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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 element grids located in each front seat, one set for the seat cushion and the other set for the seat back. Each of the heated seat element grids consists of a single length of resistor wire that is routed in a zig- zag pattern and captured between a covering and the adhesive foam rubber backing. Short pigtail wires with connectors (Fig. 2) are soldered to each end of each resistor wire element grid, which connect all of
HEATED SEAT SYSTEM
8G - 6
HEATED SEAT ELEMENT (Continued)DR
the element grids to the heated seat module through the seat wire harness.
One temperature sensor is used for each front seat, and it is located in the center insert area of the seat cushion element. The heated seat sensors and their pigtail wires are also captured between a covering and the adhesive foam rubber backing. The heated seat sensors are Negative Thermal Coefficient (NTC) thermistors. The sensors for both front seats receive a voltage feed from a single output of the heated seat module, but the module receives individual sensor inputs from the driver side and passenger side sen- sors.
The heated seat elements and sensors should not be repaired. If damaged or faulty, the heated seat ele- ment assembly must be replaced.
OPERATION
One end of the heated seat element resistor wire is connected to ground at all times through a splice in the heated seat module ground circuit. Battery cur- rent is directed to the other end of the heated seat element resistor wire by the energized N-channel Field Effect Transistor (N-FET) located within the heated seat module. The heated seat module will energize the N-FET only when the heated seat switch is in the Low or High position and the heated seat sensor indicates that the seat cushion surface temperature is below the selected (Low or High) tem- perature set point. As electrical current passes through the heating element grid, the resistance of the wire used in the element disperses some of that electrical current in the form of heat. The heat pro- duced by the heated seat element grid then radiates through the seat trim cover, warming its occupant.
The resistance of the heated seat sensor increases and decreases as the surface temperature of the seat cushion cover changes. The heated seat module sup- plies each sensor with a 5v voltage feed, then uses the sensor resistance to determine when the heated seat element grids need to be cycled on or off in order to maintain the selected temperature set point.
DIAGNOSIS AND TESTING - HEATED SEAT ELEMENT
The heated seat module will self-diagnose shorted or open heated seat element circuits and sensor cir- cuits. Refer to Heated Seat System Diagnosis and Testing in this section for additional diagnosis and testing procedures. To manually check the heated seat element, proceed as follows. The wire harness connectors for the seat cushion and seat back heating elements and sensor are located on the right side of the seat, near the edge of the seat cushion frame. The proper connector can be identified by the foam wrapping.
NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an inter- mittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test.
(1) Position the appropriate seat in the full for-
ward position.
position.
(2) Make certain the ignition switch is in the OFF
(3) Disconnect the heated seat element connector which requires testing. Check for continuity between the two heated seat element circuit cavities while moving the appropriate seat cushion. Refer to Wir- ing for the location of complete heated seat system wiring diagrams. There should be continuity. If OK, the elements within the seat assembly test OK, go to Step 4. If not OK, replace the faulty seat heating ele- ment, refer to the procedure in this section.
(4) Test the seat wire harness between the heated seat module connector and the appropriate heated seat wire harness connector for shorted or open cir- cuits. If OK, element is OK, proceed with testing the heated seat sensor and module. If not OK, repair the shorted or open seat wire harness as required.
REMOVAL
Do not remove the heating element from the seat or seat back cushion. The original element is perma- nently attached to the seat cushions and cannot be removed without damaging the cushion. The replace- ment heating element is designed to be applied directly over the original seat heating element.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate seat cushion or seat back trim cover. Refer to the Body section of this manual for the procedures.
(3) Disconnect the inoperative heated seat cushion
or seat back element electrical connectors.
(4) Locate the wires leading from the inoperative heating element and cut them off flush with the edge of the original heating element.
INSTALLATION
(1) Peel off the adhesive backing on the back of the replacement heating element and stick directly over the original heating element (Fig. 3).
the replace- CAUTION: During the installation of ment heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure.
DR HEATED SEAT ELEMENT (Continued)
HEATED SEAT SYSTEM 8G - 7
the temperature of the seat, and regulates the cur- rent flow to the seat heating elements accordingly.
