Carefully remove window track, cables and lift
motor assembly from door.
MOTOR REPLACEMENT
REMOVAL
(1) Refer to Front Door Window Regulator for re-
moval.
Fig. 4 Front Door Window or Rear Vent Window (2) The door glass must be in the full up position.
Switch Continuity (3) Tape glass to door frame to hold glass in the up
WINDOW MOTOR TEST position.
(1) Connect battery positive test lead to either of (4) If the window is not in the full up position, re-
the two motor terminals. move only the motor from the door.
(2) Connect battery negative test lead to remaining (5) Remove nuts from motor and cable housing
motor terminal. (Fig. 6).
(3) The motor should now rotate in one direction to (6) Make sure motor is facing you before separat-
either move window up or down. ing motor from housing.
Fig. 8 Assist Spring Cover

(3) Replace assist spring on cable housing. Wind
spring clockwise 3 1/2 turns on the left door. The
right door, wind spring counter clockwise 3 1/2 turns
(Fig. 9).
Fig. 6 Separating Motor from Housing

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(7) Using a flat tool slowly separate motor from

housing, making sure the cable drum under the mo-
tor stays in cable housing. When motor is fully sepa-
rated the assist spring will be completely unwound
(Fig. 7).
Fig. 9 Wind Assist Spring Cover
(4) Install the other two studs and nuts and
tighten to 4 to 5 Mzm (35 to 45 in. lbs.) torque.
(5) Inspect that cables are not twisted prior to in-
stalling motor and housing into door.
POWER VENT WINDOWS

AS-body vehicles have, as an option, power rear
vent windows. The windows are operated by switches
mounted in the overhead console. A separate switch
is used for each window.
The vent window motors are of the permanent
magnet type. A battery positive and negative connec-
tion to either of the two motor terminals will cause
the motor to rotate in one direction. Reversing cur-
rent through these same two connections will cause
Fig. 7 Cable/Drum and Motor
the motor to rotate in the opposite direction.
(8) Remove assist spring by releasing the tabs on
the opposite sides of the spring, do not remove spring VENT WINDOW SWITCH TEST
from its case (Fig. 8). For power vent window switch testing, refer to
Group 8C, Overhead Console for Rear Vent Windows
INSTALLATION Switch Test.
(1) Install motor into housing with one stud and in
center of housing to secure motor to housing. VENT WINDOW MOTOR TEST
(2) Before installing new spring, power the motor (1) Connect battery positive test lead to either of
into the full-up position. the two motor terminals.
(2) Connect battery negative test lead to remaining
motor terminal.
8S - 4 POWER WINDOWS .
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Fig. 10 Motor and Cable Assemblies

(3) The motor should now rotate in one direction to (6) Remove upper and lower trim panels for the
either move the window OPEN or CLOSED. left side or one piece trim panel for the right side.
(a) If window happens to be already in the full (7) Remove two bolts attaching crank mechanism
CLOSED position and motor is connected to rotate to quarter panel (Fig. 10).
toward the CLOSED position no movement will be (8) Remove three screws attaching cable to motor.
observed. (9) Disengage pivot from quarter glass.
(b) Also, the motor connected to rotate OPEN, no (10) Remove cable retaining clip and remove cable
movement will be observed if the window is already assembly.
in full OPEN position.
INSTALLATION
(4) Reverse battery leads (opposite steps 1 and 2)
(1) Position cable to motor making sure cable pul-
and window should now move, or move in the oppo- ley engages with motor and install three screws (Fig.
site direction. If window does not move, remove mo- 11).
tor and cable assembly.
(5) If window moved completely OPEN and
CLOSED, motor should be reversed one more time
(reverse leads from step 4) to complete a full window
movement inspection.
(6) If switch voltage, continuity and motor test are
OK, check for open circuit the between motor and
switch.
VENT CABLE AND CRANK MECHANISM

REMOVAL
(1) Remove windshield side garnish molding.
(2) Remove rear seat(s).
(3) Remove front door and liftgate scuff plates.
(4) If servicing right side cable, remove side door
scuff plate and upper track cover.
(5) Remove B-pillar garnish molding and seat belt. Fig. 11 Cable Attaching Screws
(2) Engage pivot to quarter glass. REMOVAL

(3) Install crank mechanism bolts and pull mecha- (1) Remove rear quarter trim panel.
nism rearward while tightening (Proper alignment is (2) Disconnect wiring connector.
required for smooth non-binding operation). (3) Remove three screws attaching motor to cable
(4) Install cable retaining clip. (Fig. 11).
(5) Install upper and lower trim panels for the left (4) Remove two bolts attaching motor bracket to
side or one piece trim panel right side. quarter panel.
(6) Install B pillar garnish molding and seat belt. (5) Remove motor.
(7) Install side door scuff plate and upper track
cover. INSTALLATION
(8) Install front door scuff plate, liftgate scuff (1) Position motor to cable assembly making sure
plate, rear seat(s) and windshield side garnish mold- cable pulley engages with motor and install three
ing. screws.
(2) Install motor bracket to quarter panel bolts.
VENT WINDOW MOTOR REPLACEMENT (3) Connect wiring connector.
The following procedure describes replacement of a
(4) Install rear quarter trim panel.
defective motor without removing the cable assembly
from the vehicle.
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. POWER MIRRORS 8T - 1
POWER MIRRORS
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 MIRROR MOTOR TEST . . . . . . . . . . . . . . . . . . . . 1

HEATED MIRROR . . . . . . . . . . . . . . . . . . . . . . . . 1 MIRROR SWITCH REPLACEMENT . . . . . . . . . . . 2
MIRROR ASSEMBLY REPLACEMENT . . . . . . . . . 2 MIRROR SWITCH TEST . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION (4) If results shown in chart are not obtained,

Electrically-operated remote control mirrors are check for broken or shorted circuit, or replace mirror
available as an option on AS-body vehicles. The mir- assembly as necessary.
rors are controlled by a switch assembly located on
the driver’s door armrest bezel. MIRROR SWITCH TEST
The vehicle use a rocker switch for right or left side (1) Remove power mirror switch from mounting po-
mirror selection and four buttons for mirror UP, sition.
DOWN, RIGHT, or LEFT movement. (2) Disconnect wiring harness at switch connector.
The motors which operate the mirrors are part of (3) Using a ohmmeter, test for continuity between
the mirror assembly and cannot be serviced sepa- the terminals of the switch as shown in the Mirror
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rately. Switch Continuity Chart (Fig. 2).
MIRROR MOTOR TEST

(1) Remove door trim panel. Refer to Group 23,
Body.
(2) Disconnect wiring harness connector to the
Power Mirror.
(3) Using two jumper wires:
• Connect one to a 12-volt source
• Connect the other to a good body ground
• Refer to the Mirror Test Chart for wire hookups at
the switch connector (Fig. 1).
Fig. 2 Mirror Switch Test

If results shown in the chart are not obtained, re-
place the switch.
HEATED MIRROR
Heated mirrors are available on some models with
Power Mirrors and Rear Window Defogger only. The
heated mirror is controlled by the rear window defog-
ger switch. The heated mirror is on when the rear
window defogger is on.
Fig. 1 Power Mirror Test
8T - 2 POWER MIRRORS .
TEST PROCEDURES
(1) The mirror should be warm to the touch.
(a) If not check fuse #8 in the power distribution
center and relay #9 in relay block.
(b) Test voltage at rear window defogger switch.
• If no voltage repair wire.
• Apply voltage to one wire and ground the other, re-
fer to Fig. 1 for pin numbers. Mirror should become
warm to the touch.
• If not remove mirror glass and test the wires for
continuity. If no continuity repair wires.
• If wires are OK, replace mirror glass.
• To test defogger switch refer to Group 8N, Rear
Window Defogger.
MIRROR SWITCH REPLACEMENT

(1) Remove driver’s door mirror switch bezel from
armrest (Fig.3).
(2) Disconnect wiring connector.
(3) Remove switch from bezel.
Fig. 3 Power Mirror/Window switch Bezel
MIRROR ASSEMBLY REPLACEMENT
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(1) Remove door trim panel and weather shield.

Refer to Group 23, Body.
(2) Reach inside door and disconnect mirror wiring
at connector.
(3) Remove three mirror retaining nuts (Fig. 4).
(4) Pull mirror loose from door, and feed wiring
harness out through hole in outer door panel.
Fig. 4 Power Mirror

. CHIME WARNING/REMINDER SYSTEM 8U - 1
CHIME WARNING/REMINDER SYSTEM
CONTENTS
page page
CHIME SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . 1 KEY LEFT IN IGNITION . . . . . . . . . . . . . . . . . . . . 1

EXTERIOR LAMPS LEFT ON . . . . . . . . . . . . . . . . 1 KEY-IN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FASTEN SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . 1 SEAT BELT BUCKLE REPLACEMENT . . . . . . . . . . 3
FASTEN SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . 1 TURN SIGNAL WARNING . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 TURN SIGNAL WARNING . . . . . . . . . . . . . . . . . . 1
HEADLAMP SWITCH REPLACEMENT . . . . . . . . . 3
GENERAL INFORMATION • Must have input from either the right or left turn
signal lamps creates a voltage change between 0 and
WARNING: ON VEHICLES EQUIPPED WITH AN AIR- battery voltage.
BAG, REFER TO THE AIRBAG PORTION OF THIS • The vehicle speed sensor message to the power-
SECTION FOR STEERING WHEEL OR SWITCH RE- train control module, that the vehicle has exceed 24
MOVAL AND INSTALLATION PROCEDURES. km/h (15 mph) for 1.6 km (1.0 mi.).
• When the two conditions above are met, the chime
The chime warning/reminder system includes sig-
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will sound. The chime will stop when no further volt-

nals for fasten seat belts, turn signal warning, exte-
age change is detected.
rior lamps left on and key left in ignition.
• If hazard warning signals are pulsing, then no
When using the DRB, refer to the Body Chassis Di-
chime shall sound.
agnostic Manual for the procedure.
• If speed drops below 15 mph, before the warning is
FASTEN SEAT BELTS issued, the warning will not be issued and the dis-
A warning lamp on the instrument panel, and an tance counter will be reset.
audible chime tone are used as the fasten seat belt • If turn signal lamps are not working properly, the
warning/reminder. chime will not sound.
• When using DRB, refer to the Body Chassis Diag-
TURN SIGNAL WARNING nostic Manual for the procedure.
An audible chime tone shows that the turn signal
has been on for 1.6 km (1.0 mi.) at a speed above 24 EXTERIOR LAMPS LEFT ON
km/h (15 mph). To test the headlamps left on function:
• Turn ignition off
EXTERIOR LAMPS LEFT ON • Remove ignition key
An audible chime tone indicates the exterior lamps • Turn exterior lamps on with drivers door open.
were left on with the driver door open and ignition Chime should sound until headlamps are turned off
OFF. or drivers door is closed.
KEY LEFT IN IGNITION KEY LEFT IN IGNITION

An audible chime tone indicates the key was left in To test the key left in ignition function, insert key
ignition, with the ignition is in OFF position and into the ignition and open drivers door. Do not turn
driver door is open. ignition ON. Chime should sound until key is re-
moved from ignition or drivers door is closed.
FASTEN SEAT BELTS
To test the ignition switch must be in the off posi- CHIME SYSTEM DIAGNOSIS
tion for one minute before testing the fasten seat
belts. Turn the ignition switch to the ON position CONDITION: NO TONE WHEN IGNITION
with the driver’s seat belt unbuckled. The seat belt SWITCH IS TURNED ON AND DRIVERS SEAT
warning lamp should light for 4 to 8 seconds and the BELT IS UNBUCKLED
tone should sound 4 to 8 seconds.
REPAIR
TURN SIGNAL WARNING (1) Using a DRB, check for tone in any other func-
For the turn signal warning system to operate: tion.
8U - 2 CHIME WARNING/REMINDER SYSTEM .
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Fig. 1 Chime Warning/Reminder Wiring

