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Fig.1BATTERYTEMPERATURESENSOR
LOCATION
1 - BATTERY TEMP. SENSOR 2 - BATTERY 3 - SENSOR ELEC. CONNECT. 4 - BATTERY TRAY
INSTALLATION
The battery temperature sensor is located under the vehicle battery and is attached (snapped into) a mounting hole on battery tray.
(1) Pull electrical connector up through mounting
hole in top of battery tray.
(2) Connect sensor. (3) Snap sensor into battery tray. (4) Install battery. Refer to 8, Battery for proce-
dures.
8F - 22
CHARGING
GENERATOR DESCRIPTION
The generator is belt-driven by the engine using a serpentine type drive belt. It is serviced only as a complete assembly. If the generator fails for any rea- son, the entire assembly must be replaced.
OPERATION
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a cur- rent into the windings of the stator coil. Once the generator begins producing sufficient current, it also provides the current needed to energize the rotor.
The stator winding connections deliver the induced alternating current to 3 positive and 3 negative diodes for rectification. From the diodes, rectified direct current is delivered to the vehicle electrical system through the generator battery terminal.
Although the generators appear the same exter- nally, different generators with different output rat- ings are used on this vehicle. Be certain that the replacement generator has the same output rating and part number as the original unit. Refer to Gen- erator Ratings in the Specifications section at the back of this group for amperage ratings and part numbers.
Noise emitting from the generator may be caused by: worn, loose or defective bearings; a loose or defec- tive drive pulley; incorrect, worn, damaged or misad- justed fan drive belt; loose mounting bolts; a misaligned drive pulley or a defective stator or diode.
REMOVAL
3.7L / 4.7L
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery. (2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
terminal (Fig. 2).
(4) Remove B+ terminal mounting nut at rear of generator (Fig. 2). Disconnect terminal from genera- tor.
(5) Disconnect field wire connector at rear of gen-
erator (Fig. 2) by pushing on connector tab.
(6) Remove 1 rear vertical generator mounting bolt
(Fig. 3).
DR
(7) Remove 2 front horizontal generator mounting
bolts (Fig. 3).
(8) Remove generator from vehicle.
Fig.2GENERATORCONNECTORS-3.7L/4.7L
1 - GENERATOR 2 - B+ NUT 3 - PLASTIC INSULATOR CAP 4 - FIELD WIRE CONNECTOR
Fig.3REMOVE/INSTALLGENERATOR-3.7L/4.7L 1 - LOWER BOLTS 2 - REAR BOLT 3 - GENERATOR
DR GENERATOR (Continued)
5.7L
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
CHARGING
8F - 23
(1) Disconnect negative battery cable at battery. (2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
terminal.
(4) Remove B+ terminal mounting nut at rear of
generator. Disconnect terminal from generator.
(5) Disconnect field wire connector at rear of gen-
erator by pushing on connector tab.
(6) Remove generator support bracket nuts and
bolt (Fig. 4) and remove support bracket.
(7) Remove 2 generator mounting bolts (Fig. 5). (8) Remove generator from vehicle.
Fig.5REMOVE/INSTALLGENERATOR-5.7L
1 - MOUNTING BOLT 2 - GENERATOR 3 - MOUNTING STUD / BOLT
(1) Disconnect both negative battery cables at both
batteries.
terminal.
(2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
(4) Remove B+ terminal mounting nut at rear of generator (Fig. 7). Disconnect terminal from genera- tor.
(5) Disconnect field wire connector at rear of gen-
erator by pushing on connector tab.
(6) Remove upper mounting bracket bolt (Fig. 6). (7) Remove lower mounting bracket bolt and nut
(Fig. 6).
(8) Remove generator from vehicle.
5.9L Gas
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery. (2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
Fig.4GENERATORSUPPORTBRACKET-5.7L
1 - GENERATOR 2 - SUPPORT BRACKET 3 - BRACKET NUTS 4 - BRACKET BOLT
5.9L Diesel
WARNING: DISCONNECT BOTH NEGATIVE CABLES FROM BOTH BATTERIES BEFORE REMOVING BAT- TERY OUTPUT WIRE (B+ WIRE) FROM GENERA- TOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
CHARGING
8F - 24
GENERATOR (Continued)DR
(4) Remove B+ terminal mounting nut at rear of generator (Fig. 8). Disconnect terminal from genera- tor.
(5) Disconnect field wire connector at rear of gen-
erator (Fig. 8) by pushing on connector tab.
(6) Remove 1 upper generator mounting bolt (Fig.
(7) Remove 1 lower generator mounting bolt / nut
9).
(Fig. 9).
(8) Remove generator from vehicle.
Fig.65.9LDIESELGENERATOR
1 - GENERATOR 2 - MOUNTING BOLTS
Fig.75.9LDIESELGENER.CONNECTORS
1 - B+ CONNECTOR 2 - GENERATOR 3 - FIELD WIRE CONNECTOR
(3) Unsnap plastic insulator cap from B+ output
terminal (Fig. 8).
Fig.8GENERATORCONNECTORS-5.9LGAS
1 - PLASTIC INSULATOR CAP 2 - FIELD WIRE CONNECTOR 3 - GENERATOR 4 - B+ NUT
8.0L
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE (B+ WIRE) FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY OR DAMAGE TO ELECTRICAL SYSTEM.
(1) Disconnect negative battery cable at battery. (2) Remove generator drive belt. Refer to 7, Cool-
ing System for procedure.
(3) Unsnap plastic insulator cap from B+ output
terminal.
(4) Remove B+ terminal mounting nut at rear of
generator. Disconnect terminal from generator.
(5) Disconnect field wire connector at rear of gen-
erator by pushing on connector tab.
(6) Remove upper mounting bolt and nut (Fig. 10). (7) Remove lower mounting bolt (Fig. 10).
DR GENERATOR (Continued)
CHARGING
8F - 25
INSTALLATION
3.7L / 4.7L
(1) Position generator to engine and install 2 hor-
izontal bolts and 1 vertical bolt.
(2) Tighten all 3 bolts. Refer to Torque Specifica-
tions.
tor.
(3) Snap field wire connector into rear of genera-
(4) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
Fig.9REMOVE/INSTALLGENERATOR-5.9LGAS 1 - MOUNTING BOLT 2 - GENERATOR 3 - MOUNTING BRACKET 4 - MOUNTING BOLT/NUT
(8) Remove generator from vehicle.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(5) Install generator drive belt. Refer to 7, Cooling
System for procedure.
