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Fig.46ROOF
Fig.47REARBODY
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Fig.50LEFTREARFENDER(RIGHTSIDESIMILAR)
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8W-97 POWER DISTRIBUTION
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8W-97 POWER DISTRIBUTION
TABLE OF CONTENTS
page
page
POWER DISTRIBUTION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIAL TOOLSPOWER DISTRIBUTION SYSTEMS . . . . . . . . . 2
CIGAR LIGHTER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - CIGAR LIGHTEROUTLET
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTEGRATED POWER MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7POWER OUTLET
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - POWER OUTLET . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - RELAY . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9FRONT CONTROL MODULE
MICRO RELAY
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING - FRONTCONTROL MODULE
. . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5IOD FUSE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER DISTRIBUTION DESCRIPTION
the various
This group covers
standard and optional power distribution components used on this model. The power distribution system for this vehicle consists of the following components: † Integrated Power Module (IPM) † Front Control Module (FCM) † Power Distribution Center (PDC) † Power Outlets † Cigar Lighter Outlets † Relays Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates various types of circuit control and protection fea- tures, including:
† Automatic resetting circuit breakers † Blade-type fuses † Cartridge fuses † Relays
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - MICRO-RELAY . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10Following are general descriptions of the major components in the power distribution system. See the owner’s manual in the vehicle glove box for more information on the features and use of all of the power distribution system components.
OPERATION
The power distribution system for this vehicle is designed to provide safe, reliable, and centralized dis- tribution points for the electrical current required to operate all of the many standard and optional facto- ry-installed electrical and electronic powertrain, chassis, safety, security, comfort and convenience sys- tems. At the same time, the power distribution sys- tem was designed to provide ready access to these electrical distribution points for the vehicle techni- cian to use when conducting diagnosis and repair of faulty circuits. The power distribution system can also prove useful for the sourcing of additional elec- trical circuits that may be required to provide the electrical current needed to operate many accessories that the vehicle owner may choose to have installed in the aftermarket.
8W-97 POWER DISTRIBUTION
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POWER DISTRIBUTION (Continued) SPECIAL TOOLSPOWER DISTRIBUTION SYSTEMS
TerminalPickKit6680
CIGAR LIGHTER OUTLET DESCRIPTION
On models equipped a cigar lighter outlet
is installed to the left of the center stack area in the lower instrument panel. The cigar lighter outlet is secured by a snap fit within the bezel.
The cigar lighter outlet, plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced.
OPERATION
The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or outlet shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter receives battery voltage from a fuse in the junction block when the ignition switch is in the Accessory or Run positions.
The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the outlet shell, the heating element resistor coil is grounded through its housing to the outlet shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell.
Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell. These clips engage and hold the heating element against the insulated contact long
enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat.
When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element caus- ing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heat- ing element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the outlet shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety.
DIAGNOSIS AND TESTING - CIGAR LIGHTER OUTLET
For complete circuit diagrams, refer to Wiring
Diagrams.
(1) Check the fused B(+) fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
(2) Turn the ignition switch to the Run position. Check for battery voltage at the fused B(+) fuse in the integrated power module. If OK, go to Step 3. If not OK, repair the open or short as required.
(3) Remove the cigar lighter knob and element from the cigar lighter outlet shell. Check for continu- ity between the inside circumference of the cigar lighter outlet shell and a good ground. there should be continuity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Turn the ignition switch to the Run position. Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell. If OK, replace the faulty cigar lighter knob and ele- ment. If not OK, go to Step 5.
(5) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Check for continuity between the ground circuit cav- ity of the cigar lighter wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required.
(6) Connect the battery negative cable. Turn the ignition switch to the Accessory or Run positions. Check for battery voltage at the fused B(+) circuit cavity of the cigar lighter wire harness connector. If OK, replace the faulty cigar lighter outlet. If not OK, repair the open fused B(+) circuit to the integrated power module fuse as required.
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8W-97 POWER DISTRIBUTION
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INTEGRATED POWER MODULE DESCRIPTION
components: the Power Distribution Center (PDC), the integrated power module cover, the Front Control Module (FCM) and the Integrated Power Module Assembly which includes the power distribution cen- ter, the cover and FCM. Refer to the Front Con- trol Module in the Electronic Control Module section of this service manual for information on the front control module.
