The battery cables (Fig. 17) or (Fig. 18) are large
gauge, stranded copper wires sheathed within a
heavy plastic or synthetic rubber insulating jacket.
The wire used in the battery cables combines excel-
lent flexibility and reliability with high electrical cur-
rent carrying capacity. Refer toWiring Diagrams
for battery cable wire gauge information.
A clamping type female battery terminal made of
soft lead is die cast onto one end of the battery cable
wire. A square headed pinch-bolt and hex nut are
installed at the open end of the female battery termi-
nal clamp. Large eyelet type terminals are crimped
onto the opposite end of the battery cable wire and
then solder-dipped. The battery positive cable wires
have a red insulating jacket to provide visual identi-
fication and feature a larger female battery terminal
clamp to allow connection to the larger battery posi-
tive terminal post. The battery negative cable wires
have a black insulating jacket and a smaller female
battery terminal clamp.
The battery cables cannot be repaired and, if dam-
aged or faulty they must be replaced. Both the bat-
tery positive and negative cables are available for
service replacement only as a unit with the battery
wire harness, which may include portions of the wir-
ing circuits for the generator and other components
on some models. Refer toWiring Diagramsfor more
information on the various wiring circuits included in
the battery wire harness for the vehicle being ser-
viced.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables
also provide a path back to the battery for electrical
current generated by the charging system for restor-
ing the voltage potential of the battery. The female
battery terminal clamps on the ends of the battery
cable wires provide a strong and reliable connection
of the battery cable to the battery terminal posts.
The terminal pinch bolts allow the female terminal
clamps to be tightened around the male terminal
posts on the top of the battery. The eyelet terminals
secured to the opposite ends of the battery cable
wires from the female battery terminal clamps pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.
The battery positive cable terminal clamp is die
cast onto the ends of two wires. One wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the Power Distribution
Center (PDC), and the other wire has an eyelet ter-
minal that connects the battery positive cable to the
B(+) terminal stud of the engine starter motor sole-
noid. The battery negative cable terminal clamp is
also die cast onto the ends of two wires. One wirehas an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the right side of the engine cylinder block. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the right front fender inner shield,
near the battery.
DIAGNOSIS AND TESTING - BATTERY CABLES
A voltage drop test will determine if there is exces-
sive resistance in the battery cable terminal connec-
tions or the battery cable. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion or foreign material, then reassembled.
Following reassembly, check the voltage drop for the
battery cable connection and the battery cable again
to confirm repair.
When performing the voltage drop test, it is impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached.EXAM-
PLE:When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive cable eyelet terminal at the starter solenoid
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
terminal at the starter solenoid B(+) terminal stud,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
post connection and the battery positive cable.
VOLTAGE DROP TEST
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing this
test, be certain that the following procedures are
accomplished:
²The battery is fully-charged and load tested.
Refer to Standard Procedures for the proper battery
charging and load test procedures.
²Fully engage the parking brake.
²If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position.
²Verify that all lamps and accessories are turned
off.
²To prevent the engine from starting, remove the
Automatic Shut Down (ASD) relay. The ASD relay is
located in the Power Distribution Center (PDC), in
the engine compartment. See the fuse and relay lay-
out label affixed to the underside of the PDC cover
for ASD relay identification and location.
8F - 18 BATTERY SYSTEMWJ
BATTERY CABLE (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)
(5) Remove the door cylinder lock switch from the
back of the lock cylinder.
INSTALLATION
(1) Position the door cylinder lock switch onto the
back of the lock cylinder with its pigtail wire harness
oriented toward the bottom (Fig. 2).
(2) Position the lock lever onto the pin on the back
of the door lock cylinder with the lever oriented
toward the rear.
(3) Install the retainer clip onto the pin on the
back of the door lock cylinder. Be certain that the
center tab of the retainer is engaged in the retention
hole on the lock lever.
(4) Reinstall the outside door handle unit onto the
outer door panel. (Refer to 23 - BODY/DOOR -
FRONT/EXTERIOR HANDLE - INSTALLATION).
(5) Reconnect the battery negative cable.
HOOD AJAR SWITCH
DESCRIPTION
The hood ajar switch is a self-adjusting, normally
closed, single pole, double throw momentary switch
that is used only on vehicles built for sale in certain
international markets where it is required equipment
(Fig. 3). The mounting bracket is fastened to the left
inner fender. A molded plastic striker with three inte-
gral retainers is secured to the underside of the hood
panel inner reinforcement to actuate the switch
plunger as the hood panel is closed.The switchreceives a path to ground through the left inner
fender shield in the engine compartment.