DIAGNOSIS AND TESTING - HEATED SEAT SENSOR
NOTE: Any resistance values (OHMS V) given in the following text are supplied using the automatic range generated by a FLUKET automotive meter. If another type of measuring device is used, the val- ues generated may not be the same as the results shown here, or may have to be converted to the range used here.
(1) Position the driver seat in the full rearward
position.
(2) Unclip the heated seat module from the bottom
of the drivers seat cushion pan.
(3) Back-probe the heated seat module wire har- ness connector, do not disconnect. Check cavity (#7
for passenger, #8 for driver seat) for a range in volt- age from approx. 1.72 – 3.0 volts. It should be within this range, If OK check the heated seat element. If NOT OK, check for the proper 5 volt supply to the heated seat sensor, from the module. Refer to Wiring for specific information. If 5 volts is not being sup- plied to the sensor from the module, replace the heated seat module.(4) Test the seat wire harness between the heated seat module connector and the heated seat wire har- ness connector for shorted or open circuits. If OK, refer to Diagnosis and Testing the Heated Seat Module in Electronic Control Modules, for the proper heated seat module diagnosis and testing pro- cedures. If not OK, repair the shorted or open heated seat wire harness as required.
REMOVAL
(1) For heated seat sensor replacement procedure - ELECTRICAL/HEATED SEATS/
(Refer HEATED SEAT ELEMENT - REMOVAL).
to
HEATED SEAT SWITCH DESCRIPTION
The momentary, bidirectional rocker-type heated seat switch (Fig. 4) provides a resistor-multiplexed signal to the heated seat module via a mux circuit. Each switch has a center neutral position and momentary Low and High positions so that both the driver and the front seat passenger can select a pre- ferred level of seat heating. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected mode (Low or High) of the seat heater. These indicator lamps also provide
Fig.3HeatingElementInstallation
1 - ORIGINAL (INOPERATIVE) HEATING ELEMENT 2 - REPLACEMENT HEATING ELEMENT
(2) Connect the new heating element electrical
connectors (Fig. 2).
(3) Connect the battery negative cable. (4) Verify heated seat system operation. (5) Install the appropriate seat cushion or seat back trim cover. Make certain the seat wire harness is correctly routed through the seat and seat back.
HEATED SEAT SENSOR DESCRIPTION
The heated seat temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One tem- perature sensor is used for each seat. This tempera- ture sensor is located in the seat cushion heating element on all models.
The heated seat temperature sensor cannot be repaired or adjusted and must be replaced if defec- tive. The heated seat cushion element must be replaced if the temperature sensor is defective. Refer to the procedure in this section of the service man- ual.
OPERATION
When the temperature of the seat cushion cover rises, the resistance of the sensor decreases. The heated seat module supplies five-volts to one side of each sensor, and monitors the voltage drop through the sensor on a return circuit. The heated seat mod- ule uses this temperature sensor input to monitor
HEATED SEAT SYSTEM
8G - 8
HEATED SEAT SWITCH (Continued)diagnostic feedback for the heated seat system. Each switch also has an incandescent bulb, which provides dimmer controlled back lighting of the switch when the headlamps or park lamps are on.
Fig.4HEATEDSEATSWITCH
1 - HEATED SEAT SWITCH 2 - LIGHT-EMITTING DIODE (LED) INDICATOR LAMPS
The heated seat switches are both mounted in the instrument panel center bezel, located in the lower center of the instrument panel. The two switches are snapped into the mounting holes of the heated seat switch bezel, and the heated seat switch bezel is secured with screws to the instrument panel center bezel. The heated seat switches are differentiated by the keyway in the connector receptacle on the backs of the switches and keyway on the switch housing. The instrument panel wire harness connectors for the heated seat switches are keyed to match the con- nector receptacles on the switches so that the two heated seat switches can only be connected to the proper heated seat electrical.
The two LED indicator lamps and the incandescent bulb in each heated seat switch cannot be repaired. If the indicator lamps or back lighting bulb are faulty or damaged, the individual heated seat switch must be replaced.