(2) Check for battery feed at terminal B-16 and ig- CONDITION: NO FASTEN SEAT BELT LAMP
nition feed at terminal B-12 of body control module WHEN IGNITION SWITCH IS TURNED ON
(Figs. 1 and 2). Repair as necessary.
REPAIR
(1) Check for burned out bulb.
(2) Check for battery feed at terminal B-16 and
lamp output at terminal B-21 of body control module.
(3) Check for ignition feed at terminal B-12 of body
control module.
(4) Repair as necessary.
CONDITION: FASTEN SEAT BELT LAMP OR

TONE CONTINUES FOR MORE THAN 10
SECONDS AFTER SEAT BELTS ARE
FASTENED AND DRIVERS DOOR IS CLOSED
REPAIR
Replace body control module.
CONDITION: NO TONE WHEN PARK OR

Fig. 2 Body Control Module 25-Way Connectors
HEADLAMPS ARE ON AND DRIVERS DOOR IS
(3) Check driver’s seat belt buckle switch input for OPEN
a closed circuit when unbuckled. If input not seen
look for open in wiring or switch. The switch is REPAIR
grounded when belt is unbuckled. (1) Check left door ajar switch for good ground
(4) Repair as necessary. when drivers door is open.
(2) Inspect body control module connectors and
wires for proper connection.
. CHIME WARNING/REMINDER SYSTEM 8U - 3
(3) Check for battery feed at terminal B-16 of body (2) Inspect body control module connectors and
control module, step dim input on B-6 and variable wires for proper connection.
panel lamp level input on N-20. (3) Inspect for shorted key-in switch.
(4) Check park or headlamp switch. (4) Repair as necessary.
HEADLAMP SWITCH REPLACEMENT
CONDITION: NO TONE WHEN KEY IS LEFT IN Refer to Group 8E, Instrument Panel and Gauges.
IGNITION AND DRIVERS DOOR IS OPEN
REPAIR
SEAT BELT BUCKLE REPLACEMENT
Refer to Group 23, Body for service procedures.
(1) Check left door ajar switch for good ground
when drivers door is open.
KEY-IN SWITCH
(2) Inspect body control module connectors and
The Key-in switch is built into the ignition switch
wires for proper connection.
(3) Check for battery feed at terminal B-16 of body assembly. If the Key-in switch require service, the ig-
control module (Fig. 1). nition switch assembly must be replaced. Refer to
(4) Check key-in switch input at body control mod- Group 8D, Ignition System for service procedures.
ule B-4.
CONDITION: CHIMES CONTINUE WHEN

HEADLAMPS ARE TURNED OFF AND/OR KEY
IS REMOVED FROM IGNITION
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REPAIR
(1) Check wiring for a grounded condition between
key-in switch and body control module.
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. WIRING DIAGRAMS 8W - 1
WIRING DIAGRAMS
CONTENTS
page page
COMPONENT IDENTIFICATION . . . . . . . . . . . . . 11 SPLICE LOCATION . . . . . . . . . . . . . . . . . . . . . . . 33

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . 47
GENERAL INFORMATION
INDEX
page page
Circuit Identification . . . . . . . . . . . . . . . . . . . . . ... . 2 Relay Bank Identification . . . . . . . . .. . . . . . . . . . . . 6

Component Identification . . . . . . . . . . . . . . . . . ... . 3 Secondary Ignition Wiring . . . . . . . .. . . . . . . . . . . . 1
Connector and Terminal Assembly Replacement .. . 5 Splice Locations . . . . . . . . . . . . . . .. . . . . . . . . . . . 3
Connector Replacement . . . . . . . . . . . . . . . . . ... . 5 Symbols and Fuse Identification . . .. . . . . . . . . . . . 6
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . 3 Terminal Replacement . . . . . . . . . . .. . . . . . . . . . . . 6
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . 6 Troubleshooting Wiring Problems . .. . . . . . . . . . . . 4
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Fusible Link Replacement . . . . . . . . . . . . . . . . ... . 4 Wire Code Identification . . . . . . . . .. . . . . . . . . . . . 2

Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . ... . 4 Wiring Diagram Sheets and Indexes . . . . . . . . . . . . 1
Locating A System . . . . . . . . . . . . . . . . . . . . . ... . 2 Wiring Repair . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 5
Power Distribution Center Identification . . . . . . ... . 6
The wiring diagrams contain the latest information

at the time of publication.
Throughout this group references may be made to
a particular vehicle by letter or number designation.
A chart showing the breakdown of these designations
is included in the Introduction Section at the front of
this service manual.
SECONDARY IGNITION WIRING

Secondary ignition wiring is shown in Figures 1, 2,
and 3. For additional information on ignition systems
or distributor operation refer to Group 8D Ignition
Systems in this manual.
Fig. 2 Secondary Ignition Wiring 3.0L V6 Engine

WIRING DIAGRAM SHEETS AND INDEXES
The diagrams are organized to show the basic vehicle
and all of its options. Add-on or non-factory options are
not covered. The diagram pages are identified by a
sheet number which is located at the lower right or left
hand corner of each sheet. Page numbers at the top
of each page do not apply to diagram sheets.
Diagram sheets show all information relating to
the system. This includes feeds, grounds, switch in-
ternal circuity, connectors, splices, and pin identifica-
Fig. 1 Secondary Ignition Wiring 2.5L Engine tion for controllers and modules. All components,
8W - 2 WIRING DIAGRAMS .
Fig. 3 Secondary Ignition Wiring 3.3L, 3.8L V6 Engine Fig. 4 Wiring Diagram Page Sample
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switches, and relays are shown in the at rest position

with the ignition key removed and the doors closed.
In certain instances a wire may be referenced to
another sheet. When this happens, the wire will be
identified as to what it is ie: feed, ground, etc, and
where its going (Fig. 4). This has been done to aid in
the diagnosis of wiring and component problems.
The index used for the diagrams is located at the
beginning of the section. It covers all systems shown
in the diagrams and is in alphabetical order. The
main system and all related components are covered.
WIRE CODE IDENTIFICATION

Each wire shown in the diagrams contains a code
(Fig. 5) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is Fig. 5 Wire Color Code Identification
shown as a two letter code which can be identified by
agrams. Determine the diagram sheet number. Sheet
referring to the Wire Color Code Chart (Fig. 6). If the
wire has a tracer and it is a standard color an aster- numbers are located at the lower right or left hand
isk will follow the main wire color. If the tracer is corner of each sheet. Page numbers at the top of
non-standard the main wire color will have a slash (/) the page do not apply to diagram sheets.
after it followed by the tracer color. The diagram index identifies the main system and
all components that relate to that system. There are
CIRCUIT IDENTIFICATION also sections of the index that identify specific com-
All circuits in the diagrams use an alpha/numeric ponents only (for example modules, lamps, etc.). Re-
code to identify the wire and its function. To identify fer to a components name in the index if you are
which circuit code applies to a system, refer to the unclear as to what a system may be called.
Circuit Identification Code Chart. This chart shows Diagram sheets are arranged starting with the bat-
the main circuits only and does not show the second- tery and fuses. Then working into charging, starting,
ary codes that may apply to some models. and ignition systems. After this they start at the
front of the vehicle and work to rear. The diagrams
LOCATING A SYSTEM end with connector identification pages.
To locate a system or component in the diagrams,
refer to the alphabetical index at the front of the di-
example 1). If there is more than one splice per cir-

cuit a small box will be connected to it with the
splice number in it (Fig. 7 example 2).
To locate a splice in the wiring harness determine
the splice number from the wiring diagrams, then re-
fer to the splice location index. This section shows
the general location of the splice in the harness.
The wiring diagrams also indicate what harness
the splice is located in. To identify the harness an ab-
breviated call out is placed next to the main splice
(Fig. 4).
Fig. 7 Wiring Splice Examples

CONNECTORS
Fig. 6 Wire Color Code Chart The connectors shown in the diagram sheets are
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viewed from the terminal end unless otherwise spec-

COMPONENT IDENTIFICATION
ified. For viewing bulkhead, powertrain control mod-
When looking for a components location on the ve-
ule, and transmission control module connectors refer
hicle refer to the Component Identification section in-
to the rear of the wiring diagrams. This area shows
dex. This section shows the wire harness routing and
major connectors for pin and cavity information.
the components location in the vehicle. To use this
The connectors shown in the diagrams are identi-
section refer to the wiring diagrams for the location
fied in two ways. The first is an actual view of the
of the component. Then use the component identifi-
connector. This view shows the connector and which
cation index to locate the proper figure number.
cavity the wire is in.
The second way is with the use of arrows to indicate
SPLICE LOCATIONS the connector. This is done when the connector is to
Splice locations are indicated in the diagrams by a large to be shown on the diagram page. A box placed
diamond with a splice circuit code within it (Fig. 7 next to the connector identifies the connector and the
cavity the wire is in. In certain instances there may be This can be caused by a component failure or various
more than one connector in the same location. When wiring failures. Do not just replace the fusible
this happens the connector identification box will have a link to correct the problem.
number placed in it. Refer to the rear of the diagrams When diagnosing a faulty fusible link it is impor-
for a complete pin out of the connector. tant to check the wire carefully. In some instances
the link may be blown and it will not show through
TROUBLESHOOTING WIRING PROBLEMS the insulation, the wire should be checked over its
When troubleshooting wiring problems there are entire length for internal breaks.
six steps which can aid in the procedure. The steps (1) Disconnect battery negative cable.
are listed and explained below. (2) Cut out the blown portion of the fusible link.
(1) Verify the problem. (3) Strip 1 inch of insulation from each end of the
(2) Verify any related symptoms. Do this by perform- existing fusible link.
ing operational checks on components that are in the (4) Place a piece of heat shrink tubing over one
same circuit as the problem area. Refer to the wiring di- side of the fusible link. Make sure the tubing will be
agrams fuse application chart for circuit identification. long enough to cover and seal the entire repair area.
(3) Analyze the symptoms. Use the wiring dia- (5) Cut a replacement piece of fusible link approx-
grams to determine what the circuit is doing, where imately two inches longer than the piece removed.
the problem most likely is occurring and where the (6) Remove one inch of insulation from each end of
diagnosis will continue. the replacement fusible link.
(4) Isolate the problem area. (7) Spread the strands of wire apart on each of the
(5) Repair the problem. exposed wires (Fig. 9 example 1).
(6) Verify proper operation. For this step check for (8) Push the two ends of the wire together until
the strands of wire are close to the insulation (Fig. 9
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proper operation of all items on the circuit repaired.