OPERATION
All of the current from the battery and the gener- ator output enters the integrated power module via a stud on the top of the module. The integrated power module cover is removed to access the fuses or relays. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Refer to the Wiring section of the service manual for complete integrated power module circuit schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
Fig.1DRINTEGRATEDPOWERMODULE
1 - POWER DISTRIBUTION CENTER HOUSING 2 - FRONT CONTROL MODULE ELECTRICAL CONNECTOR
The Integrated Power Module (IPM) (Fig. 1) is a combination of the Power Distribution Center (PDC) and the Front Control Module (FCM). The IPM is located in the engine compartment, next to the bat- tery on this model. The power distribution center mates directly with the Front Control Module (FCM) to form the Integrated Power Module Fuse and Relay Center. The power distribution center (PDC) is a printed circuit board based module that contains fuses and relays, while the front control module con- tains the electronics controlling the integrated power module and other functions. This integrated power module connects directly to the battery positive via a stud located on top of the unit. The ground connec- tion is via electrical connectors. The integrated power module provides the primary means of voltage distri- bution and protection for the entire vehicle.
The molded plastic integrated power module hous- ing includes a base and cover. The integrated power module cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover. This integrated power module housing base and cover are secured in place via bolts to the left front fender support assembly.
Replaceable components of the integrated power module assembly are broken down into the following
Fig.2DRINTEGRATEDPOWERMODULE
1 - COVER RETAINING BOLT 2 - INTEGRATED POWER MODULE RETAINING BOLT 3 - RETAINING SCREW 4 - INTEGRATED POWER MODULE COVER
(2) Unsnap cover and remove the B+ terminal nut from the integrated power module B+ terminal. Remove the B+ cable from the integrated power mod- ule.
(3) Disconnect the gray connector from the inte-
grated power module.
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INTEGRATED POWER MODULE (Continued)8W-97 POWER DISTRIBUTION
(4) Remove the integrated power module retaining
bolt and screw (Fig. 2).
DR
Fig.3REMOVINGINTEGRATEDPOWERMODULE (5) Grasp the integrated power module with two hands and slide the assembly in the direction shown (Fig. 3) to free the module from its mounting bracket. Position the assembly upside down to access the elec- trical connectors located on the bottom of the unit.
(6) Disconnect the electrical connectors by depress- ing the locking tab and rotating the connector arm outboard, until the connector is free from the module assembly. Be certain to pull the connectors straight off.
(7) Position the integrated power module on a bench and remove the four front control module retaining screws.
(8) Disconnect the front control module by pulling
it straight off the integrated power module.
INSTALLATION
(1) Connect the front control module by pushing it straight on the integrated power module electrical receptacle.
(2) Install the four front control module retaining
screws. Torque to 30 in. lbs. +/-5.
NOTE: Integrated power module electrical connec- tors are color coded to ease location reference (Fig. 4).
(3) Connect the electrical connectors by pushing straight on and rotating the connector arm inboard, until the connector is firmly locked in place on the module assembly.
Fig.4INTEGRATEDPOWERMODULEELECTRICAL
CONNECTIONS
1 - RETAINING LATCH 2 - GRAY CONNECTOR 3 - GREEN CONNECTOR 4 - GREEN CONNECTOR 5 - BLUE CONNECTOR 6 - WHITE CONNECTOR 7 - BLACK CONNECTOR 8 - BLACK CONNECTOR
(4) Grasp the integrated power module with two hands and install the assembly on the battery tray (Fig. 5).
(5) Install the integrated power module retaining
bolt and screw.
(6) Connect the gray connector on the integrated
power module housing.
(7) Install the B+ terminal cable and nut on the integrated power module B+ terminal. Snap the cover in place. (8) Connect
the negative and positive battery
cables.