OPERATION
The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-
DR
wired resistance signal to the heated seat module. This signal tells the module to energize the heated seat element of the selected seat and maintain the requested temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the heated seat module will change states to support the new selection. If a heated seat switch is depressed a sec- ond time, the heated seat module interprets the sec- ond input as a request to turn the seat heater OFF. The High and Low LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of each indicator lamp is controlled by the heated seat module. This control of the switch indicator lamps also allows the module to provide diagnostic feedback to the vehicle operator or technician to indi- cate heated seat system faults by flashing the indica- tor lamps on and off. One side of the incandescent back lighting bulb in each heated seat switch is con- nected to ground at all times. The other side of the incandescent bulb is connected to the fused panel lamps dimmer switch signal circuit. These bulbs are energized when the park lamps or headlamps are turned on, and their illumination intensity is con- trolled by the panel lamps dimmer switch.
DIAGNOSIS AND TESTING - HEATED SEAT SWITCH
Refer to Wiring Diagrams for connector pin-outs and the location of complete heated seat system wir- ing diagrams.
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 (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG 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.
(1) If the problem being diagnosed involves inoper- ative heated seat switch back lighting and the cluster illumination lamps operate, go to Step 2. If the prob- lem being diagnosed involves inoperative heated seat switch back lighting and the cluster illumination lamps are also inoperative, (Refer to 8 - ELECTRI- CAL/INSTRUMENT CLUSTER - DIAGNOSIS AND TESTING). If the problem being diagnosed involves
DR HEATED SEAT SWITCH (Continued)
HEATED SEAT SYSTEM 8G - 9
inoperative heated seat switch indicator lamps and the heated seat elements do not heat, proceed. If the problem being diagnosed involves inoperative heated seat switch indicator lamps and the heated seat ele- ments do heat, go to Step 6. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off, (Refer to 8 - ELECTRICAL/ ELECTRONIC CONTROL MODULES/MEMORY HEATED SEAT/MIRROR MODULE - DIAGNOSIS AND TESTING).
(2) Disconnect and isolate the battery negative cable. Remove the heated seat switch and bezel unit from the instrument panel. Disconnect the heated seat switch to be tested. Check for continuity between the ground circuit cavity of the heated seat switch and a good ground. There should be continu- ity. If OK, go to Step 3. If not OK, repair the open ground circuit to ground as required.
(3) Reconnect the battery negative cable. Turn the park lamps on with the headlamp switch. Rotate the panel lamps dimmer thumb wheel on the headlamp switch upward to just before the interior lamps detent. Check for battery voltage at the fused panel lamps dimmer circuit cavity of the heated seat switch. If OK, go to Step 4. If not OK, repair the open fused panel lamps dimmer switch signal circuit to the fuse in the Integrated Power Module as required.
(4) Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to Step 5. If not OK, repair the open fused ignition switch output (run) circuit as required.
(5) Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Conti- nuity chart. If OK, refer to Step 6. If not OK, replace the faulty heated seat switch.
HEATED SEAT SWITCH CONTINUITY
Switch Position
Neutral
Low High
Continuity Between
4 & 6
4 & 6
4 & 6Resistance
2.2 Kilohms .415 Kilohms
33 Ohms
(6) Replace the inoperative heated seat switch with a known good unit and test the operation of the switch indicator lamps. If OK, discard the faulty heated seat switch. If not OK, (Refer to 8 - ELEC- TRICAL/ELECTRONIC CONTROL MODULES/ MEMORY HEATED SEAT/MIRROR MODULE - DIAGNOSIS AND TESTING).
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Wait two minutes for the system reserve capac- itor to discharge before beginning any airbag or instrument panel service.
(3) Remove the center bezel from the instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - REMOV- AL).
(4) Remove the screws that secure the heated seat
switch bezel to the instrument panel center bezel.
(5) Remove the heated seat switch bezel and both
switches from the instrument panel as a unit.
(6) From the back of the heated seat switch bezel, gently pry the switch free and push the heated seat switch out through the front of the bezel.
INSTALLATION
NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel. The heated seat switches are differentiated by the keyway in the connector the switches and keyway on the switch housing (Fig. 4).
receptacle on the backs of
(1) From the back of the heated seat switch bezel, gently push the heated seat switch in through the front of the bezel.
(2) Position the heated seat switch bezel to the instrument panel center bezel and install the retain- ing screws. (3) Install
the center bezel on the instrument panel (Refer to 23 - BODY/INSTRUMENT PANEL/ INSTRUMENT PANEL CENTER BEZEL - INSTAL- LATION).
(4) Connect the battery negative cable. (5) Verify vehicle and system operation.