(6) Install negative battery cable to battery.
5.7L
(1) Position generator to engine and install 2
mounting bolts.
(2) Tighten bolts. Refer to Torque Specifications. (3) Position support bracket to front of generator and install bolt and nuts. Tighten bolt / nuts. Refer to Torque Specifications.
(4) Snap field wire connector into rear of genera-
tor.
(5) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
Fig.10REMOVE/INSTALLGENERATOR–8.0L
ENGINE
1 - MOUNTING BOLT 2 - GENERATOR 3 - NUT 4 - MOUNTING BRACKET 5 - MOUNTING BOLT
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(6) Install generator drive belt. Refer to 7, Cooling
System for procedure.
CHARGING
8F - 26
GENERATOR (Continued)(7) Install negative battery cable to battery.
5.9L Diesel
(1) Position generator to upper and lower mount- ing brackets and install upper bolt and lower bolt / nut.
(2) Tighten all bolts / nut. Refer to Torque Specifi-
DR
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction is installed incorrectly, causing the if engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(3) Snap field wire connector into rear of genera-
(5) Install generator drive belt. Refer to 7, Cooling
cations.
tor.
System for procedure.
(6) Install negative battery cable to battery.
5.9L Gas
cations.
tor.
(1) Position generator to engine and install upper
bolt and lower bolt / nut.
(2) Tighten all bolts / nut. Refer to Torque Specifi-
(3) Snap field wire connector into rear of genera-
(4) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction is installed incorrectly, causing the if engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(5) Install generator drive belt. Refer to 7, Cooling
(6) Install negative battery cable to battery.
(4) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump may be rotating in the wrong direction if is installed incorrectly, causing the engine to overheat. Refer to belt routing label in engine compartment, or refer to Belt Schematics in 7, Cooling System.
the belt
(5) Install generator drive belt. Refer to 7, Cooling
System for procedure.
(6) Install both negative battery cables to both bat-
teries.
8.0L
cations.
tor.
(1) Position generator to engine and install lower
bolt and upper bolt / nut.
(2) Tighten all bolts / nut. Refer to Torque Specifi-
(3) Snap field wire connector into rear of genera-
System for procedure.
(4) Install B+ terminal eyelet to generator output stud. Tighten mounting nut. Refer to Torque Specifi- cations.
CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged.
DR
CHARGING
8F - 27
VOLTAGE REGULATOR DESCRIPTION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulat- ing circuit located within the PCM (Powertrain Con- trol Module) (within the ECM for diesel engines). The EVR is not serviced separately. If replacement is nec- essary, the PCM must be replaced.
OPERATION
The amount of direct current produced by the gen- erator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the generators second rotor field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage (B+) and battery temperature (refer to Battery Temperature Sensor for more information). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM grounds the field winding until sensed battery volt- age is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capabil- ity to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charg- ing rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Also refer to Charging System Operation for additional information.
8F - 28
STARTING
STARTING
TABLE OF CONTENTS
page
DR
page
STARTING
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
DIAGNOSIS AND TESTING - STARTINGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SPECIFICATIONS
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . 33
SPECIFICATIONS - TORQUE - STARTINGSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
STARTER MOTOR
DIAGNOSIS AND TESTING - STARTER
MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37STARTER MOTOR RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - STARTER RELAY . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39STARTING DESCRIPTION The starting system consists of: † Starter relay † Starter motor (including an integral starter sole-
noid)
ing system are:
Other components to be considered as part of start- † Battery † Battery cables † Ignition switch and key lock cylinder † Clutch pedal position switch (manual transmis- sion)† Park/neutral position switch (automatic trans- mission) † Wire harnesses and connections. The Battery, Starting, and Charging systems oper- ate in conjunction with one another, and must be tested as a complete system. For correct operation of starting/charging systems, all components used in these 3 systems must perform within specifications. When attempting to diagnose any of these systems, it is important that you keep their interdependency in mind.
The diagnostic procedures used in each of these groups include the most basic conventional diagnostic methods, to the more sophisticated On-Board Diag- nostics (OBD) built into the Powertrain Control Mod- ule (PCM). Use of an induction-type milliampere ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12-volt test lamp may be required.
Certain starting system components are monitored by the PCM and may produce a Diagnostic Trouble
Code (DTC). Refer to Diagnostic Trouble Codes in Emission Control for a list of codes.
OPERATION
The starting system components form two separate circuits. A high-amperage feed circuit that feeds the starter motor between 150 and 350 amperes (700
amperes - diesel engine), and a low-amperage control circuit that operates on less than 20 amperes. The high-amperage feed circuit components include the battery, the battery cables, the contact disc portion of the starter solenoid, and the starter motor. The low- amperage control circuit components include the igni- tion switch, the clutch pedal position switch (manual transmission), the park/neutral position switch (auto- matic transmission), the starter relay, the electro- magnetic windings of the starter solenoid, and the connecting wire harness components.If the vehicle is equipped with a manual transmis- sion, it has a clutch pedal position switch installed in series between the ignition switch and the coil bat- tery terminal of the starter relay. This normally open switch prevents the starter relay from being ener- gized when the ignition switch is turned to the Start position, unless the clutch pedal is depressed. This feature prevents starter motor operation while the clutch disc and the flywheel are engaged. The starter relay coil ground terminal is always grounded on vehicles with a manual transmission.
If the vehicle is equipped with an automatic trans- mission, battery voltage is supplied through the low- amperage control circuit to the coil battery terminal of the starter relay when the ignition switch is turned to the Start position. The park/neutral posi- tion switch is installed in series between the starter relay coil ground terminal and ground. This normally
DR STARTING (Continued)
open switch prevents the starter relay from being energized and the starter motor from operating unless the automatic transmission gear selector is in the Neutral or Park positions.
When the starter relay coil is energized, the nor- mally open relay contacts close. The relay contacts connect the relay common feed terminal to the relay normally open terminal. The closed relay contacts energize the starter solenoid coil windings.
The energized solenoid pull-in coil pulls in the sole- noid plunger. The solenoid plunger pulls the shift lever in the starter motor. This engages the starter overrunning clutch and pinion gear with the starter ring gear.
As the solenoid plunger reaches the end of
its travel, the solenoid contact disc completes the high- amperage starter feed circuit and energizes the sole- noid plunger hold-in coil. Current now flows between the solenoid battery terminal and the starter motor, energizing the starter.
