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(5) Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal on the reservoir sump. Care must be taken not to damage the reservoir.
DR WASHER FLUID LEVEL SWITCH (Continued)
WIPERS/WASHERS
8R - 11
(6) Remove the washer fluid level switch from the
washer reservoir.
(7) Remove the rubber grommet seal
from the washer fluid level switch mounting hole in the washer reservoir and discard.
INSTALLATION
(1) Install a new rubber grommet seal
into the washer fluid level switch mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reservoir.
(2) Insert the float of the washer fluid level switch through the rubber grommet seal and into the washer reservoir. The connector receptacle of the washer fluid level switch should be pointed upward. (3) Using hand pressure, press firmly and evenly on the washer fluid level switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole. (4) Reconnect the right (except V-10 and diesel engine) or left (V-10 and diesel engine only) head- lamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle (Fig. 7) or (Fig. 8).
(5) Reconnect the removed washer hose to the barbed outlet nipple of the washer pump/motor unit. (6) Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure.
(7) Reconnect the battery negative cable. (8) Close and latch the hood.
WASHER HOSES/TUBES DESCRIPTION
The washer plumbing consists of a small diameter rubber reservoir washer hose that is routed from the barbed outlet nipple of the electric washer pump/mo- tor unit on the washer reservoir through a trough molded into the back of the reservoir above the washer pump and to the engine compartment washer hose (Fig. 9). On models equipped with an optional V-10 or diesel engine, the reservoir washer hose is routed through routing clips on the top of the radia- tor fan shroud from the washer reservoir on the left side of the radiator to the engine compartment washer hose on the right side of the radiator. The engine compartment washer hose is contained within the right headlamp and dash wire harness, which is routed through the engine compartment along the top of the right front fender wheel house to the dash panel.
The engine compartment washer hose is connected to the washer reservoir washer hose and to the cowl plenum washer hose with molded plastic in-line fit-
Fig.9EngineCompartmentWasherHose
1 - RIGHT FENDER 2 - RIGHT HEADLAMP & DASH WIRE HARNESS 3 - ENGINE COMPARTMENT WASHER HOSE (TO COWL PLENUM) 4 - COWL PLENUM WASHER HOSE 5 - ENGINE COMPARTMENT WASHER HOSE (TO WASHER RESERVOIR)
tings that have a barbed nipple on each end. The cowl plenum washer hose is routed from the engine compartment into the cowl plenum area through a trough formation located near the right end of the cowl plenum cover/grille panel. The cowl plenum washer hose is connected to the washer system check valve/wye fitting on the underside of the cowl plenum cover/grille panel. The cowl plenum washer hose and the two washer nozzle hoses are routed through inte- gral routing clips on the underside of the cowl ple- num cover/grille panel. The cowl plenum washer hose is connected to one nipple on the wye fitting and the two washer nozzle hoses are connected to the other two wye fitting nipples. The washer nozzle hoses are then routed along the underside of the cowl plenum cover/grille panel to the two washer nozzles.
Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings cannot be repaired. If these fittings are faulty or damaged, they must be replaced.
OPERATION
Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor through the washer system plumbing and fittings to the two washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided.
8R - 12 WIPERS/WASHERS
WASHER NOZZLE DESCRIPTION
Fig.10WasherNozzle
1 - HOOD 2 - LATCH (2) 3 - NIPPLE 4 - ANTI-ROTATION TAB 5 - ORIFICE
The two washer nozzles have integral snap fea- tures and an anti-rotation tab that secure them in dedicated holes in the cowl plenum cover/grille panel located near the base of the windshield (Fig. 10). The domed upper surface of the washer nozzle is visible on the top of the plenum cover/grille panel, and the nozzle orifice is oriented towards the windshield glass. The washer plumbing fittings for the washer nozzles are concealed beneath the cowl plenum cover/ grille panel. These fluidic washer nozzles are con- structed of molded plastic. The cowl plenum cover/ grille panel must be removed from the vehicle to access the nozzles for service. The washer nozzles cannot be adjusted or repaired. If faulty or damaged, they must be replaced.
OPERATION
The two washer nozzles are designed to dispense washer fluid into the wiper pattern area on the out- side of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the cowl plenum cover/grille panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the noz- zle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned.
DR
REMOVAL
(1) Remove both wiper arms from the wiper pivots. to 8 - ELECTRICAL/WIPERS/WASHERS/
(Refer WIPER ARM - REMOVAL).
(2) Unlatch and open the hood. (3) Remove the cowl plenum cover/grille panel from over the cowl plenum. (Refer to 23 - BODY/EX- TERIOR/COWL GRILLE - REMOVAL).
(4) From the underside of the cowl plenum cover/ grille panel, disconnect the washer nozzle hose from the barbed nipple of the washer nozzle (Fig. 11).
Fig.11WasherNozzleRemove/Install 1 - COWL PLENUM COVER/GRILLE PANEL (UNDERSIDE) 2 - ANTI-ROTATION TAB (LARGE) 3 - NIPPLE 4 - ANTI-ROTATION TAB (SMALL) 5 - PLIERS 6 - LATCH (2)
(5) From the underside of the cowl plenum cover/ grille panel, release the integral snap features of the washer nozzle and push the nozzle out through the mounting hole toward the top side of the cowl ple- num cover/grille panel.
(6) Remove the washer nozzle from the top of the
cowl plenum cover/grille panel.
INSTALLATION
(1) From the top of the cowl plenum cover/grille panel, position the nipple end of the washer nozzle through the mounting hole and engage the anti-rota- tion tab of the nipple into the anti-rotation notch in the mounting hole.
(2) Using hand pressure, push firmly and evenly on the top of the washer nozzle until the integral snap features lock into place on the underside of the cowl plenum cover/grille panel.
(3) From the underside of the cowl plenum cover/ grille panel, reconnect the washer hose to the barbed nipple of the washer nozzle (Fig. 11).
DR WASHER NOZZLE (Continued)
(4) Reinstall the washer hose for the washer noz- zle into its routing clips on the underside of the cowl plenum cover/grille panel.
(5) Reinstall the cowl plenum cover/grille panel over the cowl plenum. (Refer to 23 - BODY/EXTERI- OR/COWL GRILLE - INSTALLATION).
(6) Close and latch the hood. (7) Reinstall both wiper arms onto the wiper piv- ots. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER ARM - INSTALLATION).
