Heat JEEP GRAND CHEROKEE 2002 WJ / 2.G Manual Online

(6) Disconnect the 22-way instrument panel wire
harness connector from the Body Control Module
(BCM) connector receptacle. Check for continuity
between the seat heater switch sensor ground circuit
cavity of the instrument panel wire harness connec-
tor for the inoperative heated seat switch(es) and a
good ground. There should be no continuity. If OK, go
to Step 7. If not OK, repair the shorted seat heater
switch sensor ground circuit as required.
(7) Check for continuity between the seat heater
switch sensor ground circuit cavities of the instru-
ment panel wire harness connector for the in opera-
tive heated seat switch(es) and the 22-way
instrument panel wire harness connector for the
BCM. There should be continuity. If OK, go to Step 8.
If not OK, repair the open seat heater switch sensor
ground circuit as required.
(8) Check for continuity between the seat heater
switch mux circuit cavity of the instrument panel
wire harness connector for the inoperative heated
seat switch and a good ground. There should be no
continuity. If OK, go to Step 9. If not OK, repair the
shorted seat heater switch mux circuit as required.
(9) Check for continuity between the seat heater
switch mux circuit cavity of the instrument panel
wire harness connector for the inoperative heated
seat switch and the 22-way instrument panel wire
harness connector for the BCM. There should be con-
tinuity. If OK, use a DRBtscan tool and the proper
Diagnostic Procedures manual to test the BCM. If
not OK, repair the open seat heater switch mux cir-
cuit as required.
REMOVAL
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. 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.
(2) Remove the center lower bezel from the instru-
ment panel. Refer toInstrument Panel CenterLower Bezelin the Body section of this manual for
the procedure.
(3) Remove the four screws that secure the heated
seat switch to the back of the instrument panel cen-
ter lower bezel (Fig. 9).
(4) Remove the heated seat switch from the back
of the instrument panel center lower bezel.INSTALLATION
(1) Position the heated seat switch onto the back
of the instrument panel center lower bezel.
(2) Install and tighten the four screws that secure
the heated seat switch to the back of the instrument
panel center lower bezel. Tighten the screws to 1.5
N´m (13 in. lbs.).
(3) Install the center lower bezel onto the instru-
ment panel. Refer toInstrument Panel Center
Lower Bezelin the Body section of this manual for
the procedure.
(4) Reconnect the battery negative cable.
Fig. 9 Heated Seat Switch Remove/Install
1 - HEATED SEAT SWITCHES
2 - SCREWS (4)
3 - CENTER LOWER BEZEL
4 - CIGAR LIGHTER
5 - ILLUMINATION LAMPS
6 - POWER OUTLET
WJHEATED SEAT SYSTEM 8G - 17
PASSENGER HEATED SEAT SWITCH (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
4.7L High-Output Engine Only
NOTE: The left sensor is identified by an identifica-
tion tag (LEFT). It is also identified by a larger bolt
head. The Powertrain Control Module (PCM) must
have and know the correct sensor left/right posi-
tions. Do not mix the sensor locations.
(1) Thoroughly clean knock sensor mounting holes.
(2) Install sensors (Fig. 22) into cylinder block.
NOTE: Over or under tightening the sensor mount-
ing bolts will affect knock sensor performance, pos-
sibly causing improper spark control. Always use
the specified torque when installing the knock sen-
sors. The torque for the knock senor bolt is rela-
tively light for an 8mm bolt.
NOTE: Note foam strip on bolt threads. This foam is
used only to retain the bolts to sensors for plant
assembly. It is not used as a sealant. Do not apply
any adhesive, sealant or thread locking compound
to these bolts.
(3) Install and tighten mounting bolts.Bolt
torque is critical.Refer to torque specification.
(4) Install intake manifold. Refer to Engine sec-
tion.
(5) Connect knock sensor pigtail wiring harness to
engine wiring harness near right / rear of intake
manifold (Fig. 23).
SPARK PLUG
DESCRIPTION
Both the 4.0L 6-cylinder and the 4.7L V-8 engine
use resistor type spark plugs. Standard 4.7L V-8
engines are equipped with ªfired in suppressor sealº
type spark plugs using a copper core ground elec-
trode. High-Output (H.O.) 4.7L V-8 engines are
equipped with unique plugs using a platinum rivet
located on the tip of the center electrode.
Because of the use of an aluminum cylinder head
on the 4.7L engine, spark plug torque is very critical.