Refer to the wiring diagram fuse application chart for example 2).
circuit identification. (9) Twist the wires together (Fig. 9 example 3).
(10) Solder the wires together using rosin core type
FUSIBLE LINKS solder only. Do not use acid core type solder.
Vehicle wiring harnesses are equipped with fusible (11) Center the heat shrink tubing over the joint
links to protect against harness damage in the event and heat using a heat gun. Heat the joint until the
of a short in the system. Fusible links are color coded tubing is tightly sealed and sealant comes out of both
to indicate wire gauge and size. Refer to the fusible ends of the tubing.
link chart for color and gauge identification (Fig. 8). (12) Secure the fusible link to the existing ones to
prevent chafing or damage to the insulation.
(13) Connect battery and test affected systems.
Fig. 8 Fusible Link Chart

FUSIBLE LINK REPLACEMENT
CAUTION: Do not replace blown fusible links with a
standard wire. Only use fusible type wire with hypa-
lon insulation or damage to the electrical system
could occur. Also make sure correct gauge of wir-
ing is used. Refer to the wiring diagrams for proper
gauge and color.
When a fusible link blows it is important to find

out what the problem is. They are placed in the elec-
trical system for protection against shorts to ground. Fig. 9 Wire Repair
WIRING REPAIR into the proper cavities. For additional connector pin
When replacing or repairing a wire, it is important out identification refer to the wiring diagrams.
that the correct gauge be used as shown in the wir- (8) Insert the connector locking wedge into the re-
ing diagrams. The wires must also be held securely paired connector.
in place to prevent damage to the insulation. (9) Connect connector to its mating half.
(1) Disconnect battery negative cable. (10) Connect battery and test affected systems.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each of
the exposed wires (Fig. 9 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 9 exam-
ple 2).
(6) Twist the wires together (Fig. 9 example 3).
(7) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
(8) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing. Fig. 11 Connector Locking Finger and Locking
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(9) Secure the wire to the existing ones to prevent Wedge (Typical)
chafing or damage to the insulation.
CONNECTOR AND TERMINAL ASSEMBLY
REPLACEMENT
CONNECTOR REPLACEMENT (1) Disconnect battery.
(1) Disconnect battery. (2) Disconnect the connector being repaired from
(2) Disconnect the connector that is to be repaired its mating half.
from its mating half. (3) Cut off the existing wire connector directly be-
(3) Remove connector locking wedge (Fig. 10). hind the insulator and remove six inches of tape from
the harness.
(4) Stagger cut all wires on the harness side about
1/2 inch apart (Fig. 13).
(5) Remove 1 inch of insulation from each wire on
the harness side.
(6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair (allow extra length
for soldered connections). Check that the overall
length is the same as the original (Fig. 12).
(7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area.
(9) Spread the strands of the wire apart on each of
the exposed wires (Fig. 9 example 1).
(10) Push the two ends of wire together until the
Fig. 10 Connector Locking Wedge Tab (Typical) strands of wire are close to the insulation (Fig. 9 ex-
(4) Position the connector locking finger away from ample 2).
the terminal while pulling on the wire to remove it (11) Twist the wires together (Fig. 9 example 3).
from the connector (Fig. 11). (12) Solder the connection together using rosin
(5) Reset the terminal locking tang, if it has one. core type solder only. Do not use acid core solder.
(6) Insert the removed wire in the same cavity on (13) Center the heat shrink tubing over the joint
the repair connector. and heat using a heat gun. Heat the joint until the
(7) Repeat steps four through six for each wire in tubing is tightly sealed and sealant comes out of both
the connector, being sure that all wires are inserted ends of the tubing.
FASTENERS
CAUTION: At no time when servicing a vehicle, can
a sheet metal screw, bolt or other metal fastener be
installed in the shock tower to take the place of an
original plastic clip. Also, NO holes can be drilled
into the front shock tower in the area shown in (Fig.
5), for the installation of any metal fasteners into
the shock tower.
Because of the minimum clearance in this area (Fig.
14) installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of
the spring. If a plastic clip is missing, or is lost or bro-
Fig. 12 Stagger Cutting Wires (Typical) ken during servicing a vehicle, replace only with the
(14) Repeat steps 8 through 13 for each wire. equivalent part listed in the parts catalog.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair.
(16) Reconnect the repaired connector.
TERMINAL REPLACEMENT
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(1) Disconnect battery.

(2) Disconnect the connector being repaired from
its mating half.
(3) Remove connector locking wedge (Fig. 10).
(4) Position the connector locking finger away from
the terminal while pulling on the wire to remove the
terminal from the connector (Fig. 11).
(5) Cut the wire 6 inches from the back of the connector.
(6) Remove 1 inch of insulation from the wire on
the harness side.
(7) Select a wire from the terminal repair assembly
that best matches the color wire being repaired. Fig. 14 Shock Tower To Spring Minimum Clearance
(8) Cut the repair wire to the proper length and re- Area
move 1 inch of insulation. SYMBOLS AND FUSE IDENTIFICATION
(9) Place a piece of heat shrink tubing over one Various symbols are used throughout the wiring di-
side of the wire. Make sure the tubing will be long agrams. These symbols can be identified by referring
enough to cover and seal the entire repair area. to the symbol identification chart (Fig. 15).
(10) Spread the strands of the wire apart on each For fuse block information refer to (Fig 16).
of the exposed wires (Fig. 9 example 1).
(11) Push the two ends of wire together until the CAUTION: When replacing a blown fuse it is impor-
strands of wire are close to the insulation (Fig. 9 exam- tant to replace it with a fuse having the correct am-
ple 2). perage rating. The use of a fuse with a rating other
(12) Twist the wires together (Fig. 9 example 3). than indicated may result in an electrical overload.
(13) Solder the connection together using rosin If a proper rated fuse continues to blow, it indicates
core type solder only. Do not use acid core solder. a problem that should be corrected.
(14) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both RELAY BANK IDENTIFICATION
ends of the tubing. For relay bank identification and location, refer to
(15) Insert the repaired wire into the connector. (Fig. 17).
(16) Install the connector locking wedge and recon-
nect the connector to its mating half. POWER DISTRIBUTION CENTER IDENTIFICATION
(17) Re-tape the wire harness starting 1-1/2 inches For power distribution center fuse and relay iden-
behind the connector and 2 inches past the repair. tification, refer to (Fig. 18).
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Fig. 15 Symbol Identification

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8W - 8
WIRING DIAGRAMS
Fig. 16 Fuse Block

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.
WIRING DIAGRAMS
Fig. 17 Relay Bank Identification

8W - 9
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Fig. 18 Power Distribution Center Identification

COMPONENT IDENTIFICATION
INDEX
page page
Caption Fig. Caption Fig.

Body Left Side Wiring . . . . . . . . . . . . . . . . . . . . . . . . . .1 Instrument Panel Wiring (Connections) . . . . . . . . . . . . . .13
Body Wiring (Right Side Front) . . . . . . . . . . . . . . . . . . . .7 Instrument Panel Wiring (Routing) . . . . . . . . . . . . . . . . .12
Body Wiring (Right Side Rear) . . . . . . . . . . . . . . . . . . . .6 Liftgate Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Door Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Overhead Console Wiring . . . . . . . . . . . . . . . . . . . . . . . .4
Door Wiring (Body Side) . . . . . . . . . . . . . . . . . . . . . . . .9 Power Seat Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine Compartment Wiring 2.5L . . . . . . . . . . . . . . . . . .18 Rear A/C Heater Wiring . . . . . . . . . . . . . . . . . . . . . . . . .5
Engine Compartment Wiring 3.0L . . . . . . . . . . . . . . . . . .19 Roof Wiring (Left Side) . . . . . . . . . . . . . . . . . . . . . . . . .2
Engine Compartment Wiring 3.3L, 3.8L . . . . . . . . . . . . . .20 Roof Wiring (Right Side) . . . . . . . . . . . . . . . . . . . . . . . .3
Engine Wiring 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Steering Column Wiring . . . . . . . . . . . . . . . . . . . . . . . .11
Engine Wiring 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Transmission Wiring 2.5L . . . . . . . . . . . . . . . . . . . . . . .21
Engine Wiring 3.3L . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Transmission Wiring 3.0L . . . . . . . . . . . . . . . . . . . . . . .22
Front End Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Transmission Wiring 3.3L, 3.8L . . . . . . . . . . . . . . . . . . .23
Fuel Tank/AWD Wiring . . . . . . . . . . . . . . . . . . . . . . . . .14 Underhood Lamp Wiring . . . . . . . . . . . . . . . . . . . . . . . .16
Ground Strap Locations . . . . . . . . . . . . . . . . . . . . . . . .27
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8W - 12
WIRING DIAGRAMS
Fig. 1 Body Left Side Wiring

.
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Fig. 2 Roof Wiring (Left Side)
Fig. 3 Roof Wiring (Right Side)

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Fig. 4 Overhead Console Wiring
Fig. 5 Rear A/C Heater Wiring

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Fig. 6 Body Wiring (Right Side Rear)
Fig. 7 Body Wiring (Right Side Front)

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Fig. 8 Power Seat Wiring
Fig. 9 Door Wiring (Body Side)

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Fig. 10 Door Wiring
Fig. 11 Steering Column Wiring

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8W - 18
WIRING DIAGRAMS
Fig. 12 Instrument Panel Wiring (Routing)

.
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.
WIRING DIAGRAMS
Fig. 13 Instrument Panel Wiring (Connections)

8W - 19
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8W - 20
WIRING DIAGRAMS
Fig. 14 Fuel Tank/AWD Wiring

.
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Fig. 15 Liftgate Wiring
Fig. 16 Underhood Lamp Wiring

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8W - 22
WIRING DIAGRAMS
Fig. 17 Front End Wiring

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.
WIRING DIAGRAMS
Fig. 18 Engine Compartment Wiring 2.5L

8W - 23
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8W - 24
WIRING DIAGRAMS
Fig. 19 Engine Compartment Wiring 3.0L

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.
WIRING DIAGRAMS
Fig. 20 Engine Compartment Wiring 3.3L, 3.8L

8W - 25
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8W - 26
WIRING DIAGRAMS
Fig. 21 Transmission Wiring 2.5L

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.
WIRING DIAGRAMS
Fig. 22 Transmission Wiring 3.0L

8W - 27
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8W - 28
WIRING DIAGRAMS
Fig. 23 Transmission Wiring 3.3L, 3.8L

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.
WIRING DIAGRAMS
Fig. 24 Engine Wiring 2.5L

8W - 29
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8W - 30
WIRING DIAGRAMS
Fig. 25 Engine Wiring 3.0L

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WIRING DIAGRAMS
Fig. 26 Engine Wiring 3.3L, 3.8L

8W - 31
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Fig. 27 Ground Strap Locations

SPLICE LOCATION
ALPHABETICAL INDEX
Splice Number Fig. Splice Number Fig.

0 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 K22 3.3L, 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
A0 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . . .13 K22 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
A1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 K24 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .16
A1 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . . .13 K24-1 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . .13
A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 L1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
A31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 L2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
A41 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .13 L3 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
A142 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 L3 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . . . .14
A142 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 L7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
A142 3.3L, 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 L7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
A142-1 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . .13 L20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
A142-2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 L39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
A142-3 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 L50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
A142-3 3.3L, 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . .20 L60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
A142-4 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . .13 L61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
B47 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .15 M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
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B120 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . .15 M1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

C7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 M1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
D1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 M1-3 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
D1-1 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .14 M1-3 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . .13
D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 M2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
D2-1 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .14 M2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
E2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 M11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 M22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
F15 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .16 P33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
F15-1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 P34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
F15-1 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . .13 P36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
F15-2 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . .13 T3 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . . .14
F19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 T13 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .16
F20 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 T16 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .14
F20 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .13 T41 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .14
F20-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 V3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
F21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
F62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
G5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 V10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
G9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 V23-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
G19 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .15 V23-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
K4 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 X2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
K4 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 X2 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . . .14
K4 3.3L, 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
K4-1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 X13-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
K4-2 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .14 X13-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
K4-3 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
K4-3 3.3L, 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 X15-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
K4-4 3.3L, 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 X15-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
K6-1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 X54-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
K6 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 X56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
K6 3.3L, 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Z0 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
K7 3.3L, 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Z1 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
K7-1 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Z1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
K7-2 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Z1-3 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Splice Number Fig. Splice Number Fig.