WASHER PUMP/MOTOR DESCRIPTION
Fig.12WasherPump/Motor
1 - MOTOR 2 - SNAP POST 3 - CONNECTOR RECEPTACLE 4 - PUMP 5 - OUTLET NIPPLE 6 - INLET NIPPLE 7 - FILTER SCREEN
The washer pump/motor unit (Fig. 12) is located on the rearward facing surface of the washer reservoir, in the right (except V-10 or diesel engine) or left (V-10 and diesel engine only) front corner of the engine compartment. A small permanently lubricated and sealed electric motor is coupled to the rotor-type washer pump. A seal flange with a barbed inlet nip- ple on the pump housing passes through a rubber grommet seal installed in a dedicated mounting hole of the washer reservoir. When the pump is installed in the reservoir a barbed outlet nipple on the pump
WIPERS/WASHERS
8R - 13
housing connects the unit to the washer system through a short washer reservoir hose.
The washer pump/motor unit is retained on the reservoir by the interference fit between the barbed pump inlet nipple and the grommet seal, which is a light press fit. The top of the washer pump is also secured to the washer reservoir by the use of a snap post on the motor housing and a snap post receptacle molded into the reservoir that allows for mounting of the washer pump without the use of fasteners. An integral connector receptacle on the top of the motor housing connects the unit to the vehicle electrical system. The washer pump/motor unit cannot be repaired. If faulty or damaged, the entire washer pump/motor unit must be replaced.
OPERATION
The washer pump/motor unit features a small Direct Current (DC) electric motor. The motor is con- nected to the vehicle electrical system through a sin- gle take out and two-cavity connector of the right (except V-10 or diesel engine) or left (V-10 or diesel engine only) headlamp and dash wire harness. The motor is grounded at all times through another take out of the right (except V-10 or diesel engine) or left (V-10 or diesel engine only) headlamp and dash wire harness. On models without the V-10 or diesel engine a single eyelet terminal connector is secured by a nut to a ground stud located on the right front fender inner shield in the engine compartment. On models with a V-10 or diesel engine an eyelet terminal con- nector is secured by a ground screw to the left front fender inner shield in the engine compartment. The motor receives battery current on a washer pump/ motor control circuit.
The washer pump/motor control circuit is energized through a high side driver within the Front Control Module (FCM) whenever the FCM receives an elec- tronic message requesting washer system operation from the instrument cluster over the Programmable Communications Interface (PCI) data bus. The instrument cluster monitors a resistor multiplexed hard wired input from the momentary washer switch contacts within the multi-function switch on the steering column to determine when it should issue the electronic message requesting washer system operation.
Washer fluid is gravity-fed from the washer reser- voir to the inlet side of the washer pump. When the pump motor is energized, the motor spins the rotor within the washer pump. The spinning pump rotor pressurizes the washer fluid and forces it through the pump outlet nipple, the washer plumbing, and the washer nozzles onto the windshield glass.
The washer pump/motor unit may be diagnosed using conventional diagnostic tools and methods.
DR
8R - 14 WIPERS/WASHERS WASHER PUMP/MOTOR (Continued)
However, conventional diagnostic methods may not prove conclusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the elec- tronic message inputs to or outputs from the instru- ment cluster and the FCM that control the operation of the washer pump/motor unit. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit, the instrument cluster, the FCM, or the electronic message inputs and outputs related to the washer pump/motor unit operation requires the use of a DRBIIIt scan tool. Refer to the appro- priate diagnostic information.
REMOVAL
The washer pump/motor unit can be removed from the washer reservoir without removing the reservoir from the vehicle.
(1) Unlatch and open the hood. (2) Disconnect and isolate the battery negative
cable.
(3) Disconnect the washer hose from the barbed outlet nipple of the washer pump/motor unit and allow the washer fluid to drain into a clean container for reuse.
(4) Disconnect the right (except V-10 or diesel engine) or left (V-10 or diesel engine only) headlamp and dash wire harness connector for the washer pump/motor unit from the motor connector receptacle (Fig. 13).
(5) Firmly grasp the top of the washer pump/motor
housing.
(6) Pull lightly outward on the top of the washer pump/motor housing away from the washer reservoir far enough to disengage the snap post on the top of the motor from the receptacle in the reservoir.
(7) Pull the washer pump/motor unit straight out from the washer reservoir far enough to disengage the barbed pump inlet nipple from the rubber grom- met seal in the reservoir.
(8) Disconnect the reservoir washer hose from the
washer pump/motor unit outlet nipple.
(9) Remove washer pump/motor unit from the back
of the washer reservoir.
(10) Remove the rubber grommet seal from the
washer reservoir and discard.
INSTALLATION
(1) Install a new rubber grommet seal
into the washer pump mounting hole in the washer reservoir. Always use a new rubber grommet seal on the reser- voir.
(2) Position the barbed inlet nipple of the washer pump to the rubber grommet seal in the washer res- ervoir (Fig. 13).
Fig.13WasherPump/MotorRemove/Install
1 - CONNECTOR RECEPTACLE 2 - SNAP POST 3 - SNAP POST RECEPTACLE 4 - GROMMET SEAL 5 - WASHER FLUID LEVEL SWITCH 6 - WASHER RESERVOIR 7 - INLET NIPPLE 8 - OUTLET NIPPLE
(3) Using hand pressure, press on the washer pump/motor unit firmly and evenly until the barbed inlet nipple is fully seated in the rubber grommet seal in the washer reservoir mounting hole.
(4) Align the washer pump/motor snap post on the top of the motor housing with the snap post recepta- cle in the washer reservoir.
(5) Using hand pressure, press firmly and evenly on the top of washer pump/motor unit until the snap post snaps into the washer reservoir receptacle.
(6) Reconnect the washer reservoir hose to the
barbed outlet nipple of the washer pump.
the right
(7) Reconnect
(except V-10 or diesel engine) or left (V-10 or diesel engine only) headlamp and dash wire harness connector for the washer pump/motor unit to the motor connector receptacle.
(8) Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure.
(9) Reconnect the battery negative cable. (10) Close and latch the hood.