To prevent possible pre-ignition and/or mechanical
engine damage, the correct type/heat range/number
spark plug must be used.Do not substitute any
other spark plug on the 4.7L H.O. engine. Seri-
ous engine damage may occur.
Plugs on both engines have resistance values rang-
ing from 6,000 to 20,000 ohms (when checked with at
least a 1000 volt spark plug tester).Do not use an
ohmmeter to check the resistance values of thespark plugs. Inaccurate readings will result.
Remove the spark plugs and examine them for
burned electrodes and fouled, cracked or broken por-
celain insulators. Keep plugs arranged in the order
in which they were removed from the engine. A sin-
gle plug displaying an abnormal condition indicates
that a problem exists in the corresponding cylinder.
Replace spark plugs at the intervals recommended in
Group O, Lubrication and Maintenance.
EXCEPT 4.7L H.O. ENGINE :Spark plugs that
have low mileage may be cleaned and reused if not
otherwise defective, carbon or oil fouled. Also refer to
Spark Plug Conditions.4.7L H.O. ENGINE :Never
clean spark plugs on the 4.7L H.O. engine. Damage
to the platinum rivet will result.
CAUTION: EXCEPT 4.7L H.O. ENGINE : Never use a
motorized wire wheel brush to clean the spark
plugs. Metallic deposits will remain on the spark
plug insulator and will cause plug misfire.
H.O. Gap Adjustment:If equipped with the 4.7L
H.O. engine, do not use a wire-type gapping tool as
damage to the platinum rivet on the center electrode
may occur. Use a tapered-type gauge (Fig. 24).
DIAGNOSIS AND TESTING - SPARK PLUG
CONDITIONS
NORMAL OPERATING
The few deposits present on the spark plug will
probably be light tan or slightly gray in color. This is
evident with most grades of commercial gasoline
Fig. 24 PLUG GAP - 4.7L H.O.
1 - TAPER GAUGE
WJIGNITION CONTROL 8I - 15
KNOCK SENSOR (Continued)

CHIPPED ELECTRODE INSULATOR
A chipped electrode insulator usually results from
bending the center electrode while adjusting the
spark plug electrode gap. Under certain conditions,
severe detonation can also separate the insulator
from the center electrode (Fig. 29). Spark plugs with
this condition must be replaced.
PRE-IGNITION DAMAGE
Pre-ignition damage is usually caused by excessive
combustion chamber temperature. The center elec-
trode dissolves first and the ground electrode dis-
solves somewhat latter (Fig. 30). Insulators appear
relatively deposit free. Determine if the spark plug
has the correct heat range rating for the engine.Determine if ignition timing is over advanced or if
other operating conditions are causing engine over-
heating. (The heat range rating refers to the operat-
ing temperature of a particular type spark plug.
Spark plugs are designed to operate within specific
temperature ranges. This depends upon the thick-
ness and length of the center electrodes porcelain
insulator.)
CAUTION: If the engine is equipped with copper
core ground electrode, or platinum tipped spark
plugs, they must be replaced with the same type/
number spark plug as the original. If another spark
plug is substituted, pre-ignition will result.
Fig. 27 ELECTRODE GAP BRIDGING
1 - GROUND ELECTRODE
2 - DEPOSITS
3 - CENTER ELECTRODE
Fig. 28 SCAVENGER DEPOSITS
1 - GROUND ELECTRODE COVERED WITH WHITE OR
YELLOW DEPOSITS
2 - CENTER ELECTRODE
Fig. 29 CHIPPED ELECTRODE INSULATOR
1 - GROUND ELECTRODE
2 - CENTER ELECTRODE
3 - CHIPPED INSULATOR
Fig. 30 PRE-IGNITION DAMAGE
1 - GROUND ELECTRODE STARTING TO DISSOLVE
2 - CENTER ELECTRODE DISSOLVED
WJIGNITION CONTROL 8I - 17
SPARK PLUG (Continued)

SPARK PLUG OVERHEATING
Overheating is indicated by a white or gray center
electrode insulator that also appears blistered (Fig.
31). The increase in electrode gap will be consider-
ably in excess of 0.001 inch per 2000 miles of opera-
tion. This suggests that a plug with a cooler heat
range rating should be used. Over advanced ignition
timing, detonation and cooling system malfunctions
can also cause spark plug overheating.
CAUTION: If the engine is equipped with copper
core ground electrode, or platinum tipped spark
plugs, they must be replaced with the same type/
number spark plug as the original. If another spark
plug is substituted, pre-ignition will result.