The hood ajar switch adjusts itself as the striker
pushes the switch body down through the switch
when the hood panel is closed after the initial instal-
lation. This self-adjustment feature is only functional
the first time the hood is closed following installa-
tion. If the switch requires adjustment following the
initial installation, the switch must be replaced.
OPERATION
The normally closed hood ajar switch is normally
held open when the hood panel is closed and latched.
When the hood is opened, the switch plunger extends
from the switch body and the switch contacts are
closed. The hood ajar switch is connected in series
between ground and the hood ajar switch sense input
of the Body Control Module (BCM). The BCM uses
an internal resistor pull up to monitor the state of
the hood ajar switch contacts. The hood ajar switch
can be diagnosed using conventional diagnostic tools
and methods.
DIAGNOSIS AND TESTING - HOOD AJAR
SWITCH
The diagnosis found here addresses an inoperative
hood ajar switch. If the problem being diagnosed is
related to hood ajar switch accuracy, be certain to
confirm that the problem is not an improperly
adjusted hood ajar switch. If no hood ajar switch
adjustment problem is found, the following procedure
will help to locate a short or open in the hood ajar
switch circuit. Refer to the appropriate wiring infor-
mation.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable. Disconnect the hood ajar switch. Check for
continuity between the harness ground circuit a good
ground. There should be continuity. If OK, go to Step
2. If not OK, repair the open ground circuit to
ground.
Fig. 3 Hood Ajar Switch
1 - SWITCH
2 - STUD (2)
3 - BRACKET
4 - FENDER
5 - CONNECTOR
6 - NUT (2)
WJVEHICLE THEFT SECURITY 8Q - 9
DOOR CYLINDER LOCK SWITCH (Continued)
²Front Check Valve- The front washer system
check valve is integral to the wye fitting located in
the washer plumbing between the cowl plenum
washer hose and the front washer nozzles, and is
concealed beneath the cowl plenum cover/grille panel
at the base of the windshield.
²Front Washer Nozzle- Two fluidic front
washer nozzles are secured with integral snap fea-
tures to dedicated openings in the cowl plenum cover/
grille panel located near the base of the windshield.
²Front Washer Plumbing- The plumbing for
the front washer system consists of rubber hoses and
molded plastic fittings. The plumbing is routed along
the left side of the engine compartment from the
washer reservoir, and through the dash panel into
the cowl plenum to the front washer nozzle fittings
beneath the cowl plenum cover/grille panel.
²Front Washer Pump/Motor- The front washer
pump/motor unit is located in a dedicated hole on the
lower outboard side of the washer reservoir, behind
the inner fender liner ahead of the left front wheel.
The front washer pump is located ahead of and below
the rear washer pump.
²Front Wiper Arm- The two front wiper arms
are secured with nuts to the threaded studs on the
ends of the two wiper pivot shafts, which extend
through the cowl plenum cover/grille panel located
near the base of the windshield.
²Front Wiper Blade- The two front wiper
blades are secured to the two front wiper arms with
an integral latch, and are parked on the glass near
the bottom of the windshield when the front wiper
system is not in operation.
²Front Wiper Module- The front wiper pivot
shafts are the only visible components of the front
wiper module. The remainder of the module is con-
cealed within the cowl plenum beneath the cowl ple-
num cover/grille panel. The front wiper module
includes the module bracket, four rubber-isolated
wiper module mounts, the front wiper motor, the
wiper motor crank arm, the two wiper drive links,
and the two front wiper pivots.
²Rain Sensor Module- Models equipped with
the optional automatic wiper feature have a Rain
Sensor Module (RSM) located behind a trim cover on
a bracket bonded to the inside surface of the wind-
shield glass, just above the inside rear view mirror
mounting button.
²Right Multi-Function Switch- The right
(wiper) multi-function switch is secured to the right
side of the multi-function switch mounting housing
near the top of the steering column, just below the
steering wheel. Only the control stalk for the right
multi-function switch is visible, while the remainder
of the switch is concealed beneath the steering col-
umn shrouds. The right multi-function switch con-tains all of the switches and control circuitry for both
the front and rear wiper and washer systems.
²Washer Fluid Level Switch- The washer fluid
level switch is located in a dedicated hole near the
center of the forward surface of the washer reservoir,
behind the left front wheel house splash shield.
²Washer Reservoir- The washer reservoir is
concealed between the left inner fender shield and
the left outer fender panel, behind the inner fender
liner and ahead of the left front wheel. The washer
reservoir filler neck is the only visible portion of the
reservoir, and it is accessed from the left front corner
of the engine compartment.