DR
HORN
8H - 1
HORN
TABLE OF CONTENTS
page
page
HORN SYSTEM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING - HORN SYSTEM . . . 1HORN
DIAGNOSIS AND TESTING - HORN . . . . . . . . . . 1
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 2HORN SWITCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING - HORN SWITCH . . . 2HORN SYSTEM DESCRIPTION
The dual-note horn system features dual electro- magnetic horn units. The horn system includes the following major components: † Horn - The two horns are located on the left side of the engine compartment below the Integrated Power Module (IPM). † Horn Switch - The horn switch is molded into
the driver airbag trim cover.
OPERATION
The horn system operates on battery current received through a fuse in the Integrated Power Module (IPM). The horn system circuit is designed so that the system will remain operational, regardless of the ignition switch position.
DIAGNOSIS AND TESTING - HORN SYSTEM
The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a DRBIIIt scan tool and the proper Diag- nostic Procedures manual. The DRBIIIt scan tool can provide confirmation that the PCI data bus is functional, that all of the electronic mod- ules are sending and receiving the proper mes- sages on the PCI data bus, and that the horns are being sent the proper hard wired outputs for them to perform their functions.
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.
In most cases, any problem involving continually sounding horns can be quickly alleviated by removing the horn fuse from the Integrated Power Module (IPM).
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, 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.
HORN DIAGNOSIS AND TESTING - HORN
The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a DRBIIIt scan tool and the proper Diag- nostic Procedures manual. The DRBIIIt scan tool can provide confirmation that the PCI data bus is functional, that all of the electronic mod- ules are sending and receiving the proper mes- sages on the PCI data bus, and that the horns are being sent the proper hard wired outputs for them to perform their functions.
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.
HORN
8H - 2
HORN (Continued)THE AIRBAG SYSTEM WARNING: DISABLE BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, 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.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
the horns (Fig. 1).
(2) Disconnect the wire harness connectors from
DR
HORN SWITCH DESCRIPTION
The horn switch is molded into the driver airbag. The horn switch can not be serviced separately. For service procedures, (Refer to 8 - ELECTRICAL/RE- STRAINTS/DRIVER AIRBAG - REMOVAL).
DIAGNOSIS AND TESTING - HORN SWITCH
The most reliable, efficient, and accurate means to diagnose the horn system requires the use of a DRBIIIt scan tool and the proper Diag- nostic Procedures manual. The DRBIIIt scan tool can provide confirmation that the PCI data bus is functional, that all of the electronic mod- ules are sending and receiving the proper mes- sages on the PCI data bus, and that the horns are being sent the proper hard wired outputs for them to perform their functions.
For complete circuit diagrams, refer to the appro- priate 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 connec- tors, splices and grounds.
WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, 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.
Fig.1HORN
1 - WIRE HARNESS CONNECTORS 2 - HORNS 3 - MOUNTING BOLT
(3) Remove mounting bolt and remove horns.
INSTALLATION
(1) Position horns and install mounting bolt.
Tighten the bolt to 10 N·m (85 in. lbs.). (2) Connect wire harness connectors. (3) Connect battery negative cable.
DR
IGNITION CONTROL
8I - 1
IGNITION CONTROL
TABLE OF CONTENTS
page
page
IGNITION CONTROL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONSSPECIFICATIONS - TORQUE - IGNITION . . . . 3
. . . . . . . . . 4
ENGINE FIRING ORDER - 3.7L V-6
ENGINE FIRING ORDER – 4.7L V-8
. . . . . . . . 4
FIRING ORDER / CABLE ROUTING – 5.7LV-8 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . 4ENGINE FIRING ORDER - 5.9L V-8
SPARK PLUG CABLE ORDER – 8.0L V-10ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . . . . 5
. . . . . . . . . . . . . . . . . . . . . . . . 5
. . . . . 6
. . . . . 6
. . . . . 6
. . . . . . . . 6SPARK PLUG CABLE RESISTANCE SPARK PLUGS IGNITION COIL RESISTANCE - 3.7L V-6
IGNITION COIL RESISTANCE - 4.7L V-8
IGNITION COIL RESISTANCE - 5.7L V-8
IGNITION COIL RESISTANCE - 5.9L IGNITION COIL RESISTANCE – 8.0L V-10ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . 6AUTOMATIC SHUT DOWN RELAY
DESCRIPTION - PCM OUTPUT OPERATION
. . . . . . . . . . . . . 6
OPERATION - PCM OUTPUT OPERATION - ASD SENSE - PCM INPUT
. . . . . . . . . . . . . 6
. . . . 6DIAGNOSIS AND TESTING - ASD AND FUEL
PUMP RELAYS
. . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8CAMSHAFT POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14DISTRIBUTOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17IGNITION CONTROL DESCRIPTION
The ignition system is controlled by the Powertrain
Control Module (PCM) on all engines.