DR
WIPERS/WASHERS
8R - 15
WASHER RESERVOIR DESCRIPTION
Fig.14WasherReservoir-exceptV-10&Diesel
Engine
1 - TOP TAB 2 - HOOK FEATURE 3 - CAP 4 - RESERVOIR 5 - TROUGH 6 - HOSE 7 - LOCK FEATURE 8 - WASHER FLUID LEVEL SWITCH 9 - WASHER PUMP/MOTOR 10 - BOTTOM TAB (2)
Except on models equipped with an optional V-10
or diesel engine, the molded plastic washer fluid res- ervoir is mounted on the right rearward facing sur- face of the cooling module radiator shroud in the engine compartment (Fig. 14). On models with the V-10 or diesel engine, the molded plastic washer fluid reservoir is mounted on the rearward facing surface of the left vertical member of the radiator support in the engine compartment. The reservoir is a molded unit constructed of a translucent plastic that allows the washer fluid level to be inspected without remov- ing the washer reservoir cap. The most visible com- ponent of the washer reservoir is the filler cap unit, which is secured to and hinges on a hook feature that is integral to the filler neck near the top of the reservoir. The bright yellow plastic filler cap snaps over the filler neck opening and seals the reservoiropening with an integral rubber gasket. The filler cap is labeled with an International Control and Dis- play Symbol icon for “Windshield Washer” and the text “Washer Fluid Only” that are molded into it and highlighted in black against the yellow plastic cap for visibility.
There are dedicated holes near the bottom of the rearward facing side of the reservoir provided for the mounting of the washer pump/motor unit and the washer fluid level switch. A snap post receptacle molded into the reservoir allows for mounting of the washer pump without the use of fasteners. The res- ervoir also features an integral hose routing trough on its rearward facing side. Except on models with a V-10 or diesel engine, the washer reservoir is secured to the cooling module radiator shroud with three integral tabs, two at the bottom and one at the top. The two bottom tabs are inserted into two slots near the bottom of the shroud, while the upper tab slides into an integral channel-like slot near the top of the shroud. A molded lock feature on the forward facing surface of the reservoir engages a molded depression on the rearward facing surface of the radiator shroud when the reservoir is fully seated on the shroud, locking the unit securely in place. On models with a V-10 or diesel engine, the washer reservoir is secured with two screws through integral mounting tabs to the left vertical member of the radiator support. On many models, a molded plastic coolant recovery con- tainer or a coolant pressure container must be detached from the top of the cooling module and moved aside to access the washer fluid reservoir for service. This may be accomplished without opening or draining the engine cooling system.
OPERATION
reservoir
The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the washer system. The washer filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer/pump motor unit is located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the res- ervoir becomes depleted. The washer pump/motor unit is mounted in the lowest position in the sump. The washer fluid level switch is mounted just above the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, well before the washer sys- tem will no longer operate.
8R - 16 WIPERS/WASHERS WASHER RESERVOIR (Continued) REMOVAL
REMOVAL - EXCEPT V-10 OR DIESEL ENGINE
(1) Unlatch and open the hood. (2) Disconnect and isolate the battery negative
cable.
(3) Remove the fasteners securing the coolant recovery container or the coolant pressure container to the top of the cooling module and move the con- tainer aside. It is not necessary to open or drain the engine cooling system. (Refer to 7 - COOLING/EN- GINE/COOLANT REMOVAL) or (Refer to 7 - COOLING/ENGINE/ COOLANT RECOVERY PRESSURE CONTAINER - REMOVAL).
CONTAINER
RECOVERY
(4) Disconnect the reservoir washer hose from the barbed nipple of the inline fitting at the engine com- partment washer hose in the right headlamp and dash wire harness and allow the washer fluid to drain from the reservoir into a clean container for reuse (Fig. 15).
DR
(5) Disconnect the right headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle.
(6) Disconnect the right headlamp and dash wire harness connector for the washer pump/motor unit from the motor connector receptacle.
(7) Grasp the bottom of
the washer reservoir firmly with both hands and pull the unit sharply upward to disengage the locking feature on the washer reservoir from the depression in the radiator shroud.
(8) Continue lifting the washer reservoir upward far enough to disengage the three mounting tabs (one at the top and two at the bottom) from the channel- like slot at the top and the two slots at the bottom of the radiator shroud.
(9) Remove the washer reservoir from the right
side of the engine compartment.
REMOVAL - V-10 OR DIESEL ENGINE
(1) Unlatch and open the hood. (2) Disconnect and isolate the battery negative
cable.
(3) Disengage the reservoir washer hose from the integral routing clips on the top of the radiator fan shroud (Fig. 16).
Fig.15WasherReservoirRemove/Install
1 - TOP TAB 2 - RADIATOR SHROUD 3 - TOP SLOT 4 - RIGHT HEADLAMP & DASH WIRE HARNESS 5 - ENGINE COMPARTMENT WASHER HOSE 6 - BOTTOM SLOT (2) 7 - RESERVOIR WASHER HOSE 8 - BOTTOM TAB (2) 9 - WASHER FLUID LEVEL SWITCH 10 - WASHER PUMP/MOTOR 11 - WASHER RESERVOIR 12 - LOCK FEATURE
Fig.16WasherReservoirConnections-V-10&
DieselEngine
1 - WIRE HARNESS 2 - WASHER RESERVOIR 3 - WASHER PUMP/MOTOR 4 - WASHER HOSE 5 - WASHER FLUID LEVEL SWITCH
DR WASHER RESERVOIR (Continued)
WIPERS/WASHERS
8R - 17
(4) Reconnect the right headlamp and dash wire harness connector for the washer pump/motor unit to the motor connector receptacle.
(5) Reconnect the right headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle.
(6) Reconnect the reservoir washer hose to the barbed nipple of the inline fitting at the engine com- partment washer hose in the right headlamp and dash wire harness.
(7) Reposition the coolant recovery container or the coolant pressure container to the top of the cooling module and reinstall the fasteners that secure it there. (Refer to 7 - COOLING/ENGINE/COOLANT RECOVERY CONTAINER - INSTALLATION) or (Refer to 7 - COOLING/ENGINE/COOLANT RECOV- ERY PRESSURE CONTAINER - INSTALLATION).
(8) Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure.
(9) Reconnect the battery negative cable. (10) Close and latch the hood.
INSTALLATION - V-10 OR DIESEL ENGINE
(1) Position the washer reservoir into the left side
of the engine compartment (Fig. 17).
(2) Install and tighten the two screws that secure the washer reservoir to the left vertical member of the radiator support. Tighten the screws to 10 N·m (85 in. lbs.).
(3) Reconnect the left headlamp and dash wire harness connector for the washer pump/motor unit to the motor connector receptacle (Fig. 16).
(4) Reconnect the left headlamp and dash wire harness connector for the washer fluid level switch to the switch connector receptacle.
(5) Reconnect the reservoir washer hose to the barbed nipple of the inline fitting at the engine com- partment washer hose in the right headlamp and dash wire harness.
(6) Engage the reservoir washer hose into the inte- gral routing clips on the top of the radiator fan shroud.