Z1-3 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .14 Z1-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Z1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Z1-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Z1-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Z2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Z1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Z3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Z1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Z11 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Z1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Z11-1 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . .13
Z1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Z12 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Z1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Z12 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .13
Z1-12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 Z13 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . . .14
Z1-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Z13-1 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . .13
Z1-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Z1-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Z1-21 3.0L, 3.3L, and 3.8L . . . . . . . . . . . . . . . . . . . . .15
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Fig. 1 Liftgate Splices
Fig. 2 Rear End Splices

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Fig. 3 Floor Pan Splices (Right Side)
Fig. 4 Body Left Side Splices

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Fig. 5 Fuel Tank and AWD Splices
Fig. 6 Roof Rail Splices

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Fig. 7 Cowl Panel Splices
Fig. 8 Front End Splices

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WIRING DIAGRAMS
Fig. 9 Instrument Panel Splices

8W - 39
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8W - 40
WIRING DIAGRAMS
Fig. 10 Instrument Panel Splices

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Fig. 11 Engine Compartment Splices 2.5L
Fig. 12 Engine Compartment Splices 2.5L

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8W - 42
WIRING DIAGRAMS
Fig. 13 Engine Compartment Splices 3.0L, 3.3L, and 3.8L

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WIRING DIAGRAMS

8W - 43
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Fig. 17 Engine Splices 2.5L
Fig. 18 Engine Splices 3.0L

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Fig. 19 Engine Splices 3.3L, 3.8L
Fig. 20 Engine Splices 3.3L, 3.8L

WIRING DIAGRAMS AS-BODY H-K
INDEX
Wiring Diagram Name Sheet Number Wiring Diagram Name Sheet Number
ABS Module Connector . . . . . . . . . . . . . . . . . . . . . . . .182 A/C and Heater Vacuum Switch . . . . . . . . . . . . . . . . .120
ABS Pump Hydraulic Modulator . . . . . . . . . . . . . . . . . .131 A/C Compressor Clutch Relay . . . . . . . . . . . . . . . . . .118
ABS Pump Motor Relay . . . . . . . . . . . . . . . . . . . . . . .133 A/C Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
ABS System Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .131 A/C High Pressure Cut-Out Switch . . . . . . . . . . . . . . .117
Airbag System Control Module Connector . . . . . . . . . . . .181 A/C Low Pressure Cut-Out Switch . . . . . . . . . . . . . . .117
Airbag System . . . . . . . . . . . . . . . . . . . . . . . . . .129, 130 Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Airbag System Control Module . . . . . . . . . . . . . . . . .129 Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . .120
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Blower Slide Switch . . . . . . . . . . . . . . . . . . . . . . . .120
Driver Side Airbag . . . . . . . . . . . . . . . . . . . . . . . . .129 Combo Valve Switch . . . . . . . . . . . . . . . . . . . . . . . .117
Passenger Side Airbag Module . . . . . . . . . . . . . . . . .130 Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . .119
Squib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 Defrost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
A/C Ambient Temperature Switch . . . . . . . . . . . . . . . . . .80 Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Air Conditioning System (2.5L Engine) . . . .105, 106, 107, 108 High Speed Fan Relay . . . . . . . . . . . . . . . . . . . . . . .118
A/C and Heater Vacuum Switch . . . . . . . . . . . . . . . . .108 Low Speed Fan Relay . . . . . . . . . . . . . . . . . . . . . . .117
A/C Compressor Clutch Relay . . . . . . . . . . . . . . . . . .106 Radiator Fan Motor (2-Speed) . . . . . . . . . . . . . . . . . .118
A/C Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Radiator Fan Switch . . . . . . . . . . . . . . . . . . . . . . . .117
A/C High Pressure Clutch Cut-Out Switch . . . . . . . . . .105 A/C and Heater Blower Motor Resistor . . .108, 112, 116, 120
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A/C Low Pressure Cut-Out Switch . . . . . . . . . . . . . . .105 Anti-Lock Brake System . . . . . . . . . . . . . . . .131, 132, 133
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 ABS Module . . . . . . . . . . . . . . . . . . . . . .131, 132, 133
Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . . . .108 ABS Pump Hydraulic Modulator . . . . . . . . . . . . . . . . .131
Blower Slide Switch . . . . . . . . . . . . . . . . . . . . . . . .108 ABS Pump Motor Relay . . . . . . . . . . . . . . . . . . . . . .133
Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . . .106 ABS System Relay . . . . . . . . . . . . . . . . . . . . . . . . .131
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . . . . .107 Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Combo Valve Switch . . . . . . . . . . . . . . . . . . . . . . . .105 Left Front Wheel Speed Sensor . . . . . . . . . . . . . . . . .131
Defrost Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Left Rear Wheel Speed Sensor . . . . . . . . . . . . . . . . .132
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Right Front Wheel Speed Sensor . . . . . . . . . . . . . . . .131
High Speed Fan Ground Relay . . . . . . . . . . . . . . . . . .105 Right Rear Wheel Speed Sensor . . . . . . . . . . . . . . . .132
High Speed Fan Relay Feed . . . . . . . . . . . . . . . . . . .106 Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Low Speed Fan Relay . . . . . . . . . . . . . . . . . . . . . . .105 Automatic Shut Down Relay 2.5L Engine . . . . . . . . . . . . .24
Radiator Fan Motor (2-Speed) . . . . . . . . . . . . . . . . . .106 Automatic Shut Down Relay 3.0L Engine . . . . . . . . . .28, 36
Radiator Fan Switch . . . . . . . . . . . . . . . . . . . . . . . .105 Automatic Shutdown Relay (3.3L 3.8L Engine) . . . . . . . . .43
Air Conditioning System Back-Up Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . .5, 83
(3.0L Engine) . . .109, 110, 111, 112, 113, 114, 115, 116 Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . . . . . .16, 18
A/C and Heater Blower Motor Resistor . . . . . . . . .112, 116 Battery . . . . . . . . . . . . . . . . . . . . . . .9, 11, 13, 30, 35, 44
A/C and Heater Vacuum Switch . . . . . . . . . . . . .112, 116 Blower Slide Control Switch . . . . . . . . . .104, 108, 112, 116
A/C Compressor Clutch Relay . . . . . . . . . . . . . . .110, 114 Body Controller . . . . . . . . . . . . . . . . . . . . . . . . . .99, 100
A/C Fan Motor . . . . . . . . . . . . . . . . . . . . . . . .110, 114 Body Controller Connector . . . . . . . . . . . . . . . . . .177, 178
A/C High Pressure Clutch Cut-Out Switch . . . . . . .109, 113 Body To Instrument Panel Wiring . . . . . . . . . . . . . .170, 172
A/C Low Pressure Cut-Out Switch . . . . . . . . . . . .109, 113 Brake Warning Lamp Switch . . . . . . . . . . . . . . . . . . . . .20
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . .111, 115 Bulkhead Disconnect Connector
Blower Motor Resistor . . . . . . . . . . . . . . . . . . .112, 116 (50 Way) . . . . . . . . . . . . . . . . . .158, 159, 160, 161, 162
Blower Slide Switch . . . . . . . . . . . . . . . . . . . . .112, 116 Camshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Combo Valve Switch . . . . . . . . . . . . . . . . . . . .109, 113 Center High Mounted Stop Lamp . . . . . . . . . . . . . . . . .147
Compressor Clutch . . . . . . . . . . . . . . . . . . . . . .111, 115 Charging System (2.5L Engine) . . . . . . . . . . . . . . . . .9, 10
Defrost Switch . . . . . . . . . . . . . . . . . . . . . . . .112, 116 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111, 115 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
High Speed Fan Relay . . . . . . . . . . . . . . . . . . .110, 114 Charging System (3.0L Engine) . . . . . . . . . . . . . . . . .11, 12
High Speed Fan Ground Relay . . . . . . . . . . . . . .109, 113 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Low Speed Fan Relay . . . . . . . . . . . . . . . . . . . .109, 113 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Radiator Fan Motor (2-Speed) . . . . . . . . . . . . . .110, 114 Charging System (3.3L and 3.8L Engine) . . . . . . . . . .13, 14
Radiator Fan Switch . . . . . . . . . . . . . . . . . . . . .109, 113 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Air Conditioning System (3.3L & Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.8L Engine) . . . . . . . . . . . . . . . . . . .117, 118, 119, 120 Chime-Key-in, Seatbelt Warning, Headlamp On . . . . . . . . .92
Cigar Lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Right Door Speaker . . . . . . . . . . . . . . . . . . . . . . . . .88
Circuit Breakers Right Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . .88
Circuit Breaker - 25 Amp . . . . . . . . . . . . . . . . . . . . . .57 Right Liftgate Speaker . . . . . . . . . . . . . . . . . . . . . . . .89
Headlamp Switch-Circuit Breaker . . . . . . . . . . . . . . . . .70 Stereo Radio With Clock . . . . . . . . . . . . . . . . . . . . . .87
Ignition Switch-Circuit Breaker . . . . . . . . . . . . . . . . . .20 Electronically Tuned Radio (w/o NBS) . . . . . . . . . . . . .90, 91
Power Seat-Circuit Breaker . . . . . . . . . . . . . . . .1, 2, 137 Left Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . . .91
Power Window-Circuit Breaker . . . . . . . . . . . . . . . .4, 135 Left Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Clock-With Radio . . . . . . . . . . . . . . . . . . . . . . . . . .87, 90 Right Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . .91
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . .56, 58, 129 Right Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Cluster Connector . . . . . . . . . . . . . . . . . . . . . . . . . . .179 Stereo Radio With Clock . . . . . . . . . . . . . . . . . . . . . .90
Clutch Pedal Position Switch . . . . . . . . . . . . . . . . . . . . .20 Engine Coolant Gauge . . . . . . . . . . . . . . . . . . . . . . . . .98
Combo Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Engine Coolant Temperature Sending Unit . . . . . . .42, 49, 50
Console Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Engine Coolant Temperature Sensor . . . . . . . . .25, 32, 37, 41
Coolant Sensor 2.5L Engine . . . . . . . . . . . . . . . . . . . . .25 Engine Oil Pressure and Temp System
Coolant Sensor 3.0L Engine . . . . . . . . . . . . . . . . . . .32, 37 w/o Transmission Control (2.5L and 3.0L) . . . . . . . . . . . .49
Coolant Sensor 3.3L and 3.8L Engine . . . . . . . . . . . . . . .41 Engine Coolant Temperature Sending Unit . . . . . . . . . . .49
Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . .75, 76 Engine Oil Pressure Sending Unit/Switch . . . . . . . . . . . .49
Crankshaft Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Engine Oil Pressure and Temp System
Data Link Connector . . . . . . . . . . .24, 26, 28, 36, 43, 83, 84 w/Transmission Control (3.0L, 3.3L and 3.8L) . . . . . . . . . .50
Daytime Running Lamp Jumper . . . . . . . . . . . . . . . . . . .67 Engine Coolant Temperature Sending Unit . . . . . . . . . . .50
Daytime Running Lamp Module . . . . . . . . . . . . . . . . . . .67 Engine Oil Pressure Sending Unit/Switch . . . . . . . . . . . .50
Daytime Running Lamp Module Connector . . . . . . . . . . .176 Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . .98
Dimmer Switch-Headlamp . . . . . . . . . . . . . . . . . . . . .2, 70 Engine Starter Motor . . . . . . . . . . . . . . . . . . . . .15, 17, 19
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Diode . . . . . . . . . . . . . . . . . . . . .107, 111, 115, 119, 133 Engine Starter System (2.5L Engine) . . . . . . . . . . . . .15, 16
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . .25, 32, 38 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Distributor Ignition Coil . . . . . . . . . . . . . . . . .23, 28, 36, 41 Manual Transmission Back-Up Lamp Switch . . . . . . . . .16
Dome and Courtesy Lamps . . . . . . . . . . . . . .75, 76, 77, 78 Park/Neutral/Back-Up Lamp Switch . . . . . . . . . . . . . . . .16
Front Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .75 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Left Front Door Courtesy Lamps . . . . . . . . . . . . . . . . .75 Transmission TCC LU Solenoid . . . . . . . . . . . . . . . . . .16
Left Header Lamp and Switch . . . . . . . . . . . . . . . . . . .77 Engine Starter System (3.0L Engine)
Left Liftgate Courtesy Lamp . . . . . . . . . . . . . . . . . . . .77 w/o Transmission Control . . . . . . . . . . . . . . . . . . . .17, 18
Liftgate Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . .77 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Rear Dome and Cargo Lamp . . . . . . . . . . . . . . . . . . .76 Park/Neutral Start/Back-Up Lamp Switch . . . . . . . . . . . .18
Right Front Door Courtesy Lamp . . . . . . . . . . . . . . . . .76 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Right Header Lamp and Switch . . . . . . . . . . . . . . . . . .77 Transmission TCC LU Solenoid . . . . . . . . . . . . . . . . . .18
Right Liftgate Courtesy Lamp . . . . . . . . . . . . . . . . . . .77 Engine Starter System (3.0L, 3.3L and 3.8L
Twin MAP-Courtesy Lamps . . . . . . . . . . . . . . . . . . . . .77 w/Transmission Control) . . . . . . . . . . . . . . . . . . . . . . . .19
Vanity Mirror Lamps . . . . . . . . . . . . . . . . . . . . . .75, 76 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Dome To Instrument Panel Wiring . . . . . . . . . . . . . . . . .166 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Door Lock System . . . . . . . . . . . . . . . . . . . . . . .139, 140 EVAP/Purge Solenoid 2.5L Engine . . . . . . . . . . . . . . . . . .22
Left Front Door Lock Motor . . . . . . . . . . . . . . . . . . .139 EVAP/Purge Solenoid 3.0L Engine . . . . . . . . . . . . . . .29, 40
Left Front Door Lock Switch . . . . . . . . . . . . . . . . . . .139 EVAP/Purge Solenoid (3.3L and 3.8L Engine) . . . . . . . . . .44
Lock Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Exhaust Gas Recirculation (EGR) Solenoid . . . . . . .31, 38, 44
Right Front Door Lock Motor . . . . . . . . . . . . . . . . . .139 Flasher-Combo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Right Front Door Lock Switch . . . . . . . . . . . . . . . . . .139 Fog Lamps . . . . . . . . . . . . . .59, 60, 61, 62, 63, 64, 65, 66
Sliding Side Door Lock Motor . . . . . . . . . . . . . . . . . .140 Fog Lamp System . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Unlock Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Electronic Vehicle Information Center (EVIC) . . . . . . . .83, 84 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Back-Up Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . .83 Front Door Ajar Switches . . . . . . . . . . . . . . . . . . . . . . .86
Data Link Connector . . . . . . . . . . . . . . . . . . . . . .83, 84 Front Door Courtesy Lamps . . . . . . . . . . . . . . . . . . .75, 76
Powertrain Control Module . . . . . . . . . . . . . . . . . .83, 84 Front Door To Instrument Panel Wiring . . . . . . . . . . . . .168
Transmission Control Module . . . . . . . . . . . . . . . . . . .83 Front End Lighting . . . . . . . . . . . . . . . . . . . .59, 60, 63, 64
Electronically Tuned Radio (With NBS) . . . . . . . . .87, 88, 89 Front End Lighting (2.5 and 3.0L Engine) w/o TCM . . .59, 60
Left Door Speaker . . . . . . . . . . . . . . . . . . . . . . . . . .88 Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Left Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . . .88 Left Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Left Liftgate Speaker . . . . . . . . . . . . . . . . . . . . . . . . .89 Left Park/Turn Signal Lamp . . . . . . . . . . . . . . . . . . . .60
Name Brand Speaker Relay . . . . . . . . . . . . . . . . . . . .87 Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Radio Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Right Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Right Park/Turn Signal Lamp . . . . . . . . . . . . . . . . . . .59 Fuel Injection Ignition System w/Transmission
Front End Lighting w/Daytime Running Lamps Control (3.0L Engine) . . . . . . . .34, 35, 36, 37, 38, 39, 40
(2.5L and 3.0L Engine w/o TCM) . . . . . . . . . . . . .61, 62 Automatic Shut Down Relay . . . . . . . . . . . . . . . . . . . .36
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Left Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Data Link Connector . . . . . . . . . . . . . . . . . . . . . . . . .36
Left Park/Turn Signal . . . . . . . . . . . . . . . . . . . . . . . .62 Distributer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Distributor Ignition Coil . . . . . . . . . . . . . . . . . . . . . . .36
Right Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 Engine Coolant Temperature Sensor . . . . . . . . . . . . . . .37
Right Park/Turn Signal Lamp . . . . . . . . . . . . . . . . . . .61 EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . . .40
Front End Lighting (3.0L, 3.3L, 3.8L Engine W/TCM) . . .63, 64 Exhaust Gas Recirculation Solenoid . . . . . . . . . . . . . . .38
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . .40
Left Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . . . . .39
Left Park/Turn Signal Lamp . . . . . . . . . . . . . . . . . . . .64 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Right Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 Powertrain Control Module . . . . .34, 35, 36, 37, 38, 39, 40
Right Park/Turn Signal Lamp . . . . . . . . . . . . . . . . . . .64 Throttle Position (Sensor) . . . . . . . . . . . . . . . . . . . . .39
Front End Lighting w/Daytime Running Lamps Fuel Injection Ignition System (3.3L and
(3.0L, 3.3L, 3.8L Engines w/TCM . . . . . . . . . . . . . .65, 66 3.8L Engine) . . . . . . . . . . . . . .41, 42, 43, 44, 45, 46, 47
Left Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Automatic Shut Down Relay . . . . . . . . . . . . . . . . . . . .43
Left Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Left Park/Turn Signal . . . . . . . . . . . . . . . . . . . . . . . .66 Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . .42
Right Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . . . .47
Right Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Data Link Connector . . . . . . . . . . . . . . . . . . . . . . . . .43
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Right Park/Turn Signal Lamp . . . . . . . . . . . . . . . . . . .65 Distributor Ignition Coil . . . . . . . . . . . . . . . . . . . . . . .41