²Wiper High-Low Relay- The wiper high-low
relay is an International Standards Organization
(ISO) micro relay located in the Power Distribution
Center (PDC) in the engine compartment near the
battery.
²Wiper On-Off Relay- The wiper on-off relay is
an International Standards Organization (ISO) micro
relay located in the Power Distribution Center (PDC)
in the engine compartment near the battery.
Hard wired circuitry connects the front wiper and
washer system components to the electrical system of
the vehicle. These hard wired circuits are integral to
several wire harnesses, which are routed throughout
the vehicle and retained by many different methods.
These circuits may be connected to each other, to the
vehicle electrical system and to the front wiper and
washer system components through the use of a com-
bination of soldered splices, splice block connectors,
and many different types of wire harness terminal
connectors and insulators. Refer to the appropriate
wiring information. The wiring information includes
wiring diagrams, proper wire and connector repair
procedures, further details on wire harness routing
and retention, as well as pin-out and location views
for the various wire harness connectors, splices and
grounds.
OPERATING MODES
The components of the front wiper and washer sys-
tem are designed to work in concert to provide the
following operating modes:
²Automatic Wiper- In models equipped with
the optional automatic wiper feature, the internal
circuitry of both the right (wiper) multi-function
switch, the rain sensor module, and the BCM work
in concert to provide an automatic wiper mode with
five sensitivity selections. The BCM tells the Rain
Sensor Module (RSM) when the automatic wiper
mode is selected and the manually selected sensitiv-
ity level, then the rain sensor module tells the BCM
each time enough water droplets have accumulated
within the wipe pattern on the windshield to require
front wiper operation. The BCM then automatically
WJFRONT WIPERS/WASHERS 8R - 3
FRONT WIPERS/WASHERS (Continued)
²Washer Reservoir- The rear washer system
shares a single reservoir with the front washer sys-
tem, but has its own dedicated washer pump/motor
and plumbing. The washer reservoir is concealed
between the left inner fender shield and the left
outer fender panel, behind the inner fender liner and
ahead of the left front wheel. The washer reservoir
filler neck is the only visible portion of the reservoir,
and it is accessed from the left front corner of the
engine compartment.
Features of the rear wiper and washer system
include the following:
²Continuous Wipe Mode- When the right
multi-function switch control sleeve is moved to the
On position, the rear wiper will be operated at a
fixed speed, continual wipe cycle until the switch
sleeve is moved to the Delay or Off positions, until
the ignition switch is turned to the Off position, or
until the liftgate flip-up glass is ajar.
²Intermittent Wipe Mode- When the right
multi-function switch control sleeve is moved to the
Delay position, the rear wiper will be operated in a
fixed interval, intermittent wipe cycle until the
switch sleeve is moved to the On or Off positions,
until the ignition switch is turned to the Off position,
until the liftgate flip-up glass is ajar, or until the
right multi-function switch control stalk is pushed
forward to activate the rear washer system. The
intermittent wipe mode delay time has a fixed delay
interval of about five to eight seconds between
sweeps.
²Washer Mode- When the right multi-function
switch control stalk is pushed forward to activate the
rear washer system, washer fluid will be dispensed
from the washer reservoir onto the liftgate glass
through the rear washer nozzle and the rear wiper
will operate in a fixed cycle (not intermittent) for as
long as the rear washer pump/motor unit remains
energized. When the control stalk is released from
the momentary Wash position, the wipe-after-wash
feature will continue to operate the rear wiper at a
fixed cycle for about three additional wiper sweeps
before returning to the previously selected mode.
Hard wired circuitry connects the rear wiper and
washer system components to the electrical system of
the vehicle. These hard wired circuits are integral to
several wire harnesses, which are routed throughout
the vehicle and retained by many different methods.
These circuits may be connected to each other, to the
vehicle electrical system and to the rear wiper and
washer system components through the use of a com-
bination of soldered splices, splice block connectors,
and many different types of wire harness terminal
connectors and insulators. Refer to the appropriate
wiring information. The wiring information includes
wiring diagrams, proper wire and connector repairprocedures, further details on wire harness routing
and retention, as well as pin-out and location views
for the various wire harness connectors, splices and
grounds.