Once the engine starts, the overrunning clutch pro- tects the starter motor from damage by allowing the
STARTING
8F - 29
starter pinion gear to spin faster than the pinion shaft. When the ignition switch is released to the On position, the starter relay coil is de-energized. This causes the relay contacts to open. When the relay contacts open, the starter solenoid plunger hold-in coil is de-energized.
When the solenoid plunger hold-in coil is de-ener- gized, the solenoid plunger return spring returns the plunger to its relaxed position. This causes the con- tact disc to open the starter feed circuit, and the shift lever to disengage the overrunning clutch and pinion gear from the starter ring gear.
DIAGNOSIS AND TESTING - STARTING SYSTEM
The battery, starting, and charging systems oper- ate in conjunction with one another, and must be tested as a complete system. For correct starting/ charging system operation, all of the components involved in these 3 systems must perform within specifications.
CONDITION
POSSIBLE CAUSE
CORRECTION
Starting System Diagnosis
STARTER FAILS TO OPERATE.
STARTER ENGAGES, FAILS TO TURN ENGINE.
1. Battery discharged or faulty. 2. Starting circuit wiring faulty. 3. Starter relay faulty.
4. Ignition switch faulty.
5. Clutch pedal position switch faulty. 6. Park/Neutral position switch faulty or misadjusted. 7. Starter solenoid faulty.
8. Starter motor faulty.
1. Battery discharged or faulty. 2. Starting circuit wiring faulty. 3. Starter motor faulty.
4. Engine seized.
1. Refer to Battery. Charge or replace battery, if required.
2. Refer to 8, Wiring Diagrams. Test and repair starter feed and/or control circuits, if required. 3. Refer to Starter Relay in Diagnosis and Testing. Replace starter relay if required. 4. Refer to Ignition Switch and Key Lock Cylinder. Replace ignition switch if required. 5. Refer to Clutch Pedal Position Switch.
6. Refer to Park/Neutral Position Switch. Replace park/neutral position switch if required.
7. Refer to Starter Motor. Replace starter motor assembly if required. 8. If all other starting system components and circuits test OK, replace starter motor. 1. Refer to Battery. Charge or replace battery if required.
2. Refer to 8, Wiring Diagrams. Test and repair starter feed and/or control circuits if required. 3. If all other starting system components and circuits test OK, replace starter motor assembly. 4. Refer to Engine Diagnosis in the Diagnosis and Testing section of 9, Engine.
STARTING
8F - 30
STARTING (Continued)DR
CONDITION
POSSIBLE CAUSE
CORRECTION
Starting System Diagnosis
STARTER ENGAGES, SPINS OUT BEFORE ENGINE STARTS.
1. Starter ring gear faulty.
2. Starter motor faulty.
STARTER DOES NOT DISENGAGE.
1. Starter motor improperly installed.
2. Starter relay faulty.
3. Ignition switch faulty.
4. Starter motor faulty.
1. Refer to Starter Motor Removal and Installation. Remove starter motor to inspect starter ring gear. Replace starter ring gear if required. 2. If all other starting system components and circuits test OK, replace starter motor assembly. 1. Refer to Starter Motor Removal and Installation. Tighten starter mounting hardware to correct torque specifications. 2. Refer to Starter Relay Diagnosis and Testing. Replace starter relay if required. 3. Refer to Ignition Switch and Key Lock Cylinder. Replace ignition switch if required. 4. If all other starting system components and circuits test OK, replace starter motor.
INSPECTION
For complete starter wiring circuit diagrams, refer to 8, Wiring Diagrams. Before removing any unit from starting system for repair or diagnosis, perform the following inspections:
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO 8, PASSIVE RESTRAINT SYS- TEMS, BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY- MENT AND POSSIBLE PERSONAL INJURY.
tions. Refer to Park/Neutral Position Switch in 21, Transmission. † Starter Relay - Visually inspect starter relay for indications of physical damage and loose or cor- roded wire harness connections. † Starter Motor - Visually inspect starter motor for indications of physical damage and loose or cor- roded wire harness connections. † Starter Solenoid - Visually inspect starter sole- noid for indications of physical damage and loose or corroded wire harness connections. † Wiring - Visually inspect wire harnesses for damage. Repair or replace any faulty wiring, as required. Refer to 8, Wiring Diagrams.
† Battery - Visually inspect battery for indica- tions of physical damage and loose or corroded cable connections. Determine state-of-charge and cranking capacity of battery. Charge or replace battery if required. Refer to Battery in 8, Battery. Note: If equipped with diesel engine, a dual battery sys- tem may be used, and both batteries must be inspected.
† Ignition Switch - Visually inspect
ignition switch for indications of physical damage and loose or corroded wire harness connections. Refer to Igni- tion Switch and Key Lock Cylinder. † Clutch Pedal Position Switch - If equipped with manual transmission, visually inspect clutch pedal position switch for indications of physical dam- age and loose or corroded wire harness connections. Refer to Clutch Pedal Position Switch in 6, Clutch. † Park/Neutral Position Switch - If equipped with automatic transmission, visually inspect park/ neutral position switch for indications of physical damage and loose or corroded wire harness connec-
TESTING
COLD CRANKING TEST
For complete starter wiring circuit diagrams, refer to 8, Wiring Diagrams. The battery must be fully- charged and load-tested before proceeding. Refer to Battery in 8, Battery.
(1) Connect volt-ampere tester to battery terminals (Fig. 1). See instructions provided by manufacturer of volt-ampere tester being used. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, tester should be con- nected to battery on left side of vehicle only. Also, tester current reading must be taken from positive battery cable lead that connects to starter motor.
(2) Fully engage parking brake. (3) If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped
DR STARTING (Continued)
STARTING
8F - 31
FEED CIRCUIT TEST
The starter feed circuit test (voltage drop method) will determine if there is excessive resistance in high-amperage feed circuit. For complete starter wir- ing circuit diagrams, refer 8, Wiring Diagrams.
When performing these tests, it is important to remember that voltage drop is giving an indication of resistance between two points at which voltmeter probes are attached.
Example: When testing resistance of positive bat- tery cable, touch voltmeter leads to positive battery cable clamp and cable connector at starter solenoid. If you probe positive battery terminal post and cable connector at starter solenoid, you are reading com- bined voltage drop in positive battery cable clamp-to- terminal post connection and positive battery cable. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing tests, following procedures are accom- be certain that plished: † Battery is fully-charged and load-tested. Refer to Battery in 8, Battery. † Fully engage parking brake. † If equipped with manual transmission, place gearshift selector lever in Neutral position and block clutch pedal in fully depressed position. If equipped with automatic transmission, place gearshift selector lever in Park position. † Verify that all lamps and accessories are turned off.† To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
(1) Connect positive lead of voltmeter to negative battery cable terminal post. Connect negative lead of voltmeter to negative battery cable clamp (Fig. 2). Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and terminal post. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, procedure must be performed twice, once for each battery.