(7) Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure.
(8) Reconnect the battery negative cable. (9) Close and latch the hood.
(4) Disconnect the reservoir washer hose from the barbed nipple of the inline fitting at the engine com- partment washer hose in the right headlamp and dash wire harness and allow the washer fluid to drain from the reservoir into a clean container for reuse.
(5) Disconnect the left headlamp and dash wire harness connector for the washer fluid level switch from the switch connector receptacle.
(6) Disconnect the left headlamp and dash wire harness connector for the washer pump/motor unit from the motor connector receptacle.
(7) Remove the two screws that secure the washer reservoir to the left vertical member of the radiator support (Fig. 17).
Fig.17WasherReservoirRemove/Install-V-10&
DieselEngine
1 - RESERVOIR WASHER HOSE 2 - RADIATOR SUPPORT 3 - SCREW (2) 4 - WASHER RESERVOIR
(8) Remove the washer reservoir from the left side
of the engine compartment.
INSTALLATION
INSTALLATION - EXCEPT V-10 OR DIESEL ENGINE
(1) Position the washer reservoir into the right
side of the engine compartment.
(2) Align and insert the three mounting tabs (one at the top and two at the bottom) into the two slots at the bottom and the channel-like slot at the top of the radiator shroud (Fig. 15).
(3) Place both hands on the top of the washer res- ervoir and push the unit downward far enough for the locking feature on the washer reservoir to snap into the depression in the radiator shroud.
8R - 18 WIPERS/WASHERS
DR
WIPER ARM DESCRIPTION
Fig.18WiperArm
1 - HOOK 2 - STRAP 3 - PIVOT END 4 - KEY 5 - LATCH 6 - HINGE PIN 7 - TENSION SPRING 8 - CHANNEL
The wiper arms are the rigid members located between the wiper pivots that protrude from the cowl plenum cover/grille panel near the base of the wind- shield and the wiper blades on the windshield glass (Fig. 18). These wiper arms feature an over-center hinge that allows easy access to the windshield glass for cleaning. The wiper arm has a die cast metal pivot end with a large internally serrated socket for- mation at one end. A key within the socket formation indexes the wiper arm to a keyway in the pivot shaft of the wiper module to provide wiper alignment, and a spring-loaded latch on the underside of the wiper arm pivot end locks the unit to the pivot shaft when it is fully installed. The right and left wiper arms for this model are not interchangeable, as the right wiper arm is slightly longer than the left one.
The wide end of a tapered, stamped steel channel hinges on and is secured with a hinge pin to the blade end of the wiper arm pivot end. One end of a long, rigid, stamped steel strap, with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook. Concealed within the stamped steel channel, one end of a long spring is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The
entire wiper arm has a satin black finish applied to all of its visible surfaces.
A wiper arm cannot be adjusted or repaired. If damaged or faulty, the entire wiper arm unit must be replaced.
OPERATION
The wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The serrated and keyed socket formation in the wiper arm pivot end interlocks with the serrations and keyway on the outer circumference of the wiper pivot shaft, provid- ing positive engagement and alignment of this con- nection. The latch positively locks the wiper arm to the wiper pivot shaft when the arm is fully installed. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm.
REMOVAL
(1) Lift the wiper arm to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to wiper pivot shaft connection.
(2) Pull the latch on the pivot end of the wiper
arm outward (Fig. 19).
Fig.19WiperArmRemove/Install
1 - WIPER ARM PIVOT END 2 - LATCH
(3) Remove the wiper arm pivot end from the
wiper pivot shaft.
DR WIPER ARM (Continued) INSTALLATION
The right and left wiper arms are not interchange- able. The right wiper arm is slightly longer than the left. Be certain that each wiper arm is installed on the proper wiper pivot.
(1) Place the wiper arm hinge in its over-center
position prior to attempting installation.
(2) The wiper arms are indexed to the wiper pivot shafts with integral keys in the wiper arm pivot ends and keyways in the wiper pivot shafts. Align the key of the wiper arm to the keyway on the wiper pivot shaft.
(3) Once the wiper blade is aligned, push the pivot of the wiper arm down firmly and evenly over the wiper pivot shaft until it is fully engaged. When the wiper arm is fully engaged on the wiper pivot, the spring-loaded latch (Fig. 19) will snap back into place against the wiper arm pivot end.
(4) Gently lower the wiper arm until the wiper
blade is in position on the windshield glass.
WIPER BLADE DESCRIPTION
WIPERS/WASHERS
8R - 19
† Superstructure - The superstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. † Element - The wiper element or squeegee is the resilient rubber member of the wiper blade that con- tacts the glass. † Flexor - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure.
All models have two 60.00 centimeter (23.62 inch) long wiper blades with non-replaceable rubber ele- ments (squeegees). The wiper blades cannot be adjusted or repaired. If faulty, worn, or damaged the entire wiper blade unit must be replaced.
OPERATION
The wiper blades are moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The com- bination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature that may be encountered across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber ele- ment is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions.
Fig.20WiperBlade
REMOVAL
1 - SUPERSTRUCTURE 2 - ELEMENT 3 - PIVOT BLOCK 4 - RELEASE TAB 5 - PIVOT PIN 6 - CLAWS 7 - FLEXOR
Each wiper blade is secured by an integral latching pivot block to the hook formation on the tip of each wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation (Fig. 20). The wiper blade consists of the following components:
NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot.
(1) Lift the wiper arm to raise the wiper blade and element off of the glass, until the wiper arm hinge is in its over-center position.
(2) To remove the wiper blade from the wiper arm, depress the pivot block latch release tab under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to dis- engage the pivot block from the hook formation on the end of the arm (Fig. 21).
8R - 20 WIPERS/WASHERS WIPER BLADE (Continued)
DR
WIPER HIGH/LOW RELAY DESCRIPTION
Fig.21WiperBladeRemove/Install
1 - SUPERSTRUCTURE 2 - WIPER ARM 3 - PIVOT BLOCK 4 - RELEASE TAB 5 - HOOK 6 - ELEMENT
(3) Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure just ahead of the wiper blade pivot block/latch unit.
CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged.
(4) Gently lower the tip of the wiper arm onto the
glass.
INSTALLATION
NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot.
(1) Lift the wiper arm off of the windshield glass, until the wiper arm hinge is in its over-center position. (2) Position the wiper blade near the hook forma- tion on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot.
(3) Insert the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure ahead of the wiper blade pivot block/ latch unit far enough to engage the pivot block into the hook (Fig. 21).