FRONT CONTROL MODULE DESCRIPTION
The Front Control Module (FCM) is a micro con- troller based module located in the left front corner of the engine compartment. On this model the inte- grated power module must be positioned aside in order to access the front control module. The front control module mates to the power distribution cen- ter to form the Integrated Power Module (IPM). The integrated power module connects directly to the bat-
DR FRONT CONTROL MODULE (Continued)
8W-97 POWER DISTRIBUTION
8W - 97 - 5
† Power Ground † Ambient Temperature Sensing † Ignition Switch Run † Washer Fluid Level Switch † Windshield Wiper Park Switch † PCI Bus Circuit
DIAGNOSIS AND TESTING - FRONT CONTROL MODULE
The front control module is a printed circuit board based module with a on-board micro-processor. The front control module interfaces with other electronic modules in the vehicle via the Programmable Com- munications Interface (PCI) data bus (J1850). In order to obtain conclusive testing the Programmable Communications Interface (PCI) data bus network and all of the electronic modules that provide inputs to, or receive outputs from the front control module must be checked. All PCI (J1850) communication faults must be resolved prior to further diagnosing any front control module related issues.
The front control module was designed to be diag- nosed with an appropriate diagnostic scan tool, such as the DRB IIIt. The most reliable, efficient, and accurate means to diagnose the front control module requires the use of a DRB IIIt scan tool and the proper Body Diagnostic Procedures manual.
Before any testing of the front control module is attempted, the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle.
REMOVAL
(1) Disconnect the positive and negative battery
cables from the battery.
(2) Partially remove the integrated power module from the engine compartment (Refer to 8 - ELECTRI- CAL/POWER DISTRIBUTION/INTEGRATED POWER MODULE - REMOVAL).
(3) Remove
the
front
control module
retaining
screws.
(4) Using both hands, pull the front control module straight from the integrated power module assembly to disconnect the 49-way electrical connector and remove the front control module from the vehicle.
INSTALLATION
(1) Install the front control module on the inte- grated power module assembly by pushing the 49-way electrical connector straight in.
(2) Install
the front
control module retaining
screws. Torque the screws to 7 in. lbs.
(3) Install the integrated power module (Refer to 8
ELECTRICAL/POWER DISTRIBUTION/INTE-GRATED POWER MODULE - INSTALLATION).
(4) Connect the positive and negative battery cables.
Fig.5INTEGRATEDPOWERMODULEMOUNTING
TABS
1 - INTEGRATED POWER MODULE MOUNTING HOLES 2 - BATTERY TRAY ASSEMBLY 3 - FRONT CONTROL MODULE
tery and provides the primary means of circuit pro- tection and power distribution for all vehicle electrical systems. The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit (J1850).
For information on the Integrated Power Mod- ule Refer to the Power Distribution Section of the service manual.
OPERATION
As messages are sent over the PCI bus circuit, the front control module reads these messages and con- trols power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are Controlled by the Front Control Module:
† Headlamp Power with Voltage Regulation † Windshield Wiper “ON/OFF” Relay Actuation † Windshield Wiper “HI/LO” Relay Actuation † Windshield Washer Pump Motor † Fog Lamp Relay Actuation † Park Lamp Relay Actuation † Horn Relay Actuation The following inputs are Received/Monitored by † B+ Connection Detection
the Front Control Module:
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8W-97 POWER DISTRIBUTION
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IOD FUSE DESCRIPTION
Fig.6IODFUSELOCATION
1 - IOD FUSE
All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Inte- grated Power Module when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the Integrated Power Module as part of the preparation procedures performed just prior to new vehicle delivery.
A laser printed fuse layout map is integral to the Integrated Power Module cover to ensure proper fuse identification. The IOD fuse is a 20 ampere mini blade-type fuse, located in fuse cavity # 51 (Fig. 6). The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its Integrated Power Module cavity, and as a fuse holder that conveniently stores the fuse in the same Inte- grated Power Module cavity after it has been discon- nected.
CIRCUITS INCLUDED WITH IOD FUSE
† Cluster (CCN) † Diagnostic Connector † Map Lamps † Glove Box Lamp † Courtesy Lamps † Radio † Underhood Lamp
OPERATION
The term ignition-off draw identifies a normal con- dition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery cur- rent when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical sys- tem during new vehicle transportation and pre-deliv- ery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed by both vehi- cle transportation company and dealer personnel.