(2) Connect positive lead of voltmeter to positive battery terminal post. Connect negative lead of volt- meter to battery positive cable clamp (Fig. 3). Rotate and hold ignition switch in Start position. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and terminal post. Note: Cer- tain diesel equipped models use dual batteries. If equipped with dual battery system, this pro- cedure must be performed twice, once for each battery.
Fig.1VOLTS-AMPSTESTERCONNECTIONS-
TYPICAL
1 - POSITIVE CLAMP 2 - NEGATIVE CLAMP 3 - INDUCTION AMMETER CLAMP
with automatic transmission, place gearshift selector lever in Park position. (4) Verify that all
lamps and accessories are
turned off.
(5) To prevent a gasoline engine from starting, remove Automatic ShutDown (ASD) relay. To prevent a diesel engine from starting, remove Fuel Pump Relay. These relays are located in Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
WARNING: IF EQUIPPED WITH DIESEL ENGINE, ATTEMPT TO START ENGINE A FEW TIMES BEFORE PROCEEDING WITH FOLLOWING STEP.
(6) Rotate and hold ignition switch in Start posi- tion. Note cranking voltage and current (amperage) draw readings shown on volt-ampere tester.
(a) If voltage reads below 9.6 volts, refer to Starter Motor in Diagnosis and Testing. If starter motor is OK, refer to Engine Diagnosis in 9, Engine for further testing of engine. If starter motor is not OK, replace faulty starter motor.
(b) If voltage reads above 9.6 volts and current (amperage) draw reads below specifications, refer to Feed Circuit Test in this section.
(c) If voltage reads 12.5 volts or greater and starter motor does not turn, refer to Control Cir- cuit Testing in this section.
(d) If voltage reads 12.5 volts or greater and starter motor turns very slowly, refer to Feed Cir- cuit Test in this section.
NOTE: A cold engine will increase starter current (amperage) draw reading, and reduce battery volt- age reading.
STARTING
8F - 32
STARTING (Continued)DR
Fig.2TESTBATTERYNEGATIVECONNECTION
RESISTANCE-TYPICAL
1 - VOLTMETER 2 - BATTERY
Fig.4TESTBATTERYPOSITIVECABLE
RESISTANCE-TYPICAL
1 - BATTERY 2 - VOLTMETER 3 - STARTER MOTOR
tery cable attachment on engine block. Repeat test. If reading is still above 0.2 volt, replace faulty negative battery cable. Note: Certain diesel equipped mod- els use dual batteries. If equipped with dual battery system, this procedure must be per- formed twice, once for each battery.
Fig.3TESTBATTERYPOSITIVECONNECTION
RESISTANCE-TYPICAL
1 - VOLTMETER 2 - BATTERY
(3) Connect voltmeter to measure between battery positive terminal post and starter solenoid battery terminal stud (Fig. 4). Rotate and hold ignition switch in Start position. Observe voltmeter. If read- ing is above 0.2 volt, clean and tighten battery cable connection at solenoid. Repeat test. If reading is still above 0.2 volt, replace faulty positive battery cable. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed on driver side battery only.
(4) Connect voltmeter to measure between nega- tive battery terminal post and a good clean ground on engine block (Fig. 5). Rotate and hold ignition switch in Start position. Observe voltmeter. If read- ing is above 0.2 volt, clean and tighten negative bat-
Fig.5TESTGROUNDCIRCUITRESISTANCE-
TYPICAL
1 - VOLTMETER 2 - BATTERY 3 - ENGINE GROUND
(5) Connect positive lead of voltmeter to starter housing. Connect negative lead of voltmeter to nega- tive battery terminal post (Fig. 6). Rotate and hold ignition switch in Start position. Observe voltmeter. If reading is above 0.2 volt, correct poor starter to engine block ground contact. Note: Certain diesel equipped models use dual batteries. If equipped with dual battery system, this procedure must be performed on driver side battery only.
DR STARTING (Continued)
STARTING
8F - 33
If reading is above 0.2 volt, clean and tighten battery cables at both batteries. Repeat test. If reading is still above 0.2 volt, replace faulty positive battery cable.
If resistance tests detect no feed circuit problems, refer to Starter Motor in the Diagnosis and Testing.
CONTROL CIRCUIT TESTING
Diagnosis and Testing.
The starter control circuit components should be tested in the order in which they are listed, as fol- lows:† Starter Relay - Refer to Starter Relay Diag- nosis and Testing. † Starter Solenoid - Refer to Starter Motor † Ignition Switch - Refer to Ignition Switch † Clutch Pedal Position Switch - If equipped with manual transmission, refer to Clutch Pedal Position Switch in 6, Clutch. † Park/Neutral Position Switch - If equipped with automatic transmission, refer to Park/Neutral Position Switch in 21, Transmission. † Wire harnesses and connections - Refer to 8,
and Key Lock Cylinder
Wiring Diagrams.
Fig.6TESTSTARTERGROUND-TYPICAL
1 - STARTER MOTOR 2 - BATTERY 3 - VOLTMETER
(6) If equipped with dual battery system (certain diesel equipped models), connect positive lead of volt- meter to positive battery cable clamp on battery located on left side of vehicle. Connect negative lead of voltmeter to positive battery terminal post on bat- tery located on right side of vehicle. Rotate and hold ignition switch in Start position. Observe voltmeter.
SPECIFICATIONS
STARTING SYSTEM
Starter Motor and Solenoid
Manufacturer
Denso
Part Number
56028715AD
Engine Application
3.7L / 4.7L / 5.7L / 5.9L
Power Rating
1.4 Kilowatt / 1.9
Horsepower
Denso
56027703AD
8.0L
1.4 Kilowatt / 1.9
Horsepower
Denso 4741012
5.9L Diesel2.7 Kilowatt / 3.6
Horsepower
11 Volts
12 Volts
12 Volts
12 Volts
Gear Reduction
Gear Reduction
Voltage Number of Brushes Drive Type Free Running Test Voltage Free Running Test Amperage Draw Free Running Test Minimum Speed Solenoid Closing Maximum Voltage Required * Cranking Amperage Draw Test * Test at operating temperature. Cold engine, tight (new) engine, or heavy oil will increase starter amperage draw.