(4) Slide the wiper blade pivot block/latch up into the hook formation on the tip of the wiper arm until the latch release tab snaps into its locked position. Latch engagement will be accompanied by an audible click.
(5) Gently lower the wiper blade onto the glass.
Fig.22ISOMicroRelay
30 - COMMON FEED 85 - COIL GROUND 86 - COIL BATTERY 87 - NORMALLY OPEN 87A - NORMALLY CLOSED
The wiper high/low relay is located in the Inte- grated Power Module (IPM) in the engine compart- ment near the battery. The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay (Fig. 22). Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The relay is contained within a small, rect- angular, 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 bot- tom of the relay base.
The wiper high/low relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced.
OPERATION
The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current out- put to the wiper motor. 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 electromagnetic 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.
DR WIPER HIGH/LOW RELAY (Continued)
WIPERS/WASHERS
8R - 21
The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: † Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. † Coil Ground Terminal - The coil ground termi- nal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. † Coil Battery Terminal - The coil battery ter- minal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the Integrated Power Module (IPM) through a fused ignition switch output (run-acc) circuit. † Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized.
† Normally Closed Terminal
- The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-ener- gized.
The wiper high/low relay can be diagnosed using conventional diagnostic tools and methods. However, conventional diagnostic methods may not prove con- clusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the electronic mes- sage inputs to or outputs from the instrument cluster and the FCM that control the operation of the wiper high/low relay. The most reliable, efficient, and accu- rate means to diagnose the wiper high/low relay, the instrument cluster, the FCM, or the electronic mes- sage inputs and outputs related to the wiper high/low relay operation requires the use of a DRBIIIt scan tool. Refer to the appropriate diagnostic information.
DIAGNOSIS AND TESTING - WIPER HIGH/LOW RELAY
The wiper high/low relay (Fig. 23) is located in the Integrated Power Module (IPM) in the engine com- partment near the battery. 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.
Fig.23ISOMicroRelay
30 - COMMON FEED 85 - COIL GROUND 86 - COIL BATTERY 87 - NORMALLY OPEN 87A - NORMALLY CLOSED
(1) Remove the wiper high/low relay from the IPM. to 8 - ELECTRICAL/WIPERS/WASHERS/
(Refer WIPER HIGH/LOW RELAY - REMOVAL).
(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 75 ± 8 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 DRBIIIt scan tool to perform further testing. Refer to the appropriate diagnostic information.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Integrated Power
Module (IPM) (Fig. 24).
(3) Remove the wiper high/low relay by grasping it firmly and pulling it straight out from the receptacle in the IPM.
INSTALLATION
(1) Position the wiper high/low relay to the proper receptacle in the Integrated Power Module (IPM) (Fig. 24).
(2) Align the wiper high/low relay terminals with
the terminal cavities in the IPM receptacle.
(3) Push firmly and evenly on the top of the wiper high/low relay until the terminals are fully seated in the terminal cavities in the IPM receptacle.
(4) Reinstall the cover onto the IPM. (5) Reconnect the battery negative cable.
8R - 22 WIPERS/WASHERS WIPER HIGH/LOW RELAY (Continued)
DR
Fig.24IntegratedPowerModule
Fig.25WiperModule
1 - 15 - CARTRIDGE FUSE 16 - 53 - BLADE FUSE 54 - HEATED MIRROR RELAY 55 - WIPER ON/OFF RELAY 56 - A/C CONDENSER FAN RELAY 57 - ENGINE CONTROL RELAY 58 - FUEL PUMP RELAY 59 - TRANSMISSION RELAY 60 - WIPER HIGH/LOW RELAY 61 - SPARE 62 - FOG LAMP RELAY 63 - ADJUSTABLE PEDAL RELAY 64 - A/C CLUTCH RELAY 65 - SPARE 66 - O2 RELAY 67 - SPARE 68 - SPARE 69 - SPARE 70 - SPARE 71 - SPARE 72 - STARTER RELAY 73 - PARK LAMP RELAY
WIPER MODULE DESCRIPTION
The wiper motor bracket
is secured with two screws below the wiper motor through two rubber insulators to the bottom of the cowl plenum panel beneath the cowl plenum cover/grille panel (Fig. 25). Two screws secure the top of the wiper module bracket to the cowl plenum panel through rubber insulators located on the outboard end of each pivot bracket. The ends of the wiper pivot shafts that pro- trude through dedicated openings in the cowl plenum cover/grille panel to drive the wiper arms and blades are the only visible components of the wiper module. The wiper module consists of the following major components: † Bracket - The wiper module bracket consists of a long tubular steel main member that has a die cast
1 - PIVOT BRACKET (2) 2 - TUBE 3 - CLAMP 4 - PIVOT SHAFT (2) 5 - INSULATOR (4) 6 - LINKAGE BUSHING (4) 7 - DRIVE LINK (2) 8 - PIVOT CRANK ARM (2) 9 - PIGTAIL WIRE CONNECTOR 10 - MOTOR CRANK ARM 11 - WIPER MOTOR
pivot bracket formation near each end where the two wiper pivots are secured. A stamped steel clamp secures the center of the tubular member to the die cast bracket integral to the wiper motor with two screws. † Crank Arm - The wiper motor crank arm is a stamped steel unit with a slotted hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a ball stud secured to the drive end.† Linkage - Two stamped steel drive links con- nect the wiper motor crank arm to the wiper pivot lever arms. The left side drive link has a plastic sock- et-type bushing on each end. The right side drive link has a plastic socket-type bushing on one end, and a plastic sleeve-type bushing on the other end. The socket-type bushing on one end of each drive link is snap-fit over the ball stud on the lever arm of its respective pivot. The right side drive link sleeve- type bushing end is then fit over the motor crank arm ball stud, and the other socket-type bushing of the left side drive link is snap-fit over the exposed end of the wiper motor crank arm ball stud.
DR WIPER MODULE (Continued) † Motor - The wiper motor features an integral die cast bracket to which the wiper module bracket is secured with a stamped steel clamp and two screws near the top and which has two rubber insulated mounting ears at the bottom. This die casting also serves as the wiper motor transmission housing from which the wiper motor output shaft exits. A nut secures the wiper motor crank arm to the motor out- put shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal automatic resetting cir- cuit breaker. † Pivots - The two front wiper pivots are secured within the die cast pivot brackets on the outboard ends of the wiper module main member. The lever arms that extend from the center of the pivot shafts each have a ball stud on their end. The upper end of each pivot shaft where the wiper arms will be fas- tened each has a serrated driver with a keyway. The lower ends of the pivot shafts are installed through lubricated bushings in the pivot brackets and are secured with snap rings.
