2002 JEEP GRAND CHEROKEE 14 volt relay

CONDITION POSSIBLE CAUSES CORRECTION
HORN SOUNDS
CONTINUOUSLY1. Faulty horn relay. 1. Refer to Horn Relay for the proper horn relay
diagnosis and testing procedures. Replace the
horn relay or repair the shorted horn relay control
circuit, if required.
2. Faulty horn switch. 2. Refer to Horn Switch for the proper horn switch
diagnosis and testing procedures. Replace the
horn switch or repair the shorted horn switch
circuit, if required.
HORN
DESCRIPTION
The dual electromagnetic diaphragm-type horns
are standard equipment on this model. Both horns
are secured to a mounting bracket. The mounting
bracket is secured with a screw to the back side of
the right extension of the radiator closure assembly,
just ahead of the right front wheel house and below
the front wheel house extension. The two horns are
connected in parallel. Each horn is grounded through
its wire harness connector and circuit to an eyelet
secured to the right inner fender shield near the bat-
tery, and receives battery feed through the closed
contacts of the horn relay.
The horns cannot be repaired or adjusted and, if
faulty or damaged, they must be individually
replaced.
OPERATION
Within the two halves of the molded plastic horn
housing are a flexible diaphragm, a plunger, an elec-
tromagnetic coil and a set of contact points. The dia-
phragm is secured in suspension around its
perimeter by the mating surfaces of the horn hous-
ing. The plunger is secured to the center of the dia-
phragm and extends into the center of the
electromagnet. The contact points control the current
flow through the electromagnet.
When the horn is energized, electrical current
flows through the closed contact points to the electro-
magnet. The resulting electromagnetic field draws
the plunger and diaphragm toward it until that
movement mechanically opens the contact points.
When the contact points open, the electromagnetic
field collapses allowing the plunger and diaphragm to
return to their relaxed positions and closing the con-
tact points again. This cycle continues repeating at a
very rapid rate producing the vibration and move-
ment of air that creates the sound that is directed
through the horn outlet.
DIAGNOSIS AND TESTING - HORN
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.
(1) Disconnect the wire harness connector(s) from
the horn connector receptacle(s). Measure the resis-
tance between the ground circuit cavity of the horn(s)
wire harness connector(s) and a good ground. There
should be no measurable resistance. If OK, go to Step
2. If not OK, repair the open ground circuit to ground
as required.
(2) Check for battery voltage at the horn relay out-
put circuit cavity of the horn(s) wire harness connec-
tor(s). There should be zero volts. If OK, go to Step 3.
If not OK, repair the shorted horn relay output cir-
cuit or replace the faulty horn relay as required.
(3) Depress the horn switch. There should now be
battery voltage at the horn relay output circuit cavity
of the horn(s) wire harness connector(s). If OK,
replace the faulty horns. If not OK, repair the open
horn relay output circuit to the horn relay as
required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Raise and support the vehicle.
(3) Remove the lower front half of the inner liner
from the right front fender wheel house. (Refer to 23
- BODY/EXTERIOR/FRONT FENDER - REMOVAL).
(4) Reach through the front of the right front
fender wheel house opening to access and disconnect
the two right headlamp and dash wire harness con-
nectors from the horn connector receptacles (Fig. 1).
Be certain to disengage the connector lock tabs
before disconnecting them from the horn connector
receptacles.
(5) Remove the screw that secures the horn
mounting bracket to the right extension of the radi-
ator closure assembly.
WJHORN 8H - 3
HORN SYSTEM (Continued)

(6) Remove both horns and the mounting bracket
from the right extension of the radiator closure
assembly as a unit.
INSTALLATION
(1) Position both horns and the mounting bracket
onto the right extension of the radiator closure
assembly as a unit.
(2) Install and tighten the screw that secures the
horn mounting bracket to the right extension of the
radiator closure assembly. Tighten the screw to 11.3
N´m (100 in. lbs.).