125 - 250 Amperes
125 - 250 Amperes
450 - 700 Amperes
200 Amperes
Conventional
73 Amperes
73 Amperes
3601 rpm
3601 rpm
8.0 Volts
7.5 Volts
7.5 Volts
11 Volts
11 Volts
3000
STARTING
8F - 34
STARTING (Continued) SPECIFICATIONS - TORQUE - STARTING SYSTEMDESCRIPTION
Battery Cable Eyelet Nut at
Solenoid (large nut - gas engines)
Battery Cable Eyelet Nut at
Solenoid (large nut - diesel engine)
Starter Solenoid Nut (small nut -
diesel engine)
Starter Mounting Bolts - Gas
Engines
Starter Mounting Nut - Gas Engines
Starter Mounting Bolts - Diesel
N·m 25
14
68
68
43DR
Ft. Lbs.
19
50
50
32In. Lbs.
221
120
55
STARTER MOTOR DIAGNOSIS AND TESTING - STARTER MOTOR Correct starter motor operation can be confirmed by performing the following free running bench test. This test can only be performed with starter motor removed from vehicle. Refer to Specifications for starter motor specifications.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame.
(3) Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions pro- vided by manufacturer of volt-ampere tester being used.
(4) Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly.
(5) Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications. (6) Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications.
(7) If ammeter reading exceeds maximum amper- age draw specification, replace faulty starter motor assembly.
STARTER SOLENOID
This test can only be performed with starter motor
removed from vehicle.
(1) Remove starter motor from vehicle. Refer to
Starter Motor Removal and Installation.
(2) Disconnect wire from solenoid field coil termi-
nal.
(3) Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester (Fig. 7). There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor assembly.
Fig.7CONTINUITYBETWEENSOLENOIDAND
FIELDCOILTERMINALS-TYPICAL
1 - OHMMETER 2 - SOLENOID TERMINAL 3 - FIELD COIL TERMINAL
(4) Check for continuity between solenoid terminal and solenoid case (Fig. 8). There should be continuity. If not OK, replace faulty starter motor assembly.
REMOVAL
3.7L / 4.7L
(1) Disconnect and isolate negative battery cable. (2) Raise and support vehicle. (3) Note: If equipped with 4WD and certain trans- missions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt.
DR STARTER MOTOR (Continued)
STARTING
8F - 35
Fig.8CONTINUITYBETWEENSOLENOID
TERMINALANDCASE-TYPICAL
1 - SOLENOID TERMINAL 2 - OHMMETER 3 - SOLENOID
(4) Remove 1 bolt and 1 nut if equipped with a
manual transmission (Fig. 9).
(5) Remove 2 bolts if equipped with an automatic
transmission (Fig. 10).
(6) Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process, do not let starter motor hang from wire har- ness.
(7) Tilt nose downwards and lower starter motor far enough to access and remove nut that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness.
(8) Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud. (9) Disconnect battery positive cable wire harness connector from solenoid terminal connector recepta- cle.
(10) Remove starter motor.
5.7L Gas
(1) Disconnect and isolate negative battery cable. (2) Raise and support vehicle. (3) Note: If equipped with 4WD and certain trans- missions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt.
(4) Remove 2 mounting bolts (Fig. 11). (5) Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process, do not let starter motor hang from wire har- ness.
(6) Tilt nose downwards and lower starter motor far enough to access and remove nut that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness.
(7) Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud.
Fig.9STARTERR/I-3.7L/4.7L-MAN.TRANS.
1 - EYELET TERMINAL 2 - NUT 3 - BRACKET 4 - STUD 5 - STARTER MOTOR 6 - LOCK WASHER 7 - WIRE HARNESS CONNECTOR 8 - NUT 9 - SCREW AND WASHER (2)
Fig.10STARTERR/I-3.7L/4.7L-AUTO.TRANS.
1 - EYELET TERMINAL 2 - NUT 3 - SCREW AND WASHER (2) 4 - STARTER MOTOR 5 - WIRE HARNESS CONNECTOR
(8) Disconnect battery positive cable wire harness connector from solenoid terminal connector recepta- cle.
(9) Remove starter motor.
5.9L Diesel
(1) Disconnect and isolate both negative battery
cables at both batteries.
(2) Raise and support vehicle. (3) Remove 3 starter mounting bolts (Fig. 12).
STARTING
8F - 36
STARTER MOTOR (Continued)DR
Fig.11STARTERR/I-5.7L
Fig.12STARTERR/I-5.9LDIESEL
1 - STARTER MOTOR 2 - MOUNTING BOLTS
1 - MOUNTING BOLTS (3) 2 - STARTER MOTOR 3 - SPACER (CERTAIN TRANSMISSIONS)
(4) Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process. Do not let starter motor hang from wire har- ness.
(5) Tilt nose downwards and lower starter motor far enough to access and remove nuts securing starter wiring harness to starter (Fig. 13). Do not let starter motor hang from wire harness.
(6) Remove starter motor from engine. Note: Cer- tain diesel engines use an aluminum spacer (Fig. 12). Note position and orientation of spacer before removal.
5.9L Gas
(1) Disconnect and isolate negative battery cable. (2) Raise and support vehicle. (3) Note: If equipped with 4WD and certain trans- missions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt. (4) Remove nut and lock washer securing starter
motor to mounting stud (Fig. 14).
(5) While supporting starter motor, remove upper
mounting bolt from starter motor.
(6) If equipped with automatic transmission, slide cooler tube bracket forward on tubes far enough for starter motor mounting flange to be removed from lower mounting stud.
Fig.13STARTERELECTRICALCONNECTORS-
5.9LDIESEL
1 - STARTER MOTOR 2 - BATTERY CABLE NUT 3 - SOLENOID NUT 4 - HARNESS ASSEMBLY
(7) Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear
DR STARTER MOTOR (Continued)
housing. Always support starter motor during this process, do not let starter motor hang from wire har- ness.
(8) Tilt nose downwards and lower starter motor far enough to access and remove nut that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness.
(9) Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud. (10) Disconnect battery positive cable wire harness connector from solenoid terminal connector recepta- cle.
(11) Remove starter motor.
Fig.14STARTERR/I-5.9LGAS
1 - ENGINE 2 - STARTER MOUNTING FLANGE 3 - STUD 4 - STARTER MOTOR 5 - LOCK WASHER 6 - NUT 7 - BRACKET 8 - BOLT 9 - POSITIVE BATTERY CABLE WIRE HARNESS 10 - POSITIVE BATTERY CABLE WIRE HARNESS NUT
INSTALLATION
3.7L / 4.7L
(1) Connect solenoid wire to starter motor (snaps
on).