The wiper module cannot be adjusted or repaired. If any component of the module is faulty or damaged, the entire wiper module unit must be replaced.
OPERATION
The wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alter- nately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper sys- tem has been turned Off, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass.
resetting circuit breaker protects
WIPERS/WASHERS
8R - 23
REMOVAL
(1) Remove both wiper arms from the wiper pivots. to 8 - ELECTRICAL/WIPERS/WASHERS/
(Refer WIPER ARM - REMOVAL).
(2) Unlatch and open the hood. (3) Disconnect and isolate the battery negative
cable.
(4) Remove the cowl plenum cover/grille panel from over the cowl plenum. (Refer to 23 - BODY/EX- TERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the left headlamp and dash wire harness connector for the wiper motor from the motor pigtail wire connector (Fig. 26).
(6) Remove the two screws that secure the wiper module to the top of the cowl plenum panel at the pivot brackets.
(7) Remove the two screws that secure the wiper
module to the bottom of the cowl plenum panel.
(8) Remove the wiper module from the cowl ple-
num panel as a unit.
INSTALLATION
(1) Position the wiper module into the cowl ple-
num as a unit (Fig. 26).
(2) Install the two screws that secure the wiper module to the top of the cowl plenum panel at the pivot brackets. Tighten the screw on the driver side, followed by the screw on the passenger side. Tighten the screws to 7 N·m (60 in. lbs.).
(3) Install and tighten the screws that secure the wiper module to the bottom of the cowl plenum panel. Tighten the screw on the passenger side, fol- lowed by the screw on the driver side. Tighten the screws to 7 N·m (60 in. lbs.).
(4) Reconnect the left headlamp and dash wire harness connector for the wiper motor to the motor pigtail wire connector.
(5) Reinstall the cowl plenum cover/grille panel over the cowl plenum. (Refer to 23 - BODY/EXTERI- OR/COWL GRILLE - INSTALLATION).
(6) Reconnect the battery negative cable. (7) Close and latch the hood. (8) Reinstall both wiper arms onto the wiper piv- ots. (Refer to 8 - ELECTRICAL/WIPERS/WASHERS/ WIPER ARMS - INSTALLATION).
8R - 24 WIPERS/WASHERS WIPER MODULE (Continued)
DR
1 - COWL PLENUM WASHER HOSE 2 - PLASTIC FASTENER (6) 3 - SCREW (2) 4 - WIPER ARM & BLADE (2) 5 - COWL PLENUM COVER/GRILLE PANEL
Fig.26WiperModuleRemove/Install 6 - WIPER MODULE 7 - WIRE HARNESS CONNECTOR 8 - PLENUM PANEL 9 - SCREW (4) 10 - ENGINE COMPARTMENT WASHER HOSE
DR
WIPERS/WASHERS
8R - 25
The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: † Common Feed Terminal - The common feed terminal (30) is connected to the common feed termi- nal of the wiper high/low relay at all times through the wiper on/off relay output circuit. † Coil Ground Terminal - The coil ground termi- nal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor opera- tion by controlling a ground path through this cir- cuit.† Coil Battery Terminal - The coil battery ter- minal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. † Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit when- ever the relay is energized.
† Normally Closed Terminal
- The normally closed terminal (87A) is connected to ground at all times through a take out of the left headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay out- put circuit whenever the relay is de-energized.
The wiper on/off relay may be diagnosed using con- ventional diagnostic tools and methods. However, conventional diagnostic methods may not prove con- clusive in the diagnosis of the instrument cluster, the Front Control Module (FCM), or the electronic mes- sage inputs to or outputs from the instrument cluster and the FCM that control the operation of the wiper on/off relay. The most reliable, efficient, and accurate means to diagnose the wiper on/off relay, the instru- ment cluster, the FCM, or the electronic message inputs and outputs related to the wiper on/off relay operation requires the use of a DRBIIIt scan tool. Refer to the appropriate diagnostic information.
WIPER ON/OFF RELAY DESCRIPTION
Fig.27ISOMicroRelay
30 - COMMON FEED 85 - COIL GROUND 86 - COIL BATTERY 87 - NORMALLY OPEN 87A - NORMALLY CLOSED
The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay (Fig. 27). Relays conforming to the ISO specifi- cations have common physical dimensions, current capacities, terminal patterns, 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.
The wiper on/off relay cannot be adjusted or repaired and, if faulty or damaged, the unit must be replaced.
OPERATION
The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current out- put to the wiper motor. 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 electromagnetic 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.
8R - 26 WIPERS/WASHERS WIPER ON/OFF RELAY (Continued) DIAGNOSIS AND TESTING - WIPER ON/OFF RELAY
The wiper on/off relay (Fig. 28) is located in the Integrated Power Module (IPM) in the engine com- partment near the battery. 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.
Fig.28ISOMicroRelay
30 - COMMON FEED 85 - COIL GROUND 86 - COIL BATTERY 87 - NORMALLY OPEN 87A - NORMALLY CLOSED
(1) Remove the wiper on/off relay from the IPM. to 8 - ELECTRICAL/WIPERS/WASHERS/
(Refer WIPER ON/OFF RELAY - REMOVAL).
(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 75 ± 8 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 DRBIIIt scan tool to perform further testing. Refer to the appropriate diagnostic information.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Integrated Power
Module (IPM) (Fig. 29).
(3) Remove the wiper on/off relay by grasping it firmly and pulling it straight out from the receptacle in the IPM.
DR
Fig.29IntegratedPowerModule
1 - 15 - CARTRIDGE FUSE 16 - 53 - BLADE FUSE 54 - HEATED MIRROR RELAY 55 - WIPER ON/OFF RELAY 56 - A/C CONDENSER FAN RELAY 57 - ENGINE CONTROL RELAY 58 - FUEL PUMP RELAY 59 - TRANSMISSION RELAY 60 - WIPER HIGH/LOW RELAY 61 - SPARE 62 - FOG LAMP RELAY 63 - ADJUSTABLE PEDAL RELAY 64 - A/C CLUTCH RELAY 65 - SPARE 66 - O2 RELAY 67 - SPARE 68 - SPARE 69 - SPARE 70 - SPARE 71 - SPARE 72 - STARTER RELAY 73 - PARK LAMP RELAY
INSTALLATION
(1) Position the wiper on/off relay to the proper receptacle in the Integrated Power Module (IPM) (Fig. 29).