3.7L V-6 ENGINE
The 3.7L V-6 engine uses a separate ignition coil for each cylinder. The one-piece coil bolts directly to
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
DISTRIBUTOR CAP
DIAGNOSIS AND TESTING - DISTRIBUTOR
CAP - 5.9L V-8
. . . . . . . . . . . . . . . . . . . . . . . . 18
DISTRIBUTOR ROTOR
DIAGNOSIS AND TESTING - DISTRIBUTOR
ROTOR - 5.9L V-8
. . . . . . . . . . . . . . . . . . . . . 19
IGNITION COIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24KNOCK SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26SPARK PLUG
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - SPARK PLUGCONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . 27
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CLEANINGCLEANING AND ADJUSTMENT . . . . . . . . . . . 31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31IGNITION COIL CAPACITOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33SPARK PLUG CABLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
DIAGNOSIS AND TESTING - SPARK PLUGCABLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35the cylinder head. Rubber boots seal the secondary terminal ends of the coils to the top of all 6 spark plugs. A separate electrical connector is used for each coil.
Because of coil design, spark plug cables (second- ary cables) are not used. A distributor is not used with the 3.7L engine.
Two knock sensors (one for each cylinder bank) are
used to help control spark knock.
IGNITION CONTROL
8I - 2
IGNITION CONTROL (Continued)The Auto Shutdown (ASD) relay provides battery
voltage to each ignition coil. The ignition system consists of: † 6 Spark Plugs † 6 Separate Ignition Coils † 2 Knock Sensors † Powertrain Control Module (PCM) † Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors
4.7L V-8 ENGINE
The 4.7L V-8 engine uses a separate ignition coil for each cylinder. The one-piece coil bolts directly to the cylinder head. Rubber boots seal the secondary termi- nal ends of the coils to the top of all 8 spark plugs. A separate electrical connector is used for each coil.
Because of coil design, spark plug cables (second- ary cables) are not used. A distributor is not used with the 4.7L engine.
Two knock sensors (one for each cylinder bank) are
used to help control spark knock.
The Auto Shutdown (ASD) relay provides battery
voltage to each ignition coil.
The ignition system consists of: † 8 Spark Plugs † 8 Separate Ignition Coils † 2 Knock Sensors † Powertrain Control Module (PCM) † Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors 5.7L V-8 ENGINE
For additional information, also refer to Igni-
tion Coil Description and Operation.
The 5.7L V-8 engine is equipped with 16 spark plugs. Two plugs are used for each cylinder. The 5.7L is also equipped with 8 separate and independent ignition coils. The one-piece coil bolts directly to the cylinder head cover and attaches the coils secondary output terminal directly to a spark plug using a rub- ber boot seal. Each coil is also equipped with a sec- ond output terminal. This second terminal connects a conventional spark plug cable directly to a spark plug on the opposite cylinder bank. A separate pri- mary electrical connector is used for each coil.
Eight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylin- der bank. The cables are placed and routed in a spe- cial plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss- match of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7
DR
and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body (Fig. 1).
Two knock sensors (one for each cylinder bank) are
used to help control spark knock.
The 5.7L engine will not use a conventional distrib-
utor.