Front End Lighting w/Daytime Running Lamps . .61, 62, 65, 66 Engine Coolant Sensor . . . . . . . . . . . . . . . . . . . . . . .41
Fuel Injection Ignition System Engine Coolant Temperature Sending Unit . . . . . . . . . . .42
(2.5L Engine) . . . . . . . . . . . . . . . .21, 22, 23, 24, 25, 26 Exhaust Gas Recirculation Solenoid . . . . . . . . . . . . . . .44
Automatic Shut Down Relay . . . . . . . . . . . . . . . . . . . .24 EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . . .44
Data Link Connector . . . . . . . . . . . . . . . . . . . . . .24, 26 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . .46
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . . . . .45
Distributor Ignition Coil . . . . . . . . . . . . . . . . . . . . . . .23 Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41, 42
Engine Coolant Sensor . . . . . . . . . . . . . . . . . . . . . . .25 MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . . .22 Powertrain Control Module . . . .41, 42, 43, 44, 45, 46, 47,
Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . .21 Throttle Position (Sensor) . . . . . . . . . . . . . . . . . . . . .45
Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . . . . .21 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Fuel Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Powertrain Control Module . . . . . . . .21, 22, 23, 24, 25, 26 Fuel Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . .128
Throttle Position (Sensor) . . . . . . . . . . . . . . . . . . . . .21 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . .128
Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . .25 Fuel Tank Level Gauge Sending Unit w/Low Fuel Switch .128
Fuel Injection Ignition System w/o Transmission Fuse Application Chart . . . . . . . . . . . . . . . . . . . .1, 2, 3, 4
Control (3.0L Engine) . . . . . . . .27, 28, 29, 30, 31, 32, 33 Fuseblock Module . . . . . . . . . . . . . . . . . . . . . . . .147, 148
Automatic Shut Down Relay . . . . . . . . . . . . . . . . . . . .28 Fuses
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 68, 137
Data Link Connector . . . . . . . . . . . . . . . . . . . . . . . . .28 Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 8, 70
Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Fuse 3 . . . . . . . . . . . . . . . . . . .1, 26, 56, 83, 84, 87, 92
Distributor Ignition Coil . . . . . . . . . . . . . . . . . . . . . . .28 Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4, 20, 94
Engine Coolant Temperature Sensor . . . . . . . . . . . . . . .32 Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4, 87, 90
EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . . .29 Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4, 79, 82
Exhaust Gas Recirculation (EGR) Solenoid . . . . . . . . . . .31 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 126, 142
Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . .29 Fuse 9 . . . . . . . . . . . . . . . . . . . .3, 60, 62, 64, 66, 100
Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . . . . .33 Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 140
Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 57
MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 121, 123
Powertrain Control Module . . . . .27, 28, 29, 30, 31, 32, 33 Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . .3, 20, 129
Throttle Position (Sensor) . . . . . . . . . . . . . . . . . . . . .33 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . .3, 20, 58
Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . .32 Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . .3, 20, 85
Fuse 16 . . . . . . . . . . . . . . . . . . . .3, 20, 22, 30, 35, 44
Fuse 17 . . . . . . . . . . . . . . . . . . . .2, 60, 62, 64, 66, 70 Right Front Door Illuminated Entry Switch . . . . . . . . . . .72
Fuse 18 . . . . . . . . . . . . . . . . . .2, 60, 62, 64, 66, 68, 70 Injectors . . . . . . . . . . . . . . . . . . . . . . . .26, 27, 34, 41, 42
Fuse 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . .4, 20, 69 Instrument Panel To Body Wiring . . . . . . . . . . . . . .169, 171
Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . .4, 20, 125 Instrument Panel To Dome Wiring . . . . . . . . . . . . . . . . .165
Fuse 26 . . . . . . . . . . . . . .4, 20, 104, 107, 111, 115, 119 Instrument Panel To Front Door Wiring . . . . . . . . . . . . .167
Fuse 27 . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 125, 127 Intermittent Wiper System . . . . . . . . . . . . . . . . . . . .93, 94
Fuse-15 Amp (PDC) . . . . . . . .7, 8, 24, 28, 36, 43, 48, 55, Intermittent Windshield Wiper Motor . . . . . . . . . . . . . .94
105, 106, 109, 110, 113, 114, 117, 118, 128, 131 Intermittent Wiper Switch . . . . . . . . . . . . . . . . . . . . .93
Fuse-30 Amp (PDC) . . . . . . . . . . . . . . . . . . . . . . . .5, 7 Park Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Fuse-40 Amp (PDC) . . . . . . . . . . . . . . . . . . . . . . . .7, 8 Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . .10, 12, 14 Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Windshield Washer Low Fluid Level Sensor . . . . . . . . . .93
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . .10, 12, 14 Windshield Washer Pump Motor . . . . . . . . . . . . . . . . .93
Glove Box Lamp and Switch . . . . . . . . . . . . . . . . . . . . .74 Key-In, Seatbelt Warning, Headlamp on Chime
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 w/Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Headlamp Dimmer Switch (Optical Horn) . . . . . . . . . . .2, 70 Lamps
Headlamps . . . . . . . . . . . . . .59, 60, 61, 62, 63, 64, 65, 66 Airbag Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . .85
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .3, 69 Anti-Lock (Yellow) Warning Lamp . . . . . . . . . . . . . . . .85
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . .69, 70 Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . . . . . .73
Combo Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . .143, 144
Dimmer Slider Switch . . . . . . . . . . . . . . . . . . . . . . . .69 Brake Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . .85
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Center High Mounted Stop Lamps . . . . . . . . . . . . . . .147
Left Pod Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Check Gauges Lamp . . . . . . . . . . . . . . . . . . . . . . . . .98
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Low Beam Switch . . . . . . . . . . . . . . . . . . . . . . . . . .69 Door Ajar Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Low Beam Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Front Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .75
Optical Horn Headlamp Dimmer Switch . . . . . . . . . . . . .70 Front Door Courtesy Lamps . . . . . . . . . . . . . . . . .75, 76
Park Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Front Switch Illumination . . . . . . . . . . . . . . . . . . . . .121
Park Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . .69 Glove Box Lamp/Switch . . . . . . . . . . . . . . . . . . . . . . .74
Headlamp Switch Controlled Interior Lamps . . . . . . . . . . .73 High Beam Indicator Lamp . . . . . . . . . . . . . . . . . . . . .85
Headlamp Switch Connector . . . . . . . . . . . . . .173, 174, 175 Illumination Lamps . . . . . . . . . . . . . . . . . . . . . . . . . .98
Heated Oxygen Sensor 2.5L Engine . . . . . . . . . . . . . . . . .21 Left Fog Lamp . . . . . . . . . . . . . . . . . . . . .60, 62, 64, 66
Heated Oxygen Sensor 3.0L Engine . . . . . . . . . . . . . .29, 40 Left Front Door Courtesy Lamp . . . . . . . . . . . . . . . . . .75
Heated Oxygen Sensor 3.3L and 3.8L Engine . . . . . . . . . .46 Left Header Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .77
Heated Rear Window System . . . . . . . . . . . . . . . . . .125 Left Headlamp . . . . . . . . . . . . . . . . . . . . .60, 62, 64, 66
Heated Rear Window . . . . . . . . . . . . . . . . . . . . . . . .126 Left Liftgate Courtesy Lamp . . . . . . . . . . . . . . . . . . . .77
Heated Rear Window Relay . . . . . . . . . . . . . . . . . . . .125 Left Park and Turn Signal Lamp . . . . . . . . .60, 62, 64, 66
Heated Rear Window Switch . . . . . . . . . . . . . . . . . . .125 Left Pod Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 Left Tail, Stop, Turn & Side Marker Lamp . . . . . . .143, 145
Heated Blower Motor Resistor . . . . . . . . . . . . . . . . . . .104 Left Turn Signal Indicator Lamp . . . . . . . . . . . . . . . . .85
Heater System 2.5L, 3.0L and 3.3L Engine . . . . . . . . . . .104 License Lamp . . . . . . . . . . . . . . . . . . . . . . . . .143, 144
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Liftgate Ajar Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .98
Blower Slide Control . . . . . . . . . . . . . . . . . . . . . . . .104 Low Fuel Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . .104 Malfunction Indicator Lamp . . . . . . . . . . . . . . . . . . . .98
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Overdrive Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
High Beam Indicator Lamp . . . . . . . . . . . . . . . . . . . . . .85 Rear Switch Illumination . . . . . . . . . . . . . . . . . . . . .122
Horn System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Rear Dome and Cargo Lamp . . . . . . . . . . . . . . . . . . .76
Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Right Fog Lamp . . . . . . . . . . . . . . . . . . . .59, 61, 63, 65
Horn (Hi Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Right Front Door Courtesy Lamp . . . . . . . . . . . . . . . . .76
Horn (Lo Note) . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Right Header Lamp . . . . . . . . . . . . . . . . . . . . . . . . .77
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Right Headlamp . . . . . . . . . . . . . . . . . . . .59, 61, 63, 65
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Right Liftgate Courtesy Lamp . . . . . . . . . . . . . . . . . . .77
Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . . . .21, 23 Right Park and Turn Signal Lamp . . . . . . . .59, 61, 63, 65
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .3, 20 Right Pod Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Clutch Pedal Position Switch . . . . . . . . . . . . . . . . . . .20 Right Tail, Stop, Turn & Side Marker Lamp . . . . . .144, 145
Brake Warning Lamp Switch . . . . . . . . . . . . . . . . . . . .20 Right Turn Signal Indicator Lamp . . . . . . . . . . . . . . . .85
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . .20 Seat Belt (Timed On) . . . . . . . . . . . . . . . . . . . . . . . .85
Illuminated Entry System . . . . . . . . . . . . . . . . . . . . . . .72 SRI Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Left Front Door Illuminated Entry Switch . . . . . . . . . . . .72 Twin Map-Courtesy Lamps . . . . . . . . . . . . . . . . . . . . .77
Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Name Brand Speaker Relay . . . . . . . . . . . . . . . . . . . . . .87
Washer Fluid Lamp . . . . . . . . . . . . . . . . . . . . . . . . .98 Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . .49, 50
Vanity Mirror Lamps . . . . . . . . . . . . . . . . . . . . . .75, 76 Overhead Console . . . . . . . . . . . . . . . . . . . . . . .8, 79, 183
Liftgate Courtesy Lamps . . . . . . . . . . . . . . . . . . . . . . . .77 Overhead Console Connector . . . . . . . . . . . . . . . . .134, 183
Liftgate Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Overhead Console Lamp w/Mini-Trip Computer . . . . . . .79, 80
Liftgate Release Solenoid . . . . . . . . . . . . . . . . . . . . . . .127 Overhead Console Lamp w/o Mini-Trip Computer . . . . .81, 82
Liftgate Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Park and Turn Signal Lamps . . .59, 60, 61, 62, 63, 64, 65, 66
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Park Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Park/Neutral Position Switch . . . . . . . . . . . . . . . .16, 18, 53
Liftgate Wiper Washer System . . . . . . . . . . . . . . . . .95, 96 Power Distribution Center . . . . . . . . . . . . . . . .1, 5, 6, 7, 8
Integral Wiper Park Switch . . . . . . . . . . . . . . . . . . . . .96 A/C Compressor Clutch Relay . . . . . . . . . . . . . . . . . . . .6
Liftgate Washer Motor . . . . . . . . . . . . . . . . . . . . . . . .96 Automatic Shut Down Relay . . . . . . . . . . . . . . . . . . . . .6
Liftgate Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . .96 Back-Up Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . .5
Rear Wash-Wiper Module . . . . . . . . . . . . . . . . . . . . .95 Engine Starter Relay . . . . . . . . . . . . . . . . . . . . . . . . . .7
Rear Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . .95 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Right Pod Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Fuse-15 Amp (PDC) . . . . . . . . . . . . . . . . . . . . . . . .7, 8
Low Beam Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Fuse-30 Amp (PDC) . . . . . . . . . . . . . . . . . . . . . . . .5, 7
Map Sensor 2.5L Engine . . . . . . . . . . . . . . . . . . . . . . . .22 Fuse-40 Amp (PDC) . . . . . . . . . . . . . . . . . . . . . . . .7, 8
Map Sensor 3.0L Engine . . . . . . . . . . . . . . . . . . . . .39, 33 High Speed Fan Ground Relay . . . . . . . . . . . . . . . . . . .5
Map Sensor 3.3L and 3.8L Engine . . . . . . . . . . . . . . . . .46 High Speed Fan Relay . . . . . . . . . . . . . . . . . . . . . . . .6
Mechanical Cluster Printed Circuit Board . . . . . . . . . . . . .98 Low Speed Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . .6
Micro Relay Block . . . . . . . . . . . . . . . . . . . . . . . . . . .152 Safety Shutdown Relay . . . . . . . . . . . . . . . . . . . . . . . .5
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Modules Power Distribution Center . . . . . . . . . . . . . . . . . . .149, 150