(2) Align the wiper on/off relay terminals with the
terminal cavities in the IPM receptacle.
(3) Push firmly and evenly on the top of the wiper on/off relay until the terminals are fully seated in the terminal cavities in the IPM receptacle. (4) Reinstall the cover onto the IPM. (5) Reconnect the battery negative cable.
DR
WIRING
WIRING
TABLE OF CONTENTS
8W - 1
page
page
WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1
COMPONENT INDEX . . . . . . . . . . . . . . . . . . 8W-02-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . 8W-20-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1
REAR WHEEL ANTILOCK BRAKES . . . . . . . 8W-34-1
ALL WHEEL ANTILOCK BRAKES . . . . . . . . 8W-35-1
VEHICLE THEFT SECURITY SYSTEM . . . . . 8W-39-1
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING . . . . . . . . . . . . . . . . . . 8W-42-1
AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . 8W-43-1INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . 8W-49-1
FRONT LIGHTING . . . . . . . . . . . . . . . . . . . . 8W-50-1
REAR LIGHTING . . . . . . . . . . . . . . . . . . . . . 8W-51-1
TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
POWER SEATS . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
SPLICE INFORMATION . . . . . . . . . . . . . . . . 8W-70-1
CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1
CONNECTOR/GROUND/SPLICELOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-97-1DR
8W-01 WIRING DIAGRAM INFORMATION
8W - 01 - 1
8W-01 WIRING DIAGRAM INFORMATION
TABLE OF CONTENTS
page
page
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION - CIRCUIT INFORMATION . . . . 5
DESCRIPTION - CIRCUIT FUNCTIONS . . . . . . 6
DESCRIPTION - SECTION IDENTIFICATIONAND INFORMATION . . . . . . . . . . . . . . . . . . . . 6
DESCRIPTION - CONNECTOR, GROUND
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - TESTING FOR A
SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS . . . . . . . . . . . 10
STANDARD PROCEDURE - TESTING FOR A
VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . 10
SPECIAL TOOLS
WIRING/TERMINAL
. . . . . . . . . . . . . . . . . . . . 10
AND SPLICE INFORMATION . . . . . . . . . . . . . . 7
CONNECTOR
WARNING
WARNINGS - GENERAL
. . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - WIRING
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STANDARD PROCEDURE
STANDARD PROCEDURE -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11DIODE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14TERMINAL
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES . . . . . . . . . . . . . . . . . . . 8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14STANDARD PROCEDURE - TESTING OF
WIRE
VOLTAGE POTENTIAL . . . . . . . . . . . . . . . . . . . 9
STANDARD PROCEDURE - WIRE SPLICING . . 15
STANDARD PROCEDURE - TESTING FOR
CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . 9
WIRING DIAGRAM INFORMATION
DESCRIPTION
DESCRIPTION - HOW TO USE WIRING DIAGRAMS
DaimlerChrysler Corporation wiring diagrams are designed to provide information regarding the vehi- cles wiring content. In order to effectively use the wiring repair DaimlerChrysler Corporation vehicles, it is important to understand all of their features and characteris- tics.
diagrams
diagnose
and
to
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page (Fig. 1).
All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition (Fig. 2).
Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indi- cates that the component is being shown is not com- plete. components have a reference number to indicate the page where the component is shown complete.
Incomplete
It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only.
SYMBOLS
International symbols are used throughout the wir- ing diagrams. These symbols are consistent with those being used around the world (Fig. 3).
8W - 01 - 2
WIRING DIAGRAM INFORMATION (Continued)8W-01 WIRING DIAGRAM INFORMATION
DR
Fig.1WIRINGDIAGRAMEXAMPLE1
DR WIRING DIAGRAM INFORMATION (Continued)
8W-01 WIRING DIAGRAM INFORMATION
8W - 01 - 3
Fig.2WIRINGDIAGRAMEXAMPLE2
8W - 01 - 4
WIRING DIAGRAM INFORMATION (Continued)8W-01 WIRING DIAGRAM INFORMATION
DR
Fig.3WIRINGDIAGRAMSYMBOLS
DR WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY
8W-01 WIRING DIAGRAM INFORMATION
8W - 01 - 5
WIRE COLOR CODE CHART
COLOR CODE
COLOR
BL BK BR DB DG GY LB LG OR PK RD TN VT WT YL
BLUE BLACK BROWN DARK BLUE DARK GREEN GRAY LIGHT BLUE LIGHT GREEN ORANGE PINK RED TAN VIOLET WHITE YELLOW WITH TRACER
This is a list of terms and definitions used in the
wiring diagrams.
LHD . . . . . . . . . . . . . . . . . Left Hand Drive Vehicles RHD . . . . . . . . . . . . . . . Right Hand Drive Vehicles ATX . . Automatic Transmissions-Front Wheel Drive MTX . . . Manual Transmissions-Front Wheel Drive AT . . . . Automatic Transmissions-Rear Wheel Drive MT . . . . . Manual Transmissions-Rear Wheel Drive SOHC . . . . . . . . . . . Single Over Head Cam Engine DOHC . . . . . . . . . . Double Over Head Cam Engine Built-Up-Export . . . . . . . Vehicles Built For Sale In Markets Other Than North America Except Built-Up-Export . . . . . . . . . . . Vehicles Built For Sale In North America
DESCRIPTION - CIRCUIT INFORMATION
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main circuit, gage of wire, and color (Fig. 4).
Fig.4WIRECODEIDENTIFICATION
1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER 2 - GAGE OF WIRE (18 GAGE) 3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON EQUIPMENT) 4 - MAIN CIRCUIT IDENTIFICATION
8W - 01 - 6
WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS8W-01 WIRING DIAGRAM INFORMATION
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DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION
The wiring diagrams are grouped into individual sections. If a component is most likely found in a par- ticular group, it will be shown complete (all wires, connectors, and pins) within that group. For exam- ple, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring.
Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice dia- grams that are not shown in their entirety some- where else in the wiring diagrams.
Section 8W-80 shows each connector and the cir- cuits involved with that connector. The connectors are identified using the name/number on the dia- gram pages.
WIRING SECTION CHART
GROUP
TOPIC
8W-01 thru 8W-09
8W-10 thru 8W-19
8W-20 thru 8W-29
8W-30 thru 8W-39
8W-40 thru 8W-49
8W-50 thru 8W-59
8W-60 thru 8W-69
8W-70
8W-80
8W-91General information and Diagram Overview Main Sources of Power and Vehicle Grounding Starting and Charging
Powertrain/Drivetrain Systems
Body Electrical items and A/C
Exterior Lighting, Wipers and Trailer Tow Power Accessories
Splice Information Connector Pin Outs Connector, Ground and Splice Locations
All circuits in the diagrams use an alpha/numeric code to identify the wire and it’s function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the second- ary codes that may apply to some models.