(3) Reconnect the two right headlamp and dash
wire harness connectors to the horn connector recep-
tacles. Be certain to engage the connector lock tabs
after reconnecting them to the horn connector recep-
tacles.
(4) Install the lower front half of the inner liner to
the right front fender wheel house. (Refer to 23 -
BODY/EXTERIOR/FRONT FENDER - INSTALLA-
TION) for the procedure.
(5) Lower the vehicle.
(6) Reconnect the battery negative cable.
HORN RELAY
DESCRIPTION
The horn relay is a electromechanical device that
switches battery current to the horn when the horn
switch grounds the relay coil. The horn relay is
located in the Power Distribution Center (PDC) inthe engine compartment. If a problem is encountered
with a continuously sounding horn, it can usually be
quickly resolved by removing the horn relay from the
PDC until further diagnosis is completed. See the
fuse and relay layout label affixed to the inside sur-
face of the PDC cover for horn relay identification
and location.
The horn relay is a International Standards Orga-
nization (ISO) micro-relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions. The ISO micro-relay terminal functions
are the same as a conventional ISO relay. However,
the ISO micro-relay terminal pattern (or footprint) is
different, the current capacity is lower, and the phys-
ical dimensions are smaller than those of the conven-
tional ISO relay.
The horn relay cannot be repaired or adjusted and,
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 the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.
When the electromagnetic coil is de-energized,
spring pressure returns the movable contact to the
normally closed position. The resistor or diode is con-
nected in parallel with the electromagnetic coil in the
relay, and helps to dissipate voltage spikes that are
produced when the coil is de-energized.
DIAGNOSIS AND TESTING - HORN RELAY
The horn relay (Fig. 2) is located in the Power Dis-
tribution Center (PDC) between the battery and the
right inner fender shield on the passenger side of the
engine compartment. If a problem is encountered
with a continuously sounding horn, it can usually be
quickly resolved by removing the horn relay from the
PDC until further diagnosis is completed. See the
fuse and relay layout label affixed to the inside sur-
face of the PDC cover for horn relay identification
and location. For complete circuit diagrams, refer to
the appropriate wiring information. The wiring infor-
mation 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 con-
nectors, splices and grounds.
Fig. 1 Horns Remove/Install
1 - RADIATOR CLOSURE ASSEMBLY
2 - HORNS AND MOUNTING BRACKET
3 - RIGHT HEADLAMP AND DASH WIRE HARNESS
CONNECTORS
8H - 4 HORNWJ
HORN (Continued)

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
AND POSSIBLE PERSONAL INJURY.
(1) Remove the horn relay from the PDC. (Refer to
8 - ELECTRICAL/HORN/HORN RELAY -
REMOVAL) for the procedures.
(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   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
RELAY CIRCUIT TEST
(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 the open
circuit to the fuse in the PDC as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the horn(s). There should be continuity between
the cavity for relay terminal 87 and the horn relay
output circuit cavity of each horn wire harness con-
nector at all times. If OK, go to Step 4. If not OK,
repair the open circuit to the horn(s) as required.
(4) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is connected to bat-
tery voltage and should be hot at all times. Check for
battery voltage at the cavity for relay terminal 86. If
OK, go to Step 5. If not OK, repair the open circuit to
the fuse in the PDC as required.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. It is grounded
through the horn switch when the horn switch is
depressed. The horn relay coil ground terminal can
also be grounded by the Body Control Module (BCM)
in response to certain inputs related to the RKE sys-
tem or the Vehicle Theft Security System. Check for
continuity to ground at the cavity for relay terminal
85. There should be continuity with the horn switch
depressed, and no continuity with the horn switch
released. If not OK, (Refer to 8 - ELECTRICAL/
HORN/HORN SWITCH - DIAGNOSIS AND TEST-
ING).
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 3) .
(3) See the fuse and relay layout label affixed to
the underside of the PDC cover for horn relay iden-
tification and location.