The IOD fuse is disconnected from Integrated Power Module fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is pre- pared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B(+) circuit fuse.
thirty days. However,
The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be discon- nected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the bat- tery from becoming discharged or damaged.
REMOVAL
The Ignition-Off Draw (IOD) fuse is disconnected from Integrated Power Module fuse cavity # 51 when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation.
(1) Turn the ignition switch to the Off position. (2) Remove the Integrated Power Module cover. (3) Grasp the outer tabs of the IOD fuse holder unit in fuse cavity # 51 between the thumb and fore- finger and pull the unit firmly upward.
(4) Install the Integrated Power Module cover.
8W-97 POWER DISTRIBUTION
8W - 97 - 7
DR IOD FUSE (Continued) INSTALLATION
(1) Turn the ignition switch to the Off position. (2) Remove the Integrated Power Module cover. (3) To install the IOD fuse, use a thumb to press the IOD fuse holder unit in fuse cavity # 51 firmly into the Integrated Power Module.
(4) Install the Integrated Power Module cover.
POWER OUTLET DESCRIPTION
Two power outlets are utilized on this model. One in the instrument panel center lower bezel and the other in the center console. The power outlet bases are secured by a snap fit within the instrument panel or trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power out- let is in use.
The power outlet receptacle unit and the accessory power outlet protective cap are available for service. The power outlet receptacle cannot be repaired and, if faulty or damaged, it must be replaced.
OPERATION
The power outlet base or receptacle shell is con- nected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the integrated power module at all times.
While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the recepta- cle shell that are used to secure the cigar lighter heating element to the insulated contact.
DIAGNOSIS AND TESTING - POWER OUTLET
For complete circuit diagrams, refer to Wiring
Diagrams.
(1) Check the fused B(+) fuse in the integrated power module. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse in the integrated power module. If OK, go to Step 3. If not OK, repair the open fused B(+) circuit to the battery as required.
(3) Remove the plastic protective cap from the power outlet receptacle. Check for continuity between the inside circumference of the power outlet recepta- cle and a good ground. There should be continuity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con- tact located at the back of the power outlet recepta- cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative cable. Remove the power outlet receptacle from the instrument panel. Disconnect the wire harness con- nector from the power outlet receptacle. Check for continuity between the ground circuit cavity of the power outlet wire harness connector and a good ground. There should be continuity. If OK, go to Step 6. If not OK, repair the open ground circuit to ground as required.
(6) Connect the battery negative cable. Check for battery voltage at the fused B(+) circuit cavity of the power outlet wire harness connector. If OK, replace the faulty power outlet receptacle. If not OK, repair the open fused B(+) circuit to the integrated power module fuse as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Pull the cigar lighter knob and element out of the cigar lighter receptacle base, or unsnap the pro- tective cap from the power outlet receptacle base.
(3) Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangu- lar retaining bosses of the mount that secures the receptacle base to the panel (Fig. 7).
(4) Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount.
(5) Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and, using a gentle rocking motion, pull the pliers and the receptacle base out of the mount.
(6) Pull the receptacle base away from the instru- far enough to access the instrument
ment panel panel wire harness connector.
(7) Disconnect the instrument panel wire harness connector from the cigar lighter or power outlet receptacle base connector receptacle.
(8) Remove the cigar lighter or power outlet mount
from the instrument panel.
INSTALLATION
(1) Reconnect the instrument panel wire harness connector to the cigar lighter or power outlet recep- tacle base connector receptacle.
(2) Install the cigar lighter or power outlet mount
into the instrument panel.
(3) Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount.
8W - 97 - 8
POWER OUTLET (Continued)8W-97 POWER DISTRIBUTION
DR
Fig.8ISORelay
Fig.7CigarLighterandPowerOutletRemove/
Install
1 - KNOB AND ELEMENT 2 - RETAINING BOSSES-ENGAGE PLIERS HERE 3 - BASE 4 - PARTIALLY REMOVED 5 - EXTERNAL SNAP-RING PLIERS 6 - MOUNT 7 - BASE
(4) Press firmly on the cigar lighter or power out- let receptacle base until the retaining bosses of the mount are fully engaged in their receptacles.
(5) Install the cigar lighter knob and element into the cigar lighter receptacle base, or the protective cap into the power outlet receptacle base.