Airbag System Control Module . . . . . . . . . . . . . . . . .129 Power Rear Quarter Window . . . . . . . . . . . . . . . . . . . .134
ABS Module . . . . . . . . . . . . . . . . . . . . . .131, 132, 133 Powertrain Control Module . . . . . . . . . . . .21-47, 57, 83, 84
Daytime Running Lamp Module . . . . . . . . . . . . . . . . .67 Power Remote Mirrors . . . . . . . . . . . . . . . . . . . . .141, 142
Fuseblock Module . . . . . . . . . . . . . . . . . . . . . .147, 148 Left Heated Mirror . . . . . . . . . . . . . . . . . . . . . . . . .141
Passenger Side Airbag Module . . . . . . . . . . . . . . . . .130 Left Power Mirror . . . . . . . . . . . . . . . . . . . . . . . . . .141
Powertrain Control Module . . . . . . . . . . .21-47, 57, 83, 84 Mirror Control Switch . . . . . . . . . . . . . . . . . . . . . . .141
Rear Wash-Wiper Module . . . . . . . . . . . . . . . . . . . . .95 Right Heated Mirror . . . . . . . . . . . . . . . . . . . . . . . .142
Remote Keyless Entry Module . . . . . . . . . . . . . .101, 102 Right Power Mirror . . . . . . . . . . . . . . . . . . . . . . . . .142
Transmission Control Module . . . . . .51, 52, 53, 54, 55, 83 Power Seat System . . . . . . . . . . . . . . . . . . . . . . .137, 138
Motors Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
A/C Blower Motor . . . . . . . . . . . .107, 111, 115, 119, 122 Front Vertical Motor . . . . . . . . . . . . . . . . . . . . . . . .138
A/C Fan Motor . . . . . . . . . . . . . .103, 106, 110, 114, 118 Horizontal Motor . . . . . . . . . . . . . . . . . . . . . . . . . .138
Engine Starter Motor . . . . . . . . . . . . . . . . . . .15, 17, 19 Rear Vertical Motor . . . . . . . . . . . . . . . . . . . . . . . . .138
Fuel Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . .128 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Heater Blower Motor . . . . . . . . . . . . . . . . . . . .104, 124 Powertrain Control Module 60 Way Connector . .153, 154, 156
Idle Air Control Motor . . . . . . . . . . . . . . . .21, 33, 39, 45 Power Vent Motors . . . . . . . . . . . . . . . . . . . . . . . . . .134
Intermittent Windshield Wiper Motor . . . . . . . . . . . . . .94 Power Vent Window Switch . . . . . . . . . . . . . . . . . . . . . .79
Left Front Door Lock Motor . . . . . . . . . . . . . . . . . . .139 Power Window Lift System . . . . . . . . . . . . . . . . . .135, 136
Left Power Vent Motor . . . . . . . . . . . . . . . . . . . . . .134 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Liftgate Washer Motor . . . . . . . . . . . . . . . . . . . . . . . .96 Left Door Master Window Lift Switch . . . . . . . . . . . . .135
Liftgate Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . .96 Left Front Door Window Lift Motor . . . . . . . . . . . . . .135
Mode Servo Motor . . . . . . . . . . . . . . . . . . . . . . . . .122 Left Front Door Window Lift Switch . . . . . . . . . . . . . .135
Power Remote Mirror Motors . . . . . . . . . . . . . . .141, 142 Right Door Window Lift Switch . . . . . . . . . . . . . . . . .136
Power Seat Motors . . . . . . . . . . . . . . . . . . . . . . . . .138 Right Front Door Window Lift Motor . . . . . . . . . . . . .136
Power Window Motors . . . . . . . . . . . . . . . . . . .135, 136 Printed Circuit Board Connector . . . . . . . . . . . . . . . . . . .97
Radiator Fan Motor (2-Speed) . . . .103, 106, 110, 114, 118 Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . .103
Right Front Door Lock Motor . . . . . . . . . . . . . . . . . .139 Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Right Power Vent Motor . . . . . . . . . . . . . . . . . . . . .134 Radiator Fan System With Heater (2.5L, 3.0L
Sliding Side Door Lock Motor . . . . . . . . . . . . . . . . . .140 and 3.3L Engine) . . . . . . . . . . . . . . . . . . . . . . . . . .103
Starter (2.5L Engine) Motor . . . . . . . . . . . . . . . . . . . .15 High Speed Fan Ground Relay . . . . . . . . . . . . . . . . . .103
Starter (3.0L Engine) Motor . . . . . . . . . . . . . . . . . . . .17 High Speed Fan Relay . . . . . . . . . . . . . . . . . . . . . . .103
Starter (3.3 and 3.8L) Engine . . . . . . . . . . . . . . . . . . .19 Radiator Fan Motor (2 Speed) . . . . . . . . . . . . . . . . . .103
Windshield Washer Pump Motor . . . . . . . . . . . . . . . . .93 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87, 90
Multi-Function Switch Connector . . . . . . . . . . . . . . . . . .157 Radio Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Radio Speakers . . . . . . . . . . . . . . . . . . . . . . . .88, 89, 91 Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Radio with Clock . . . . . . . . . . . . . . . . . . . . . . . . . .87, 90 Sensors
Rear Heater-Only . . . . . . . . . . . . . . . . . . . . . . . . .123, 124 Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . .42
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .124 Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . . . .47
Front Control Switch . . . . . . . . . . . . . . . . . . . . . . . .123 Engine Coolant Sensor (2.5L Engine) . . . . . . . . . . . . . .25
Micro Temp Sensor . . . . . . . . . . . . . . . . . . . . . . . . .124 Engine Coolant Temperature Sensor (3.0L Engine) . . .32, 37
Rear A/C Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .123 Engine Coolant Sensor (3.3L and 3.8L Engine) . . . . . . . .41
Rear Blower Slide Switch . . . . . . . . . . . . . . . . . . . . .124 Heated Oxygen Sensor (2.5L Engine) . . . . . . . . . . . . . .21
Rear Heater Assembly . . . . . . . . . . . . . . . . . . . . . . .124 Heated Oxygen Sensor (3.0L Engine) . . . . . . . . . . .29, 40
Rear Heater and A/C System . . . . . . . . . . . . . . . . .121, 122 Heated Oxygen Sensor 3.3L and 3.8L Engine) . . . . . . . .46
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . .122 Left Front Wheel Speed Sensor . . . . . . . . . . . . . . . . .131
Front Control Switch . . . . . . . . . . . . . . . . . . . . . . . .121 Left Rear Wheel Speed Sensor . . . . . . . . . . . . . . . . .132
Lamp-Switch Illumination Front . . . . . . . . . . . . . . . . .121 Map Sensor (2.5L Engine) . . . . . . . . . . . . . . . . . . . . .22
Lamp-Switch Illumination Rear . . . . . . . . . . . . . . . . .122 Map Sensor (3.0L Engine) . . . . . . . . . . . . . . . . . .33, 39
Microtemp Sensor . . . . . . . . . . . . . . . . . . . . . . . . .122 Map Sensor (3.3L and 3.8L Engine) . . . . . . . . . . . . . . .46
Mode Servo Power . . . . . . . . . . . . . . . . . . . . . . . . .122 Micro Temp Sensor . . . . . . . . . . . . . . . . . . . . .122, 124
Mode Slide Switch . . . . . . . . . . . . . . . . . . . . . . . . .122 Right Front Wheel Speed Sensor . . . . . . . . . . . . . . . .131
Rear A/C Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Right Rear Wheel Speed Sensor . . . . . . . . . . . . . . . .132
Rear Blower slide Switch . . . . . . . . . . . . . . . . . . . . .122 Throttle Position Sensor (2.5L Engine) . . . . . . . . . . . . .21
Rear Heater and A/C Assembly . . . . . . . . . . . . . . . . .122 Throttle Position Sensor (3.0L Engine) . . . . . . . . . .33, 39
Rear Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . .143, 144 Throttle Position Sensor (3.3L and 3.8L Engine) . . . . . . .45
Left Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . . .143 Transmission Output Speed . . . . . . . . . . . . . . . . . . . .54
Left License Lamp . . . . . . . . . . . . . . . . . . . . . . . . .143 Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . .54
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Left Tail, Stop, Turn & Side Marker Lamp . . . . . . . . . .143 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . .25, 32
Right Back-Up Lamp . . . . . . . . . . . . . . . . . . . . . . . .144 Windshield Washer Low Fluid Level Sensor . . . . . . . . . .93
Right License Lamp . . . . . . . . . . . . . . . . . . . . . . . .144 Solenoids
Right Tail, Stop, Turn & Side Marker Lamp . . . . . . . . .144 EVAP/Purge Solenoid (2.5L Engine) . . . . . . . . . . . . . . .22
Rear Wiper Switch Connector . . . . . . . . . . . . . . . . . . . .185 EVAP/Purge Solenoid (3.0L Engine) . . . . . . . . . . . .29, 40
Relays EVAP/Purge Solenoid (3.3L and 3.8L Engine) . . . . . . . . .44
ABS Pump Motor Relay . . . . . . . . . . . . . . . . . . . . . .133 Exhaust Gas Recirculation Solenoid . . . . . . . . . .31, 38, 44
ABS System Relay . . . . . . . . . . . . . . . . . . . . . . . . .131 Liftgate Release Solenoid . . . . . . . . . . . . . . . . . . . . .127
A/C Compressor Clutch Relay . . . . . .6, 106, 110, 114, 118 Transmission TCC LU Solenoid . . . . . . . . . . . . . . .16, 18
A/C Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . .121, 123 Vacuum Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . .51
Automatic Shut Down Relay . . . . . . . . . .6, 24, 28, 36, 43 Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88, 89, 94
Back-Up Lamp Relay . . . . . . . . . . . . . . . . . . . . . . .5, 83 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Door Lock Relay . . . . . . . . . . . . . . . . . . . . . . . . . .140 Splices
Door Unlock Relay . . . . . . . . . . . . . . . . . . . . . . . . .140 Splice A1 . . . . . . . . . . . . . . . . . . . . . . . . . . .15, 17, 19
Engine Starter Relay . . . . . . . . . . . . . . . . . .7, 15, 17, 19 Splice A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 57
Fog Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Splice A4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1, 25
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . .6, 128 Splice A11-1 . . . . . . . . . . . . . . . . . . . . . . . . .10, 12, 14
Heated Rear Window Relay . . . . . . . . . . . . . . . . . .1, 125 Splice A11-2 . . . . . . . . . . . . . . . . . . . . . . . . .10, 12, 14
High Speed Fan Ground Relay . .5, 103, 105, 109, 113, 117 Splice A31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4, 20
High Speed Fan Relay . . . . . . .5, 103, 106, 110, 114, 118 Splice A41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Splice A142 . . . . . . . . . . . . . . . . . . . . . . . . . .9, 12, 23
Liftgate Release Relay . . . . . . . . . . . . . . . . . . . . . . .127 Splice A142-1 . . . . . . . . . . . . . . . . . . . . . . . . . .13, 43
Low Beam Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Splice A142-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 24
Low Speed Fan Relay . . . . . . . . . . .6, 105, 109, 113, 117 Splice A142-3 . . . . . . . . . . . . . . . . . . . . . . . .27, 34, 41
Name Brand Speaker Relay . . . . . . . . . . . . . . . . . . . .87 Splice A142-4 . . . . . . . . . . . . . . . . . . . . . . . .11, 28, 36
Park Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . .3, 70 Splice B47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . . . .103 Splice B120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Rear A/C Relay . . . . . . . . . . . . . . . . . . . . . . . .121, 123 Splice C7 . . . . . . . . . . . . . . . . .104, 108, 112, 116, 120
Safety Shut Down Relay . . . . . . . . . . . . . . . . . . . .5, 55 Splice C15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Relay Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151 Splice D1 . . . . . . . . . . . . . . . . . . . . . . . .26, 80, 83, 84
Remote Keyless Entry System . . . . . . . . . . . . . . . .101, 102 Splice D1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Remote Keyless Entry Module . . . . . . . . . . . . . . . .101, 102 Splice D2 . . . . . . . . . . . . . . . . . . . . . . . .26, 80, 83, 84
Remote Keyless Entry Module Connectors . . . . . . . . . . . .184 Splice D2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Splice E2 . . . . . . . . . . . . . . . . . . . . . . .73, 87, 90, 121
Seat Belt Warning System . . . . . . . . . . . . . . . . . . . . . . .92 Splice E2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .73, 121
Splice E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Splice V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Splice F15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Splice V10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Splice F15-1 . . . . . . . . . . . . . . . . . . . . . .22, 30, 35, 44 Splice V23-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Splice F15-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .35, 44 Splice V23-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Splice F19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Splice X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Splice F20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Splice X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Splice F20-1 . . . . . . . . . . . . . . . . . . . . . .121, 125, 129 Splice X13-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Splice F21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135 Splice X13-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Splice F62 . . . . . . . . . . . . . . . . . .26, 56, 83, 84, 87, 92 Splice X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Splice G5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Splice X15-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Splice G6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49, 50 Splice X15-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Splice G9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Splice X54-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Splice G19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133 Splice X56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Splice K4 . . . . . . . . . . . . . . . . . . . . . . . .25, 29, 40, 46 Splice Z0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Splice K4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Splice Z1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9, 107
Splice K4-2 . . . . . . . . . . . . . . . . . . . . . . . . .31, 37, 47 Splice Z1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .56, 92
Splice K4-3 . . . . . . . . . . . . . . . . . . . . . . . . .32, 38, 47 Splice Z1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . .72, 142
Splice K4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Splice Z1-3 . . . . . . . . . . . . . . . . . . . .56, 59, 65, 61, 63
Splice K6 . . . . . . . . . . . . . . . . . . . . . . . . . . .33, 39, 45 Splice Z1-4 . . . . . . . . . . . . . . . . . . . . .60, 62, 131, 133
Splice K6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 Splice Z1-6 . . . . . . . . . . . . . . . . . . . .60, 62, 64, 66, 68
Splice K7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Splice Z1-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Splice K7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Splice Z1-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Splice K7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Splice Z1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . .51, 144
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Splice K22 . . . . . . . . . . . . . . . . . . . . . . . . . . . .39, 56 Splice Z1-10 . . . . . . . . . . . . . . . . . . . . . . . . . . .79, 81