(4) Remove the horn relay from the PDC.
INSTALLATION
(1) See the fuse and relay layout label affixed to
the underside of the PDC cover for the proper horn
relay location.
(2) Position the horn relay in the proper receptacle
in the PDC.
(3) Align the horn relay terminals with the termi-
nal cavities in the PDC receptacle.
(4) Push down firmly on the horn relay until the
terminals are fully seated in the terminal cavities in
the PDC receptacle.
(5) Install the cover onto the PDC.
(6) Reconnect the battery negative cable.
Fig. 2 Horn Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
WJHORN 8H - 5
HORN RELAY (Continued)

SPARK PLUGS
ENGINE PLUG TYPE ELECTRODE GAP
4.0L 6-CYL. RC12ECC 0.89 mm (.035 in.)
4.7L V-8 (Exc. HO) RC12MCC4 1.01 mm (.040 in.)
4.7L V-8 High
Output (HO)RC7PYCB4 1.01 mm (.040 in.)
TORQUE - IGNITION SYSTEM
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Crankshaft Position Sensor
Bolts - 4.0L Engine7- 60
Crankshaft Position Sensor
Bolt - 4.7L V-8 Engine28 21 -
Camshaft Position
Sensor±to±base bolts - 4.0L
Engine2- 15
Camshaft Position Sensor
Bolt - 4.7L V-8 Engine12 - 106
Oil Pump Drive Hold-down
Bolt - 4.0L Engine23 17 -
Ignition Coil Rail Mounting
Bolts - 4.0L Engine29 - 250
Ignition Coil Mounting Nut -
4.7L V-8 Engine8- 70
* Knock Sensor Bolt - 4.7L
HO V-8 Engine*20 *15 -
Spark Plugs - 4.0L Engine 35-41 26-30 -
Spark Plugs - 4.7L V-8
Engine24-30 18-22 -
* Do not apply any sealant,
thread-locker or adhesive to
bolts. Poor sensor
performance may result.
Refer to Removal / Installation
for additional information.
AUTO 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.
WJIGNITION CONTROL 8I - 3
IGNITION CONTROL (Continued)

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:
²the ignition key is left in the ON position. This
is if the engine has not been running for approxi-
mately 1.8 seconds.
²there 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. If 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).
REMOVAL
The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 1). Refer to label on PDC cover
for relay location.
(1) Remove PDC cover.
(2) Remove relay from PDC.
(3) Check condition of relay terminals and PDC
connector terminals for damage or corrosion. Repair
if necessary before installing relay.
(4) Check for pin height (pin height should be the
same for all terminals within the PDC connector).
Repair if necessary before installing relay.
INSTALLATION
The ASD relay is located in the Power Distribution
Center (PDC) (Fig. 1). Refer to label on PDC cover
for relay location.
(1) Install relay to PDC.
(2) Install cover to PDC.
CAMSHAFT POSITION
SENSOR
DESCRIPTION
DESCRIPTION - 4.0L
The Camshaft Position Sensor (CMP) on the 4.0L
6±cylinder engine is bolted to the top of the oil pump
drive shaft assembly (Fig. 2). The sensor and drive
shaft assembly is located on the right side of the
engine near the oil filter (Fig. 3).
Fig. 1 Power Distribution Center (PDC) Location
1 - PCM
2 - COOLANT TANK
Fig. 2 CMP and Oil Pump Drive ShaftÐ4.0L Engine
1 - CAMSHAFT POSITION SENSOR
2 - MOUNTING BOLTS (2)
3 - PULSE RING
4 - DRIVE GEAR (TO CAMSHAFT)
5 - OIL PUMP DRIVESHAFT
6 - SENSOR BASE (OIL PUMP DRIVESHAFT ASSEMBLY)
8I - 4 IGNITION CONTROLWJ
AUTO SHUT DOWN RELAY (Continued)

OPERATION
Although cylinder firing order is the same as 4.0L
Jeep engines of previous years, spark plug firing is
not. The 3 coils dual-fire the spark plugs on cylinders
1-6, 2-5 and/or 3-4. When one cylinder is being fired
(on compression stroke), the spark to the opposite
cylinder is being wasted (on exhaust stroke).