(6) Reconnect the battery negative cable.
RELAY DESCRIPTION
A relay (Fig. 8) is an electromechanical device that switches fused battery current to a electrical compo- nent when the ignition switch is turned to the Acces- sory or Run positions, or when controlled by a electronic module. The relays are located in the inte- grated power module.
The relay is a International Standards Organiza- tion (ISO) relay. Relays conforming to the ISO speci- fications have common physical dimensions, current capacities, terminal patterns, and terminal functions. if
A relay cannot be repaired or adjusted and,
faulty or damaged, it must be replaced.
30
85
86
87
87AOPERATION
COMMON FEED COIL GROUND COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
is held against one of
The ISO relay consists of an electromagnetic coil, a resistor and three (two fixed and one movable) elec- trical contacts. The movable (common feed) relay con- tact the fixed contacts (normally closed) by spring pressure. When the elec- tromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, and holds it against the other (normally open) fixed contact.
When the electromagnetic coil
is de-energized, spring pressure returns the movable contact to the normally closed position. The resistor is connected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are pro- duced when the coil is de-energized.
DIAGNOSIS AND TESTING - RELAY
The relays are located in the integrated power module. For complete circuit diagrams, refer to Wir- ing Diagrams.
(1) Remove the relay from its mounting location. (2) A relay in the 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 the faulty relay.
(3) Resistance between terminals 85 and 86 (elec- tromagnet) should be 60.7 - 80.3 ohms. If OK, go to Step 4. If not OK, replace the faulty relay.
(4) Connect a 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 the Relay Circuit Test that follows. If not OK, replace the faulty relay.
8W-97 POWER DISTRIBUTION
8W - 97 - 9
DR RELAY (Continued) DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of the integrated power module is connected to battery voltage and should be hot at all times. Check for bat- tery voltage at the fused B(+) circuit cavity in the integrated power module receptacle for the relay. If OK, go to Step 2. If not OK, repair the fused B(+) cir- cuit to the integrated power module fuse as required. is connected to terminal 30 in the de-energized position, but is not used for this application. Go to Step 3.
(2) The relay normally closed terminal
(87A)
(3) The relay normally open terminal (87) is con- nected to the common feed terminal (30) in the ener- gized position. This terminal supplies battery voltage to the fused B(+) fuse in the integrated power module that feeds the accessory when the relay is energized by the ignition switch. There should be continuity between the integrated power module cavity for relay terminal 87 and the fused B(+) fuse in the integrated power module at all times. If OK, go to Step 4. If not OK, repair the open fused B(+) circuit to the inte- grated power module fuse as required.
(4) The coil ground terminal (85) is connected to the electromagnet in the relay. It receives battery feed to energize the relay when the ignition switch is in the Accessory or Run positions. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (acc/run) circuit cavity for relay terminal 85 in the integrated power module receptacle for the relay. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (acc/run) circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to the electromagnet in the relay. The integrated power module cavity for this terminal should have continu- ity to ground at all times. If not OK, repair the open ground circuit to ground as required.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process.
INSTALLATION
(1) Position the relay to the proper receptacle. (2) Align the relay terminals with the terminal
cavities in the receptacle.
(3) Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle.
(4) Connect the negative battery cable.
MICRO RELAY DESCRIPTION
Fig.9DRISOMicroRelay
30 - COMMON FEED 85 - COIL GROUND 86 - COIL BATTERY 87 - NORMALLY OPEN 87A - NORMALLY CLOSED
A micro-relay is a conventional International Stan- dards Organization (ISO) micro relay (Fig. 9). Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal pat- terns, and terminal functions. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs by five integral male spade-type terminals that extend from the bottom of the relay base.
Relays cannot be adjusted or repaired and, if faulty
or damaged, the unit must be replaced.
OPERATION
A micro-relay is an electromechanical switch that uses a low current input from one source to control a high current output to another device. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electro- magnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses.
DIAGNOSIS AND TESTING - MICRO-RELAY
(1) Remove the relay from its mounting location. (2) A relay in the de-energized position should have continuity between terminals 87A and 30, and
8W - 97 - 10
MICRO RELAY (Continued)8W-97 POWER DISTRIBUTION
DR
no continuity between terminals 87 and 30. If OK, go to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec- tromagnet) should be 67.5 - 82.5 ohms. If OK, go to Step 4. If not OK, replace the faulty relay.