(2) Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. Refer to Torque Specifications. Do not allow starter motor to hang from wire harness.
(3) Position starter motor to transmission. (4) If equipped with automatic transmission, slide
cooler tube bracket into position.
STARTING
8F - 37
(5) Install and tighten both bolts (auto. trans.), or 1 nut and 1 bolt (man. trans.). Refer to Torque Spec- ifications.
(6) Lower vehicle. (7) Connect negative battery cable.
5.7L
(1) Connect solenoid wire to starter motor (snaps
on).
(2) Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. Refer to Torque Specifications. Do not allow starter motor to hang from wire harness.
(3) Position starter motor to engine. (4) If equipped with automatic transmission, slide
cooler tube bracket into position.
(5) Install and tighten both mounting bolts. Refer
to Torque Specifications.
(6) Lower vehicle. (7) Connect negative battery cable.
5.9L Diesel
nut.
(1) If Equipped: Position and hold aluminum spacer to rear of starter while positioning starter to engine.
(2) Connect solenoid wire to starter motor. Tighten
(3) Position battery cable to starter stud. Install and tighten battery cable nut. Refer to Torque Spec- ifications. Do not allow starter motor to hang from wire harness.
(4) Position starter motor to transmission. (5) If equipped with automatic transmission, slide
cooler tube bracket into position.
(6) Install and tighten 3 starter mounting bolts.
Refer to Torque Specifications.
(7) Lower vehicle. (8) Connect both negative battery cables to both
batteries.
5.9L Gas
on).
(1) Connect solenoid wire to starter motor (snaps
(2) Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut. Refer to Torque Specifications. Do not allow starter motor to hang from wire harness.
(3) Position starter motor to transmission. (4) If equipped with automatic transmission, slide
cooler tube bracket into position.
(5) Install and tighten both bolts (auto. trans.), or 1 nut and 1 bolt (man. trans.). Refer to Torque Spec- ifications.
(6) Lower vehicle. (7) Connect negative battery cable.
8F - 38
STARTING
DR
STARTER MOTOR RELAY DESCRIPTION
The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when ignition switch is turned to Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine com- partment. See PDC cover for relay identification and location.
The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, cur- rent capacities, terminal patterns, and terminal func- tions.
The starter relay cannot be repaired or adjusted. If
faulty or damaged, it must be replaced.
OPERATION
The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one mov- able) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electro- magnetic coil is energized, it draws the movable con- tact away from normally closed fixed contact, and holds it against the other (normally open) fixed con- tact.
When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-en- ergized.
DIAGNOSIS AND TESTING - STARTER RELAY
The starter relay (Fig. 15) is located in Power Dis- tribution Center (PDC). Refer to PDC cover for relay identification and location. For complete starter relay wiring circuit diagrams, refer to 8, Wiring Diagrams.
(1) Remove starter relay from PDC. (2) A relay in de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace faulty relay.
(3) Resistance between terminals 85 and 86 (elec- tromagnet) should be 75 ± 5 ohms. If OK, go to Step 4. If not OK, replace faulty relay.
(4) Connect 12V battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, perform Relay Circuit Test that fol- lows. If not OK, replace faulty relay.
Fig.15TYPE1RELAY
TERMINAL LEGEND
NUMBER
IDENTIFICATION
30
85
86
87
87ARELAY CIRCUIT TEST
COMMON FEED COIL GROUND COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
(1) The relay common feed terminal cavity (30) is connected to battery voltage and should be hot at all times. If OK, go to Step 2. If not OK, repair open cir- cuit to fuse in PDC as required.
(2) The relay normally closed terminal
is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3.
(87A)
(3) The relay normally open terminal (87) is con- nected to common feed terminal (30) in the energized position. This terminal supplies battery voltage to starter solenoid field coils. There should be continu- ity between cavity for relay terminal 87 and starter solenoid terminal at all times. If OK, go to Step 4. If not OK, repair open circuit to starter solenoid as required.
(4) The coil battery terminal (86) is connected to electromagnet in relay. It is energized when ignition switch is held in Start position. On vehicles with manual transmission, clutch pedal must be fully depressed for this test. Check for battery voltage at cavity for relay terminal 86 with ignition switch in Start position, and no voltage when ignition switch is released to On position. If OK, go to Step 5. If not OK with automatic transmission, check for open or short circuit to ignition switch and repair, if required. If circuit to ignition switch is OK, refer to Ignition Switch and Key Lock Cylinder. If not OK with a manual transmission, check circuit between relay and clutch pedal position switch for open or a short. If circuit is OK, refer to Clutch Pedal Position Switch in 6 , Clutch.
STARTING
8F - 39
DR STARTER MOTOR RELAY (Continued)
(5) The coil ground terminal (85) is connected to the electromagnet in the relay. On vehicles with manual transmission, it is grounded at all times. On vehicles with automatic transmission, it is grounded through park/neutral position switch only when gear- shift selector lever is in Park or Neutral positions. Check for continuity to ground at cavity for relay ter- minal 85. If not OK with manual transmission, repair circuit to ground as required. If not OK with automatic transmission, check for pen or short circuit to park/neutral position switch and repair, if required. If circuit to park/neutral position switch is OK, refer to Park/Neutral Position Switch in 21, Transmission.
REMOVAL
The starter relay is located in the Power Distribu- tion Center (PDC) (Fig. 16). Refer to label on PDC cover for relay location.
(1) Disconnect and isolate negative battery cable. (2) Remove cover from Power Distribution Center
(PDC) for relay identification and location.
(3) Remove starter relay from PDC. (4) Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay.
(5) Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay.
INSTALLATION
(1) Push down firmly on starter relay until termi-
nals are fully seated into PDC receptacle.
Fig.16PDCLOCATION
1 - BATTERY 2 - PDC (POWER DISTRIBUTION CENTER)
(2) Install PDC cover. (3) Connect battery cable.