OPERATION
The rear wiper and washer system is intended to
provide the vehicle operator with a convenient, safe,
and reliable means of maintaining visibility through
the liftgate glass. The various components of this sys-
tem are designed to convert electrical energy pro-
duced by the vehicle electrical system into the
mechanical action of the wiper blade to wipe the out-
side surface of the glass, as well as into the hydraulic
action of the washer system to apply washer fluid
stored in an on-board reservoir to the area of the
glass to be wiped. When combined, these components
provide the means to effectively maintain clear visi-
bility for the vehicle operator by removing excess
accumulations of rain, snow, bugs, mud, or other
minor debris from the outside liftgate glass surface
that might be encountered while driving the vehicle
under numerous types of inclement operating condi-
tions. The vehicle operator initiates all rear wiper
and washer system functions with the right multi-
function switch located on the right side of the steer-
ing column, just below the steering wheel. Moving
the switch control sleeve to a detent position selects
the rear wiper system operating mode. Moving the
switch control stalk forward to a momentary position
activates the rear washer pump/motor, which dis-
penses washer fluid onto the liftgate glass through
the rear washer nozzle and operates the rear wiper
system in the fixed cycle mode for as long as the
washer switch is closed plus about three wiper
sweeps.
When the ignition switch is in the Accessory or On
positions, battery current from a fuse in the Junction
Block (JB) is provided to the right multi-function
switch through a fused ignition switch output (run-
acc) circuit. A separate fuse in the JB provides bat-
tery current to the electronic control circuitry of the
rear wiper module through a fused B(+) circuit.
When the right multi-function switch control sleeve
On position is selected, the On position circuitry
within the switch directs a battery current rear
wiper motor control signal input to the rear wiper
module electronic circuitry, which causes the rear
wiper motor to run at a fixed continuous wipe cycle.
When the right multi-function switch control sleeve
Delay position is selected, the Delay position cir-
cuitry within the switch directs a battery current
rear washer switch output signal input to the rear
wiper module electronic circuitry, which causes the
rear wiper motor to run at a fixed intermittent wipe
cycle. When the right multi-function switch control
8R - 34 REAR WIPERS/WASHERSWJ
REAR WIPERS/WASHERS (Continued)
HVAC HOUSING
REMOVAL
The HVAC housing assembly must be removed
from the vehicle and the two halves of the housing
separated for service access of the heater core, evap-
orator coil, blend door(s), and each of the various
mode doors.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN AN ACCIDENTAL
AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN PLUMBING BEFORE PERFORMING THE
FOLLOWING OPERATION. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - WARNING) (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
CAUTION)
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument panel from the vehi-
cle(Refer to 23 - BODY/INSTRUMENT PANEL -
REMOVAL).
(3) Recover the refrigerant from the refrigerant
system. (Refer to 24 - HEATING & AIR CONDI-
TIONING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT RECOVERY)
(4) Disconnect the liquid line refrigerant line from
the evaporator inlet tube(Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING/LIQUID LINE -
REMOVAL) or (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/LIQUID LINE - REMOV-
AL). Install plugs in, or tape over all of the opened
refrigerant line fittings.
(5) Disconnect the suction line refrigerant line
from the evaporator outlet tube(Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING/SUCTION
LINE - REMOVAL), (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/SUCTION LINE -
REMOVAL) or (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING/SUCTION LINE - REMOV-
AL). Install plugs in, or tape over all of the opened
refrigerant line fittings.(6) Disconnect the heater hoses from the heater
core tubes. Clamp off the heater hoses to prevent loss
of coolant. Refer to Cooling for the procedures. Install
plugs in, or tape over the opened heater core tubes.
(7) If the vehicle is equipped with the manual tem-
perature control system, unplug the HVAC system
vacuum supply line connector from the tee fitting
near the heater core tubes.
(8) Remove the coolant reserve/overflow bottle
from the passenger side inner fender shield. Refer to
Cooling for the procedures.
(9) Remove the Powertrain Control Module (PCM)
from the passenger side dash panel in the engine
compartment and set it aside. Do not unplug the
PCM wire harness connectors. Refer to Electronic
Control Modules for the procedures.
(10) Remove the nuts from the HVAC housing
mounting studs on the engine compartment side of
the dash panel (Fig. 9).
(11) Remove the rear floor heat ducts from the
floor heat duct outlets (Fig. 10).
(12) Unplug the HVAC housing wire harness con-
nectors.
(13) Remove the HVAC housing mounting nuts
from the studs on the passenger compartment side of
the dash panel (Fig. 11).
Fig. 9 HVAC Housing - (rear view)
1 - Instrument Panel
2 - Air Intake
3 - Expansion Valve
4 - HVAC Housing
5 - Heater Core Input/Output Ports
6 - Instrument Panel Wiring Harness
7 - Blower Motor
WJDISTRIBUTION 24 - 41