Battery voltage is supplied to the three ignition
coils from the ASD relay. The Powertrain Control
Module (PCM) opens and closes the ignition coil
ground circuit for ignition coil operation.
Base ignition timing is not adjustable.By con-
trolling the coil ground circuit, the PCM is able to set
the base timing and adjust the ignition timing
advance. This is done to meet changing engine oper-
ating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
Because of coil design, spark plug cables (second-
ary cables) are not used. The cables are integral
within the coil rail.
REMOVAL
A one-piece coil rail assembly containing three
individual coils is used on the 4.0L engine (Fig. 13).
The coil rail must be replaced as one assembly. The
bottom of the coil is equipped with 6 individual rub-
ber boots (Fig. 13) to seal the 6 spark plugs to the
coil. Inside each rubber boot is a spring. The spring
is used for an electrical contact between the coil and
the top of the spark plug. These rubber boots and
springs are a permanent part of the coil and are not
serviced separately.
(1) Disconnect negative battery cable at battery.
(2) The coil is bolted directly to the cylinder head.
Remove 4 coil mounting bolts (Fig. 14).
(3) Carefully pry up coil assembly from spark
plugs. Do this by prying alternately at each end of
coil until rubber boots have disengaged from all
spark plugs. If boots will not release from spark
plugs, use a commercially available spark plug boot
removal tool. Twist and loosen a few boots from a few
spark plugs to help remove coil.
(4) After coil has cleared spark plugs, position coil
for access to primary electrical connector. Disconnect
connector from coil by pushing slide tab outwards to
right side of vehicle (Fig. 15). After slide tab has been
positioned outwards, push in on secondary release
lock (Fig. 15) on side of connector and pull connector
from coil.
(5) Remove coil from vehicle.
Fig. 13 Ignition Coil AssemblyÐ4.0L 6±Cylinder
Engine
1 - CYL. #6
2 - CYL. #5
3 - CYL. #4
4 - CYL. #3
5 - CYL. #2
6 - CYL. #1
7 - COILS (3)
8 - MOUNTING BOLTS (4)
9 - BOLT BASES (4)
10 - RUBBER BOOTS (6)
Fig. 14 Ignition Coil Rail LocationÐ4.0L 6±Cylinder
Engine
1 - COIL RAIL
2 - COIL MOUNTING BOLTS (4)
3 - COIL
4 - COIL ELECTRICAL CONNECTION
8I - 10 IGNITION CONTROLWJ
COIL RAIL (Continued)

OPERATION
Battery voltage is supplied to the 8 ignition coils
from the ASD relay. The Powertrain Control Module
(PCM) opens and closes each ignition coil ground cir-
cuit at a determined time for ignition coil operation.
Base ignition timing is not adjustable.By con-
trolling the coil ground circuit, the PCM is able to set
the base timing and adjust the ignition timing
advance. This is done to meet changing engine oper-
ating conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
Because of coil design, spark plug cables (second-
ary cables) are not used.
REMOVAL
An individual ignition coil is used for each spark
plug (Fig. 18). The coil fits into machined holes in the
cylinder head. A mounting stud/nut secures each coil
to the top of the intake manifold (Fig. 19). The bot-
tom of the coil is equipped with a rubber boot to seal
the spark plug to the coil. Inside each rubber boot is
a spring. The spring is used for a mechanical contact
between the coil and the top of the spark plug. These
rubber boots and springs are a permanent part of the
coil and are not serviced separately. An o-ring (Fig.
18) is used to seal the coil at the opening into the cyl-
inder head.
(1) Depending on which coil is being removed, the
throttle body air intake tube or intake box may need
to be removed to gain access to coil.