The ignition system consists of: † 16 Spark Plugs (2 per cylinder) † 8 Separate, Dual-Secondary Output, Ignition Coils † 2 Knock Sensors † 8 Secondary Ignition Cables † Powertrain Control Module (PCM) † Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position, 2 knock and MAP Sensors
Fig.1FIRINGORDER/CABLEROUTING-5.7LV-8
ENGINE
1 - TOP OF INTAKE MANIFOLD 2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER) 3 - CORRESPONDING SPARK PLUG NUMBER
5.9L V-8 ENGINE
The 5.9L V-8 ignition system will use a conven- tional distributor and 1 remotely mounted coil. Con- ventional spark plug cables are used with the 5.9L. Knock sensors are not used with the 5.9L engine. The ignition system consists of: † 8 Spark Plugs † 1 Ignition Coil † Secondary Ignition Cables † Distributor (contains rotor and camshaft position † Powertrain Control Module (PCM)
sensor)
DR IGNITION CONTROL (Continued) † Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Cam- shaft Position, Throttle Position and MAP Sensors
8.0L V-10 ENGINE
. The 8.0L V-10 engine is equipped with 2 remote coil packs. Conventional spark plug cables are used with the 8.0L engine. The 8.0L engine will not use a conventional distributor
The ignition coils are individually fired, but each coil is a dual output. Refer to Ignition Coil for addi- tional information.
SPECIFICATIONS
SPECIFICATIONS - TORQUE - IGNITION
DESCRIPTION
Camshaft Position Sensor - 3.7L V-6 Engine Camshaft Position Sensor - 4.7L V-8 Engine Camshaft Position Sensor - 5.7L V-8 Engine Camshaft Position Sensor - 8.0L V-10 Engine Crankshaft Position Sensor - 3.7L V-6 Engine Crankshaft Position Sensor - 4.7L V-8 Engine Crankshaft Position Sensor - 5.7L V-8 Engine Crankshaft Position Sensor - 5.9L V-8 Engine Crankshaft Position Sensor - 8.0L V-10 Engine Distributor Hold Down Bolt - 5.9L V-8 Engine
Ignition Coil Mounting - 5.9L V-8 Engine
(if tapped bolts are used)
Ignition Coil Mounting - 5.9L V-8 Engine
(if nuts/bolts are used)
Ignition Coil Mounting - 3.7L V-6 Engine Ignition Coil Mounting - 4.7L V-8 Engine Ignition Coil Mounting - 5.7L V-8 Engine Ignition Coil Mounting - 8.0L V-10 Engine
* Knock Sensor - 3.7L V-6 Engine * Knock Sensor - 4.7L V-8 Engine * Knock Sensor - 5.7L V-8 Engine
Spark Plugs - 3.7L V-6 Engine Spark Plugs - 4.7L V-8 Engine ** Spark Plugs - 5.7L V-8 Engine Spark Plugs - 5.9L V-8 Engine Spark Plugs - 8.0L V-10 Engine
* Do not apply any sealant, thread-locker or adhesive to bolts. Poor sensor performance may result. ** Torque critical tapered design. Do not exceed 15 ft. lbs.
IGNITION CONTROL
8I - 3
Knock sensors are not used with the 8.0L engine. The ignition system consists of: † 10 Spark Plugs † 2 Ignition Coil packs containing 10 individual coils† 10 Secondary Ignition Cables † Powertrain Control Module (PCM) † Also to be considered part of the ignition system are certain inputs from the Crankshaft Position, Camshaft Position, Throttle Position and MAP Sen- sors
N·m 12
12
12
28
28
12
2311
12
10
20
20
20
27
27Ft. Lbs.
In. Lbs.
21
21
1715
15
15
20
20106
106
105
50
205
205
105
70
70
50100
70
70105 (± 20)
90
176
176
17618 (± 3)
13 (± 2)
41
4130
30IGNITION CONTROL
8I - 4
IGNITION CONTROL (Continued) ENGINE FIRING ORDER - 3.7L V-61 - 6 - 5 - 4 - 3 - 2
ENGINE FIRING ORDER – 4.7L V-8
DR
Fig.2FIRINGORDER/CABLEROUTING-5.7LV-8
ENGINE
1 - TOP OF INTAKE MANIFOLD 2 - CYLINDER FIRING ORDER (IGNITION COIL NUMBER) 3 - CORRESPONDING SPARK PLUG NUMBER
ENGINE FIRING ORDER - 5.9L V-8
FIRING ORDER / CABLE ROUTING – 5.7L V-8
ENGINEEight conventional spark plug cables are used with the 5.7L. These cables connect a coil on one cylinder bank, directly to a spark plug on the opposite cylin- der bank. The cables are placed and routed in a spe- cial plastic loom to keep them separated. This loom is clipped to the intake manifold. To prevent a miss- match of cables, a corresponding spark plug / coil number is displayed on each plug cable: 1/6, 2/3, 4/7
and 5/8. These numbers can also be found on the top of the intake manifold to the right of the throttle body (Fig. 2).DR IGNITION CONTROL (Continued) SPARK PLUG CABLE ORDER – 8.0L V-10
ENGINEIGNITION CONTROL
8I - 5
SPARKPLUGCABLEORDER–8.0LV-10ENGINE SPARK PLUG CABLE RESISTANCE
MINIMUM
MAXIMUM
250 Ohms Per Inch 3000 Ohms Per Foot
1000 Ohms Per Inch 12,000 Ohms Per Foot
SPARK PLUGS
ENGINE 3.7L V-6
4.7L V-8
5.7L V-8
5.9L V-8
8.0L V-10PLUG TYPE
ZFR6F - 11G (NGK)
RC12MCC4
Champion - RE14MCC4
RC12LC4
QC9MC4ELECTRODE GAP
1.1 (0.042 in.)