DR
HEATED SYSTEMS
8G - 1
HEATED SYSTEMS
TABLE OF CONTENTS
HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 1
HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 3
page
page
HEATED MIRRORS
TABLE OF CONTENTS
page
page
HEATED MIRRORS
DESCRIPTION - HEATED MIRROR SYSTEM . . . 1
OPERATION - HEATED MIRROR SYSTEM . . . . . 1HEATED MIRRORS DESCRIPTION - HEATED MIRROR SYSTEM
DIAGNOSIS AND TESTING - HEATED
MIRROR SYSTEM . . . . . . . . . . . . . . . . . . . . . . 2
lower inboard corner of each outside mirror glass (Fig. 1); or, by the heated mirror switch that is located in the lower left corner of the a/c heater con- trol unit face plate. The heated mirror system helps the vehicle operator maintain outside rear view mir- ror visibility during inclement operating conditions by keeping both outside mirror glasses clear of ice, snow, or fog. The heated mirror system for this vehi- cle includes the following major components: † The heated mirror switch, including the heated mirror system solid state electronic control logic and timer circuitry, the heated mirror relay and the heated mirror system indicator lamp. All of these components are integral to the a/c heater control unit on the instrument panel. † The two outside mirror heating grids, which are
integral to the power outside mirror units.
Following are general descriptions of the major components in the heated mirror system. See the owner’s manual in the vehicle glove box for more information on the features, use and operation of the heated mirror system.
Fig.1HEATEDMIRROR-typical 1 - POWER HEATED OUTSIDE REAR VIEW MIRROR 2 - REAR WINDOW DEFOGGER ICON
Electrically heated outside rear view mirrors are an additional factory-installed option on models that are equipped with factory-installed dual power mir- rors. Vehicles with this option can be visually identi- fied by the International Control and Display Symbol icon for rear window defogger, which appears on the
OPERATION - HEATED MIRROR SYSTEM
The solid state electronic control logic and timer circuitry for the heated mirror system receives bat- tery current from a fuse in the Junction Block (JB) only when the ignition switch is in the On or Start positions. After the heated mirror system is turned On, the electronic control logic and timer circuitry will automatically turn the system off after a pro- grammed time interval of about fifteen minutes. if the After the initial time interval has expired,
HEATED MIRRORS
8G - 2
HEATED MIRRORS (Continued)DR
and
logic
timer
control
heated mirror switch is depressed and released a sec- ond time during the same ignition cycle, the elec- tronic circuitry will automatically turn the heated mirror system off after a programmed time interval of about five minutes. The heated mirror system will be shut off automati- cally if the ignition switch is turned to the Off or Accessory positions. After the heated mirror system is turned On, it can also be turned off manually by depressing and releasing the heated mirror switch a second time.
When the heated mirror system is turned On, the heated mirror system control logic and timer cir- cuitry energizes the heated mirror system indicator lamp and the heated mirror relay. When energized, the heated mirror relay supplies fused ignition switch output (run/start) current from a fuse in the JB to the outside mirror heating grids located behind the mirror glass of each of the outside rear view mir- rors. When energized, each of the outside mirror heating grids produces enough heat to warm the glass of the outside rear view mirrors.
DIAGNOSIS AND TESTING - HEATED MIRROR SYSTEM
If only one of the outside mirror heating grids is inoperative, perform continuity checks on the circuits and heater grid for that mirror only. If both outside mirror heating grids are inoperative, proceed with the heated mirror system diagnosis as follows. (Refer to Appropriate Wiring Information).
WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER- FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
The operation of the heated mirror system can be
confirmed in one of the following manners:
1. Turn the ignition switch to the On position. While monitoring the instrument panel voltmeter, momentarily depress and release the heated mirror switch. When the heated mirror system is turned On, a distinct voltmeter needle deflection should be noted.
2. Turn the ignition switch to the On position. Momentarily depress and release the heated mirror switch to turn the heated mirror system On. The heated mirror operation can be checked by feeling the outside rear view mirror glass. A distinct differ- ence in temperature between the unheated and heated mirror glass can be detected within three to four minutes of system operation.
The above checks will confirm system operation. Illumination of the heated mirror system indicator lamp means that there is electrical current available at the heated mirror relay, but does not confirm that the electrical current is reaching the outside mirror heating grids.
If the heated mirror system does not operate, the problem should be isolated in the following manner: (1) Confirm that the ignition switch is in the On
position.
(2) Check the fuses in the Power Distribution Cen- ter (PDC) and in the Junction Block (JB). The fuses must be tight in their receptacles and all electrical connections must be secure.
When the above steps have been completed and both outside mirror heating grids are still inopera- tive, one or more of the following is faulty:
† Heated mirror switch, electronic control logic and timer circuitry, and heated mirror relay. † Heated mirror wire harness circuits or connec- tors.† Outside mirror heating grid (both mirror grids would have to be faulty). If turning On the heated mirror system produces a severe voltmeter deflection or fuse failures, check for a shorted circuit between the output of the heated mirror relay and the outside mirror heating grids.
DR
HEATED SEAT SYSTEM 8G - 3
HEATED SEAT SYSTEM
TABLE OF CONTENTS
page
page
HEATED SEAT SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - HEATED SEATSYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HEATED SEAT ELEMENT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DIAGNOSIS AND TESTING - HEATED SEATELEMENT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6HEATED SEAT SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
HEATED SEAT SYSTEM DESCRIPTION
Individually controlled, electrically heated front seats are available as a factory-installed option on some DR models. Vehicles with this option can be visually identified by the leather trim seats and two separate heated seat switches mounted in the lower center of the instrument panel. The heated seat sys- tem allows the front seat driver and passenger to select from two different levels of electrical seat heat- ing, or no seat heating to suit their individual com- fort requirements. The heated seat system for this vehicle includes the following major components, which are described in further detail later in this sec- tion:† Heated Seat Switches - Two heated seat switches are used per vehicle. One switch is used for each front seat. The switches are mounted in the instrument panel, below the radio (Fig. 1). Each switch also includes two Light-Emitting Diode (LED) indicator lamps and an incandescent back lighting bulb.† Heated Seat Module - also referred to as the Seat Heat Interface Module (SHIM), this module con- tains the solid state electronic control and diagnostic logic circuitry for the heated seat system. One heated seat module is used per vehicle and is mounted under the drivers front seat cushion (Fig. 1). Refer to the Electronic Control Modules section of the service manual for additional heated seat module informa- tion.
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - HEATED SEATSENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7REMOVAL
HEATED SEAT SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - HEATED SEAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9† Heated Seat Elements - Four heated seat ele- ments are used per vehicle. One element is used for each front seat back and one element and sensor assembly is used for each front seat cushion (Fig. 1). The heating elements are integral to the individual front seat and seat back cushions and cannot be removed once installed at the factory. Replacement seat heating elements are available, without having to replace the entire seat cushion or trim cover. Refer to the detailed procedure later in this section. † Heated Seat Sensors - Two heated seat sen- sors are used per vehicle. One heated seat tempera- ture sensor is used for each front seat cushion. The sensors are integral to the individual front seat cush- ion heating elements (Fig. 1) and cannot be removed once installed at the factory. Replacement seat heat- ing elements with the sensors are available, without having to replace the entire seat cushion or trim cover. Refer to the detailed procedure later in this section.