Splice K24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Splice Z1-11 . . . . . . . . . . . . . . . . . . . . . . . . . .51, 143
Splice K24-1 . . . . . . . . . . . . . . . . . . . . . . . . . . .38, 53 Splice Z1-12 . . . . . . . . . . . . . . . . . . . . . . . . . .143, 147
Splice L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144 Splice Z1-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Splice L1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Splice Z1-18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Splice L2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Splice Z1-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Splice L3 . . . . . . . . . . . . . . . . . . . . . . . .59, 61, 63, 65 Splice Z1-21 . . . . . . . . . . . . . . . . . . . . . . . .64, 66, 113
Splice L7 . . . . . . . . . . . . . . . . . . . . . .3, 60, 62, 64, 66 Splice Z1-22 . . . . . . . . . . . . . . . . . . . . . . . . . .51, 128
Splice L7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Splice Z1-23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Splice L7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Splice Z1-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Splice L20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2, 70 Splice Z2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Splice L39 . . . . . . . . . . . . . . . . . . . . .60, 62, 64, 66, 68 Splice Z3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Splice L50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 Splice 73-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Splice L60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Splice Z11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Splice L61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Splice Z11-1 . . . . . . . . . . . . . . . . . . . . . . . . .30, 35, 44
Splice L62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Splice Z12 . . . . . . . . . . . . . . . . . . . . . . .23, 30, 36, 43
Splice L63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Splice Z13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Splice M1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Splice Z13-1 . . . . . . . . . . . . . . . . . . . . . . . . .30, 44, 52
Splice M1-1 . . . . . . . . . . . . . . . . . . . . . . . . . .139, 142 Squib (Airbag Igniter) . . . . . . . . . . . . . . . . . . . . . . . . .129
Splice M1-2 . . . . . . . . . . . . . . . . . . . . . . . . .76, 79, 81 Stereo Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87, 90
Splice M1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Stop Lamp/Speed Control Switch . . . . . . . . . . . . . . . . . .57
Splice M2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Stop/Turn and Hazard Flasher Systems . . . . . . . . . . . . . .71
Splice M2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . .76, 77 Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Splice M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143 Switches
Splice M11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 A/C Ambient Temp Switch . . . . . . . . . . . . . . . . . . . . .80
Splice M11-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 A/C and Heater Vacuum Switch . . . . . . . . . . . . .108, 112
Splice M22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 A/C/Htr Front Control Switch . . . . . . . . . . . . . . . . . . .121
Splice P33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139 A/C High Pressure Clutch Cut-Out Switch (2.5L Engine) .105
Splice P36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140 A/C High Pressure Clutch Cut-Out Switch
Splice T3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 (3.0L Engine) . . . . . . . . . . . . . . . . . . . . . . . .109, 113
Splice T13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 A/C High Pressure Clutch Cut-Out Switch (3.3L
Splice T16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 and 3.8L Engine) . . . . . . . . . . . . . . . . . . . . . . . . .117
Splice T41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 A/C Low Pressure Cut-Out Switch . . . . .105, 109, 113, 117
Splice V3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Back-Up Lamp Switch . . . . . . . . . . . . . . . . . . . . .16, 18
Splice V5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Blower Slide Control Switch . . . . .104, 108, 112, 116, 120 Transmission Range Switch . . . . . . . . . . . . . . . . . . . .52
Brake Warning Lamp Switch . . . . . . . . . . . . . . . . . . . .20 Transmission Solenoids & Pressure Switch . . . . . . . . . .51
Clutch Pedal Position Switch . . . . . . . . . . . . . . . . . . .20 Turn Signal Switch . . . . . . . . . . . . . . . . . . . . . . . . . .71
Combo Valve Switch . . . . . . . . . . . . . .105, 109, 113, 117 Vanity Mirror Lamp On Switch . . . . . . . . . . . . . . .75, 76
Dimmer Slider Switch . . . . . . . . . . . . . . . . . . . . . . . .69 Vehicle Speed Control Switch . . . . . . . . . . . . . . . . . . .58
Defrost Switch . . . . . . . . . . . . . . . . .108, 112, 116, 120 Windshield Wiper-Intermittent Switch . . . . . . . . . . . . . .93
Engine Oil Pressure Sending Unit/Switch . . . . . . . . .49, 50 Wiper Park Switch . . . . . . . . . . . . . . . . . . . . . . . . . .94
Fog Lamps Switch . . . . . . . . . . . . . . . . . . . . . . . . . .68 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Front Control Switch . . . . . . . . . . . . . . . . . . . .121, 123 Throttle Position Sensor (2.5L Eng) . . . . . . . . . . . . . . . .21
Front Left Door Ajar Switch . . . . . . . . . . . . . . . . . . . .86 Throttle Position Sensor (3.0L Eng) . . . . . . . . . . . . . . . .33
Front Right Door Ajar Switch . . . . . . . . . . . . . . . . . . .86 Throttle Position Sensor (3.3L and 3.8L) . . . . . . . . . . . . .45
Glove Box Lamp Switch . . . . . . . . . . . . . . . . . . . . . .74 Trailer Tow System . . . . . . . . . . . . . . . . . . . . . . . . . .145
Hazard Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Transaxle Solenoid Connector . . . . . . . . . . . . . . . . . . . .164
Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . .3, 69 Transmission Control Module Connector . . . . . . . . . . . . .163
Headlamp Dimmer Switch . . . . . . . . . . . . . . . . . . .2, 70 Transmission Solenoids and Pressure Switch . . . . . . . . . .51
Heated Rear Window Switch . . . . . . . . . . . . . . . . . . .125 Transmission Control and AWD System . . .51, 52, 53, 54, 55
Heater Blower Control Switch . . . . . . . . . . . . . . . . . .104 Overdrive Switch and Lamp . . . . . . . . . . . . . . . . . . . .55
Heater Control Switch . . . . . . . . . . . . . . . . . . . . . . .123 Park/Neutral Position Switch . . . . . . . . . . . . . . . . . . . .53
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Safety Shut Down Relay . . . . . . . . . . . . . . . . . . . . . .55
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .3, 20 Transmission Control Module . . . . . . . . .51, 52, 53, 54, 55
Integral Wiper Pack Switch . . . . . . . . . . . . . . . . . . . .96 Transmission Solenoids & Pressure Switches . . . . . . . . .51
Intermittent Wiper Switch . . . . . . . . . . . . . . . . . . . . .93 Transmission Output Speed Sensor . . . . . . . . . . . . . . .54
Key Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Transmission Range Switch . . . . . . . . . . . . . . . . . . . .52
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Left Door Master Window Lift Switch . . . . . . . . . . . . .135 Turbine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . .54
Left Front Door Lock Switch . . . . . . . . . . . . . . . . . . .139 Vacuum Solenoid A . . . . . . . . . . . . . . . . . . . . . . . . .51
Left Front Door Illuminated Entry Switch . . . . . . . . . . . .72 Vacuum Solenoid B . . . . . . . . . . . . . . . . . . . . . . . . .51
Left Front Door Ajar Switch . . . . . . . . . . . . . . . . . . . .86 Transmission TCC LU Solenoid . . . . . . . . . . . . . . . . .16, 18
Left Header Lamp Switch . . . . . . . . . . . . . . . . . . . . . .77 Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Left Vent Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .134 Vacuum Solenoid (AWD) . . . . . . . . . . . . . . . . . . . . . . . .51
Liftgate Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . .77 Vehicle Speed Control and Stop Lamp Switch . . . . . . .57, 58
Liftgate Release Switch . . . . . . . . . . . . . . . . . . . . . .127 Clockspring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Low Beam Switch . . . . . . . . . . . . . . . . . . . . . . . . . .69 Powertrain Control Module . . . . . . . . . . . . . . . . . . . . .57
Manual Transmission Back-Up Lamp Switch . . . . . . . . .16 Stop Lamp Switch with Vehicle Speed Control . . . . . . . .57
Master Window Lift Switch . . . . . . . . . . . . . . . . . . . .135 Vehicle Speed Control Servo . . . . . . . . . . . . . . . . . . . .58
Mirror Control Switch . . . . . . . . . . . . . . . . . . . . . . .141 Vehicle Speed Control Switch . . . . . . . . . . . . . . . . . . .58
Mode Slide Switch . . . . . . . . . . . . . . . . . . . . . . . . .122 Vehicle Speed Control Servo . . . . . . . . . . . . . . . . . . . . .58
Optical Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . .70 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . .25, 32
Overdrive Switch and Lamp . . . . . . . . . . . . . . . . . . . .55 Voltage Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . .20 Warning Lamp Center . . . . . . . . . . . . . . . . . . . . . . . . .85
Park Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . .69 Anti-Lock Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Park/Neutral Position Switch . . . . . . . . . . . . . .16, 18, 53 Airbag Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Power Seat Switches . . . . . . . . . . . . . . . . . . . . . . . .138 Brake Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . .85
Power Vent Window Switch . . . . . . . . . . . . . . . . . . . .79 Hi-Beam Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Radiator Fan Switch . . . . . . . . . . . . . .105, 109, 113, 117 Left Turn Signal Lamp . . . . . . . . . . . . . . . . . . . . . . . .85
Rear Blower Slide Switch . . . . . . . . . . . . . . . . .122, 124 Right Turn Signal Lamp . . . . . . . . . . . . . . . . . . . . . . .85
Rear Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . . .95 Seat Belt (Timed On) Lamp . . . . . . . . . . . . . . . . . . . .85
Right Door Window Lift Switch . . . . . . . . . . . . . . . . .136 SRI Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Right Front Door Lock Switch . . . . . . . . . . . . . . . . . .139 Warning Lamp Center Connector . . . . . . . . . . . . . . . . . .180
Right Front Door Illuminated Entry Switch . . . . . . . . . . .72 Warning Lamp System . . . . . . . . . . . . . . . . . . . . . . . . .86
Right Front Door Ajar Switch . . . . . . . . . . . . . . . . . . .86 Left Front Door Ajar Switch . . . . . . . . . . . . . . . . . . . .86
Right Header Lamp Switch . . . . . . . . . . . . . . . . . . . . .77 Right Front Door Ajar Switch . . . . . . . . . . . . . . . . . . .86
Right Vent Switch . . . . . . . . . . . . . . . . . . . . . . . . . .134 Sliding Door Ajar Switch . . . . . . . . . . . . . . . . . . . . . .86
Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Wheel Speed Sensors . . . . . . . . . . . . . . . . . . . . .131, 132
Sliding Door Ajar Switch . . . . . . . . . . . . . . . . . . . . . .86 Windshield Wiper . . . . . . . . . . . . . . . . . . . . . . . . . .93, 94
Stop Lamp/Speed Control Switch . . . . . . . . . . . . . . . . .57 Wiper - Intermittent . . . . . . . . . . . . . . . . . . . . . . . .93, 94
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1994 Town&Country/Caravan/Voyager
TSB 26-04-95 June, 1995
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Chrysler AS Town Country Caravan Voyager 1994 Service Manual Electrical PDF