1.01 mm (.040 in.) 1.14 mm (.045 in.) 1.01 mm (.040 in.) 1.14 mm (.045 in.)
DR
IGNITION COIL RESISTANCE - 5.7L V-8
PRIMARY RESISTANCE @ 21-27°C (70-80°F)
0.558 - 0.682 Ohms
(Plus or Minus 10% @ 70-80° F)
IGNITION CONTROL
8I - 6
IGNITION CONTROL (Continued) IGNITION COIL RESISTANCE - 3.7L V-6PRIMARY RESISTANCE
21-27°C (70-80°F)
SECONDARY
RESISTANCE 21-27°C
(70-80°F)
0.6 - 0.9 Ohms
6,000 - 9,000 Ohms
IGNITION COIL RESISTANCE - 4.7L V-8
PRIMARY
SECONDARY
RESISTANCE 21-27°C
RESISTANCE 21-27°C
(70-80°F)
0.6 - 0.9 Ohms
(70-80°F)
6,000 - 9,000 Ohms
IGNITION COIL RESISTANCE - 5.9L
COIL MANUFACTURER
Diamond Toyodenso
PRIMARY RESISTANCE
SECONDARY RESISTANCE 21-27°C
21-27°C (70-80°F) 0.97 - 1.18 Ohms 0.95 - 1.20 Ohms
(70-80°F)
11,300 - 15,300 Ohms 11,300 - 13,300 Ohms
IGNITION COIL RESISTANCE – 8.0L V-10
ENGINEPrimary Resistance: 0.53-0.65 Ohms. Test across the primary connector. Refer to text for test procedures. Secondary Resistance: 10.9-14.7K Ohms. Test across the individual coil towers. Refer to text for test procedures.
IGNITION TIMING
Ignition timing is not adjustable on any engine.
AUTOMATIC SHUT DOWN RELAY DESCRIPTION - PCM OUTPUT
The 5–pin, 12–volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location.
OPERATION
OPERATION - PCM OUTPUT
The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12–volts to the oxygen sensor heating elements.
The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switch- ing its ground circuit on and off.
The ASD relay will be shut–down, meaning the 12–volt power supply to the ASD relay will be de-ac- tivated by the PCM if: † the ignition key is left in the ON position. This is if the engine has not been running for approxi- mately 1.8 seconds. † there is a crankshaft position sensor signal to the PCM that is lower than pre-determined values.
OPERATION - ASD SENSE - PCM INPUT
A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply.
This input is used only to sense that the ASD relay is energized. the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC).
If
DR AUTOMATIC SHUT DOWN RELAY (Continued) DIAGNOSIS AND TESTING - ASD AND FUEL PUMP RELAYS
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and fuel pump relays. The terminals on the bottom of each relay are numbered. Two different types of relays may be used, (Fig. 3) or (Fig. 4).
Fig.3TYPE1RELAY(ISOMICRORELAY)
Fig.4ASDANDFUELPUMPRELAYTERMINALS—
TYPE2
TERMINAL LEGEND
NUMBER
IDENTIFICATION
30
85
86
87
87ACOMMON FEED COIL GROUND COIL BATTERY
NORMALLY OPEN
NORMALLY CLOSED