(4) Connect a 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, reinstall the relay and use a DRB IIIt scan tool to perform further testing. Refer to the appropriate diagnostic information.
Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds.
REMOVAL
cable.
(1) Disconnect and isolate the negative battery
(2) Remove the relay by grasping it firmly and pulling it straight out from its receptacle. A slight back and fourth rocking motion may help the removal process.
INSTALLATION
(1) Align the micro-relay terminals with the termi-
nal cavities in the receptacle.
(2) Push firmly and evenly on the top of the relay until the terminals are fully seated in the terminal cavities in the receptacle.
(3) Connect the battery negative cable.
DR
ENGINE
9 - 1
ENGINE
TABLE OF CONTENTS
ENGINE - 3.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ENGINE - 4.7L . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
ENGINE - 5.7L . . . . . . . . . . . . . . . . . . . . . . . . . . 176ENGINE - 5.9L . . . . . . . . . . . . . . . . . . . . . . . . . . 223
ENGINE 5.9L DIESEL . . . . . . . . . . . . . . . . . . . . . 280
ENGINE 8.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . 351page
page
ENGINE - 3.7L
TABLE OF CONTENTS
page
page
ENGINE - 3.7L
CAMSHAFT(S)
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - ENGINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 4
CYLINDER HEAD COVER(S)
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 4
DIAGNOSIS AND TESTING - ENGINE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6
INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - LUBRICATION . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE . . . . . . . . . . . . . . 8
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE . . . . . . . 8
STANDARD PROCEDURE
STANDARD PROCEDURE - REPAIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
STANDARD PROCEDURE - REFACING . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29ROCKER ARM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30DAMAGED OR WORN THREADS . . . . . . . . . . 9
VALVE GUIDE SEALS
STANDARD PROCEDURE - FORM-IN-
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
PLACE GASKETS AND SEALERS . . . . . . . . . . 9
VALVE SPRINGS
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION . . . . . . . . 10
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
SPECIFICATIONSSPECIFICATIONS – 3.7L ENGINE . . . . . . . . . 12
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
. . . . . . . . . . . . . . . . . . . . . . . 16SPECIAL TOOLS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31CYLINDER HEAD - RIGHT
DIAGNOSIS AND TESTING - HYDRAULIC
LASH ADJUSTER
. . . . . . . . . . . . . . . . . . . . . 31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32AIR CLEANER ELEMENT
CAMSHAFT(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20CYLINDER HEAD - LEFT
DIAGNOSIS AND TESTING - CYLINDER HEAD
GASKET
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35CYLINDER HEAD COVER(S)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 369 - 2
ENGINE - 3.7L
DR
ROCKER ARM
REAR MOUNT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 60VALVE GUIDE SEALS
LUBRICATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
VALVE SPRINGS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37ENGINE BLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
STANDARD PROCEDURE—CYLINDER BOREHONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 38
CRANKSHAFTDESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41CRANKSHAFT MAIN BEARINGS
STANDARD PROCEDURE
MAIN BEARING FITTING . . . . . . . . . . . . . . . . 43
CRANKSHAFT OIL SEAL - FRONT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45CRANKSHAFT OIL SEAL - REAR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46FLEX PLATE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 47PISTON & CONNECTING ROD
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 47
STANDARD PROCEDURECONNECTING ROD BEARING FITTING . . . . 48
STANDARD PROCEDURE—PISTONFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 51
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51PISTON RINGS
STANDARD PROCEDURE - PISTON RING
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
VIBRATION DAMPER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55STRUCTURAL COVER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 56
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 56FRONT MOUNT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 60
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING—ENGINE OIL
LEAK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
DIAGNOSIS AND TESTING - CHECKING
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . 64
DIAGNOSIS AND TESTING - REAR SEAL
AREA LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . 64
OIL PAN
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 65
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 66
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 66OIL PRESSURE SENSOR/SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 66
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 67OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 67
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 67
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 68OIL FILTER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70OIL