(2) Disconnect electrical connector (Fig. 19) from
coil by pushing downward on release lock on top of
connector and pull connector from coil.
(3) Clean area at base of coil with compressed air
before removal.
(4) Remove coil mounting nut from mounting stud
(Fig. 19).
(5) Carefully pull up coil from cylinder head open-
ing with a slight twisting action.
(6) Remove coil from vehicle.
INSTALLATION
(1) Using compressed air, blow out any dirt or con-
taminants from around top of spark plug.
(2) Check condition of coil o-ring and replace as
necessary. To aid in coil installation, apply silicone to
coil o-ring.
(3) Position ignition coil into cylinder head opening
and push onto spark plug. Do this while guiding coil
base over mounting stud.
(4) Install mounting stud nut and tighten to 8 N´m
(70 in. lbs.) torque.(5) Connect electrical connector to coil by snapping
into position.
(6) If necessary, install throttle body air tube or
box.
Fig. 18 Ignition CoilÐ4.7L V±8
1 - O-RING
2 - IGNITION COIL
3 - ELECTRICAL CONNECTOR
Fig. 19 Ignition Coil
1 - IGNITION COIL
2 - COIL ELECTRICAL CONNECTOR
3 - COIL MOUNTING STUD/NUT
8I - 12 IGNITION CONTROLWJ
IGNITION COIL (Continued)

INSTALLATION - CHMSL
(1) Connect the wire harness connector.
(2) Position the CHMSL on liftgate.
(3) Install the screws attaching the CHMSL to the
liftgate.
COMBINATION FLASHER
DESCRIPTION
The combination flasher is located in the Junction
Block (JB) (Fig. 6). The JB is located underneath the
driver side of the instrument panel outboard of the
steering column. The combination flasher is a smart
relay that functions as both the turn signal system
and the hazard warning system flasher. The combi-
nation flasher contains active electronic Integrated
Circuitry (IC) elements. This flasher is designed to
handle the current flow requirements of the factory-
installed lighting. If supplemental lighting is added
to the turn signal lamp circuits, such as when towing
a trailer with lights, the combination flasher will
automatically try to compensate to keep the flash
rate the same.The combination flasher has nine blade-type termi-
nals that connect it to the vehicle electrical system.
Refer to the appropriate wiring information.
Because of the active electronic elements within
the combination flasher, it cannot be tested with con-
ventional automotive electrical test equipment. If the
combination flasher is believed to be faulty, test the
turn signal system and hazard warning system cir-
cuits.(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING
- EXTERIOR - DIAGNOSIS AND TESTING - TURN
SIGNAL & HAZARD WARNING SYSTEM). The com-
bination flasher cannot be repaired or adjusted and,
if faulty or damaged, it must be replaced.
OPERATION
The combination flasher controls the following
inputs and outputs: B(+), fused ignition switch out-
put, left turn switch sense, right turn switch sense,
hazard switch sense, left front turn signal circuit,
right front turn signal circuit, left rear turn signal
circuit and right rear turn signal circuit. Constant
battery voltage is supplied to the flasher so that it
can perform the hazard warning function, and igni-
tion switched battery voltage is supplied for the turn
signal function. However, when the flasher is idle no
current is drawn through the module. The unit does
not become active until it is provided a signal ground
from the turn signal switch, hazard warning switch
or the Body Control Module (BCM).
The IC within the combination flasher (Fig. 7) con-
tains the logic that controls the flasher operation and
the flash rate. When a bulb is burnt out, or when a
circuit for a lamp is open, the turn signal flash rate
will increase. However, an open lamp circuit or burnt
out bulb does not change the hazard warning flash
rate.
Fig. 6 Combination Flasher
1 - COMBINATION FLASHER
2 - JUNCTION BLOCK
WJLAMPS/LIGHTING - EXTERIOR 8L - 7
CENTER HIGH MOUNTED STOP LAMP (Continued)