Following are general descriptions and operations of the major components in the heated seat system. See the owner’s manual in the vehicle glove box for more information on the features, use and operation of the heated seat system. Refer to Wiring for the location of complete heated seat system wiring dia- grams.
HEATED SEAT SYSTEM
8G - 4
HEATED SEAT SYSTEM (Continued)DR
The heated seat module monitors inputs from the heated seat sensors and the heated seat switches. In response to these inputs the heated seat module uses its internal programming to control 12v to the heated seat elements in both front seats and to control the heated seat LED indicator lamps located in both of the heated seat switches. The heated seat module is also programmed to provide self-diagnostics, if a problem with the heated seat system is detected. If the module detects certain failures within the heated seat system, it will provide a visual indication of the failure by flashing the indicator lamps in the appro- priate heated seat switch. The heated seat module will automatically turn off the heated seat elements if it detects a short or open in the heated seat ele- ment circuit or a heated seat sensor value that is out of range.
DIAGNOSIS AND TESTING - HEATED SEAT SYSTEM
HEATED SEAT SYSTEM SELF-DIAGNOSIS
The heated seat system is capable of performing some self-diagnostics. The following table depicts the various monitored failures which will be reported to the vehicle operator or technician by flashing the individual heated seat switch Light Emitting Diode (LED) indicator lamps. Refer to the HEATED SEAT SYSTEM SELF-DIAGNOSIS table for failure identi- fication. The drivers heated seat switch indicator lamps will flash if a failure occurs in the driver heated seat, and the passengers heated seat switch indicator lamps will flash for a passenger heated seat failure. If a monitored heated seat system failure occurs, the switch indicator lamps will flash at a pulse rate of about one-half second on, followed by about one-half second off for a duration of about one minute after the switch for the faulty heated seat is depressed in either the Low or High direction. This process will repeat every time the faulty heated seat switch is actuated until the problem has been cor- rected.
HEATED SEAT SYSTEM SELF-DIAGNOSIS
Monitored Failure
Heated Seat
Element Shorted
Heated Seat Element Open Heated Seat
Switch High
Switch Low
Indicator Lamp
Indicator Lamp
Flashing
Flashing
Flashing
Off
Sensor Value Out
Off
Flashing
of Range
Fig.1DRHeatedSeatSystemDiagram
1 - WIRE HARNESS 2 - DRIVER HEATED SEAT SWITCH 3 - PASSENGER HEATED SEAT SWITCH 4 - PASSENGER HEATED SEAT CUSHION ELEMENT 5 - SEAT CUSHION/BACK ELEMENT ELECTRICAL CONNECTOR LOCATION 6 - DRIVER HEATED SEAT BACK ELEMENT 7 - DRIVER HEATED SEAT CUSHION ELEMENT 8 - HEATED SEAT MODULE
OPERATION
The heated seat module receives fused battery cur- rent through the Integrated Power Module only when the engine is running. The heated seat switches receive battery current through fuse #48 in the Inte- grated Power Module only when the ignition switch is in the On position. The heated seat module shares a common ground circuit with each of the heated seat elements. The heated seat system will only operate when the surface temperature of the seat cushion is below the designed temperature set points of the sys- tem.
The heated seat system will also automatically turn off whenever the ignition switch is turned to any position except On, or if the engine quits run- ning. If the ignition switch is turned to the Off posi- tion or if the engine quits running while a heated seat is ON, the heated seat will remain Off after the engine is restarted until a heated seat switch is depressed again. This helps prevent the vehicles bat- tery from being drained by the heated seat system.
DR HEATED SEAT SYSTEM (Continued)
Diagnostic logic is built into the heated seat mod- ule to help the person trying to locate the problem by the most efficient means possible. Anytime a problem is suspected, locate the diagnosis and testing proce- dure for the component in question and follow the steps until the specific problem is located and resolved. Once the problem is thought to be cor- rected, verify correct system operation. If the heated seat system is functioning correctly return the vehi- cle to service.
If a problem could not be verified such as not find- ing anything wrong when following the diagnostic procedure, this is a good indication that a INTER- MITTENT problem may be present. You must then attempt to find the intermittent problem, such as moving the heating element within the seat while testing continuity or wiggling the wire harness’s/elec- trical connectors under the seat while testing conti- nuity. Always, eliminate all other potential problems before attempting to replace the heated seat module.
PRELIMINARY TEST
Refer to Wiring for the location of complete heated seat system wiring diagrams. Before testing the indi- vidual components in the heated seat system, per- form the following preliminary checks:
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCON- NECT AND ISOLATE THE BATTERY NEGATIVE CABLE, THEN WAIT TWO MINUTES FOR THE AIR- BAG SYSTEM CAPACITOR TO DISCHARGE BEFORE PERFORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DIS- ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI- BLE PERSONAL INJURY.
† If the heated seat switch back lighting and the cluster illumination lamps do not illuminate with the headlamps or park lamps turned On, refer to the Instrument Cluster section of the service manual for the location of cluster illumination lamp diagnosis and testing procedures. If the heated seat switch back lighting does not illuminate, but the cluster illu- mination lamps do illuminate with the headlamps or park lamps turned On, refer to Diagnosis and Test- ing the Heated Seat Switch in this section for the location of the heated seat switch diagnosis and test- ing procedures. † If a single LED indicator lamp for one heated seat switch does not operate and the heated seat ele- ments do heat, refer to Diagnosis and Testing the
HEATED SEAT SYSTEM 8G - 5
Heated Seat Switch in this section for heated seat switch diagnosis and testing procedures. † If both LED indicator lamps for a heated seat switch operate, but the heated seat elements do not heat, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules for heated seat module diagnosis and testing procedures. † If the indicator lamp on either heated seat switch remains illuminated after the heated seat has been turned Off, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules for heated seat module diagnosis and test- ing procedures.
HEATED SEAT ELEMENT DESCRIPTION
Fig.2HeatingElementInstalledonSeatCushion
Foam
1 - SEAT BACK WIRE HARNESS 2 - HEATED SEAT WIRE HARNESS CONNECTOR 3 - HEATED SEAT CUSHION ELEMENT
Vehicles equipped with the optional heated seat system have two sets of electrically operated heating