CIRCUIT IDENTIFICATION CODE CHART
CIRCUIT
FUNCTION
BATTERY FEED BRAKE CONTROLS CLIMATE CONTROLS DIAGNOSTIC CIRCUITS DIMMING ILLUMINATION CIRCUITS FUSED CIRCUITS MONITORING CIRCUITS (GAUGES) OPEN NOT USED OPEN POWERTRAIN CONTROL MODULE EXTERIOR LIGHTING INTERIOR LIGHTING NOT USED NOT USED POWER OPTION (BATTERY FEED) POWER OPTIONS (IGNITION FEED) PASSIVE RESTRAINT SUSPENSION/STEERING TRANSMISSION/TRANSAXLE/ TRANSFER CASE OPEN SPEED CONTROL, WIPER/ WASHER OPEN AUDIO SYSTEMS OPEN GROUNDS
8W-01 WIRING DIAGRAM INFORMATION
8W - 01 - 7
DR WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND SPLICE INFORMATION
WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON.
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typ- ical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair.
IDENTIFICATION
series numbers.
In-line connectors are identified by a number, as follows: † In-line connectors located in the engine compart- ment are C100 series numbers † In-line connectors located in the Instrument Panel area are C200 series numbers. † In-line connectors located in the body are C300
† Jumper harness connectors are C400 series † Grounds and ground connectors are identified with a “G” and follow the same series numbering as the in-line connectors. † Splices are identified with an “S” and follow the † Component connectors are identified by the com- ponent name instead of a number. Multiple connec- tors on a component use a C1, C2, etc. identifier.same series numbering as the in-line connectors.
numbers.
LOCATIONS
Section 8W-91 contains
connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ ground/splice location charts in section 8W-91 refer- ence the figure numbers of the illustrations.
The abbreviation T/O is used in the component location section to indicate a point in which the wir- ing harness branches out to a component. The abbre- viation N/S means Not Shown in the illustrations
WARNING
WARNINGS - GENERAL
WARNINGS provide information to prevent per- sonal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced.
WARNING: ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
WARNING: USE SAFETY STANDS ANYTIME A PRO- CEDURE REQUIRES BEING UNDER A VEHICLE.
WARNING: SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN NEUTRAL.
WARNING: OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
WARNING: KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE FAN AND BELTS.
WARNING: TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIA- TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA- LYTIC CONVERTER AND MUFFLER.
WARNING: DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY.
WARNING: ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY AND AVOID LOOSE CLOTHING.
DIAGNOSIS AND TESTING - WIRING HARNESS
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. † Jumper Wire - This is a test wire used to con- nect two points of a circuit. It can be used to bypass an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND.
† Voltmeter - Used to check for voltage on a cir- cuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today’s vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating.
8W-01 WIRING DIAGRAM INFORMATION
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8W - 01 - 8
WIRING DIAGRAM INFORMATION (Continued) † Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity.factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. (1) Verify the problem. (2) Verify any related symptoms. Do this by per- forming operational checks on components that are in the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia- grams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue.
(4) Isolate the problem area. (5) Repair the problem area. (6) Verify the proper operation. For this step, items on the
check for proper operation of all repaired circuit. Refer to the wiring diagrams.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES
All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When han- dling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inad- vertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is.
(1) Always touch a known good ground before han- dling the part. This should be repeated while han- dling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part form it’s protective
packing until it is time to install the part.
(5) Before removing the part from it’s pakage, ground the pakage to a known good ground on the vehicle.
CAUTION: Most of the electrical components used in today’s vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the cir- cuit. Circuits that are powered up by the vehicle’s electrical system can cause damage to the equip- ment and provide false readings. † Probing Tools - These tools are used for probing terminals in connectors (Fig. 5). Select the proper size tool from Special Tool Package 6807, and insert it into the terminal being tested. Use the other end of the tool to insert the meter probe.
Fig.5PROBINGTOOL
1 - SPECIAL TOOL 6801
2 - PROBING ENDINTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. † Connectors are fully seated † Spread terminals, or terminal push out † Terminals in the wiring assembly are fully seated into the connector/component and locked into position † Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem † Damaged connector/component casing exposing † Wire insulation that has rubbed through causing † Some or all of the wiring strands broken inside † Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS
the item to dirt or moisture
a short to ground
of the insulation
When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-
Fig.6ELECTROSTATICDISCHARGESYMBOL
8W-01 WIRING DIAGRAM INFORMATION
8W - 01 - 9
DR WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL
known good ground (Fig. 7).
(2) Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropri- ate test procedure.
STANDARD PROCEDURE - TESTING FOR CONTINUITY
or, disconnect the battery.
(2) Connect one lead of the ohmmeter to one side
of the circuit being tested (Fig. 8).
(3) Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity.
(1) Connect the ground lead of a voltmeter to a
(1) Remove the fuse for the circuit being checked
Fig.7TESTINGFORVOLTAGEPOTENTIAL
Fig.8TESTINGFORCONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and disconnect all
items
involved with the fuse.
terminals of the fuse.
(2) Connect a test light or a voltmeter across the
(3) Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp.
(4)
If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that gen- eral area of the wiring harness.
8W-01 WIRING DIAGRAM INFORMATION
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8W - 01 - 10
WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADSSPECIAL TOOLS
WIRING/TERMINAL
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the suspected fused circuits.
(2) Replace the blown fuse. (3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.
(4) Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated.
STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP
PROBINGTOOLPACKAGE6807
(1) Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). (2) Connect the other lead of the voltmeter to the
other side of the switch, component or circuit.
(3) Operate the item. (4) The voltmeter will show the difference in volt-
age between the two points.
TERMINALPICKTOOLSET6680
Fig.9TESTINGFORVOLTAGEDROP
TERMINALREMOVINGTOOLS6932AND8638
TERMINALREMOVINGTOOL6934
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8W-01 WIRING DIAGRAM INFORMATION
8W - 01 - 11
INSTALLATION
(1) Insert the removed terminal in the same cavity
on the repair connector.
(2) Repeat steps for each terminal in the connec- tor, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams.
(3) When the connector is re-assembled, the sec- ondary terminal lock must be placed in the locked position to prevent terminal push out.