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Chrysler AS Town Country Caravan Voyager 1994 Service Manual Electrical PDF

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AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8F POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . 8T

BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS

BATTERY TEST PROCEDURES ON-VEHICLE . . . 3 IGNITION OFF DRAW (IOD) . . . . . . . . . . . . . . . . 8

Fig. 1 Starting System Components Fig. 2 Charging System Components

BATTERY TEST PROCEDURES ON-VEHICLE

Fig. 5 Test Indicator Sight Glass

WARNING: DO NOT USE OPEN FLAME NEAR BAT-

be charged until green dot is visible, (12.4 volts or

Fig. 7 Testing Open Circuit Voltage Fig. 9 Volt-Ammeter-Load Tester

Fig. 8 Battery Open Circuit Voltage

WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-

(1) Remove both battery cables, NEGATIVE cable

EXPLOSIVE GASES FORM OVER THE BATTERY.

CAUTION: Disconnect the battery NEGATIVE cable

Fig. 14 Disconnect Battery Negative Cable

Fig. 16 CHARGE RATE

some time before it accepts a current in excess of a

IGNITION OFF DRAW (IOD)

depending on the electronic components on the ve-

VEHICLES WITH ELECTRONIC AUTOMATIC TRANSMISSION

STARTER TEST PROCEDURES ON VEHICLE

less than 20 amps.

Fig. 2 Starter Relay

STARTER FEED CIRCUIT TESTS

CAUTION: Ignition system also must be disabled to

(1) Connect a volt-ampere tester (Fig. 4) to the bat-

Fig. 3 Starter System Diagnostics

Fig. 4 Volt Ampere Tester Fig. 5 Volt-Ampere Tester Connections

charge battery if necessary. Disconnect all testing

STARTER FEED CIRCUIT RESISTANCE TEST

CAUTION: Ignition system also must be disabled to

• VEHICLES WITH DIRECT IGNITION SYSTEM:

Fig. 7 Ignition Coils Electrical Connection

Fig. 9 Test Battery Connection Resistance

Fig. 12 Test Battery Positive Cable Resistance

STARTER CONTROL CIRCUIT TESTS

STARTER SOLENOID TEST

WARNING: CHECK TO ENSURE THAT THE TRANS-

(1) Verify battery condition. Battery must be in

STARTER RELAY TEST

WARNING: CHECK TO ENSURE THAT THE TRANS-

(1) Verify battery condition. Battery must be in

Fig. 14 Starter Relay Tests

IGNITION SWITCH TEST

BENCH TESTING STARTER SOLENOID

Fig. 18 Continuity Test Between Solenoid Terminal

Fig. 19 Continuity Test Between Solenoid Terminal

Fig. 16 Field Coil Wire Terminal—Nippondenso

Fig. 20 Continuity Test Between Solenoid Terminal

(4) If continuity is not detected in either test, sole-

GENERATOR TEST PROCEDURES ON VEHICLE

Fig. 1 Charging Diagnostics

Fig. 4 Volt/Amp Tester Connections

Fig. 3 Generator Output Wire Resistance Test

Fig. 5 Generator Current Output Test

DIAGNOSTIC CODES—ON BOARD DIAGNOSTICS

GENERAL DESCRIPTION/INFORMATION POWERTRAIN CONTROL MODULE

Fig. 8 Generator Diagnostic Codes

Fig. 9 CHECK FOR INADEQUATE/LOW CHARGING—USING ON BOARD DIAGNOSTIC CODES

Fig. 10 CHECK FOR OVERCHARGING—USING ON BOARD DIAGNOSTIC CODES

Fig. 11 Generator Wiring Connections Fig. 13 Electrical Resistance Test