REMOVAL
CAUTION: If equipped with a 4.7L H.O. (High-Out-
put) engine, never substitute the original platinum
tipped spark plug with a different part number. Seri-
ous engine damage may result.
On the 4.0L 6±cylinder engine, the spark plugs are
located below the coil rail assembly. On the 4.7L V±8
engine, each individual spark plug is located under
each ignition coil.
(1) 4.0L 6±Cylinder Engine: Prior to removing
spark plug, spray compressed air around spark plug
hole and area around spark plug. This will help pre-
vent foreign material from entering combustion
chamber.
(2) 4.7L V±8 Engine: Prior to removing spark plug,
spray compressed air around base of ignition coil at
cylinder head. This will help prevent foreign material
from entering combustion chamber.
(3) On the 4.0L engine the coil rail assembly must
be removed to gain access to any/all spark plug.
Refer to Ignition Coil Removal/Installation. On the4.7L V-8 engine each individual ignition coil must be
removed to gain access to each spark plug. Refer to
Ignition Coil Removal/Installation.
(4) Remove spark plug from cylinder head using a
quality socket with a rubber or foam insert. If
equipped with a 4.7L V-8 engine, also check condition
of coil o-ring and replace as necessary.
(5) Inspect spark plug condition. Refer to Spark
Plug Conditions.
CLEANING
Except 4.7L H.O. Engine:The plugs may be
cleaned using commercially available spark plug
cleaning equipment. After cleaning, file center elec-
trode flat with a small point file or jewelers file
before adjusting gap.
CAUTION: Never use a motorized wire wheel brush
to clean spark plugs. Metallic deposits will remain
on spark plug insulator and will cause plug misfire.
4.7L H.O. Engine:Never clean spark plugs on the
4.7L H.O. engine. Damage to the platinum rivet on
the center electrode will result.
INSTALLATION
CAUTION: The standard 4.7L V-8 engine is
equipped with copper core ground electrode spark
plugs. They must be replaced with the same type/
number spark plug as the original. If another spark
plug is substituted, pre-ignition will result.
CAUTION: If equipped with a 4.7L H.O. (High-Out-
put) engine, never substitute the original platinum
tipped spark plug with a different type/part number.
Serious engine damage may result.
Special care should be taken when installing spark
plugs into cylinder head spark plug wells. Be sure
plugs do not drop into plug wells as ground straps
may be bent resulting in a change in plug gap, or
electrodes can be damaged.
Always tighten spark plugs to specified torque. Over
tightening can cause distortion resulting in a change
in spark plug gap or a cracked porcelain insulator.
(1) Start spark plug into cylinder head by hand to
avoid cross threading.
(2) 4.0L 6±Cylinder Engine: Tighten spark plugs to
35-41 N´m (26-30 ft. lbs.) torque.
(3) 4.7L V±8 Engine: Tighten spark plugs to 27
N´m (20 ft. lbs.) torque.
(4)
4.7L V±8 Engine: Before installing coil(s), check
condition of coil o-ring and replace as necessary. To aid
in coil installation, apply silicone to coil o-ring.
(5) Install ignition coil(s). Refer to Ignition Coil
Removal/Installation.
Fig. 31 SPARK PLUG OVERHEATING
1 - BLISTERED WHITE OR GRAY COLORED INSULATOR
8I - 18 IGNITION CONTROLWJ
SPARK PLUG (Continued)

WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
CLUSTER BULB
This procedure applies to each of the incandescent
cluster illumination lamp or indicator bulb and bulb
holder units. However, the illumination lamps and
the indicators use different bulb and bulb holder unit
sizes. They must never be interchanged.
CAUTION: Be certain that any bulb and bulb holder
unit removed from the cluster electronic circuit
board is reinstalled in the correct position. Always
use the correct bulb size and type for replacement.
An incorrect bulb size or type may overheat and
cause damage to the instrument cluster, the elec-
tronic circuit board and/or the gauges.
(1) Insert the bulb and bulb holder straight into
the correct bulb mounting hole in the cluster elec-
tronic circuit board (Fig. 4).
(2) With the bulb holder fully seated against the
cluster electronic circuit board, turn the bulb holder
clockwise about sixty degrees to lock it into place.
(3) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(4) Reconnect the battery negative cable.
CLUSTER LENS, HOOD AND MASK
(1) Position the cluster lens, hood and mask unit
over the face of the instrument cluster (Fig. 5). Be
certain that the odometer/trip odometer switch but-
ton is inserted through the proper clearance holes in
the mask and the lens.
(2) Press firmly and evenly on the cluster lens,
hood and mask unit to install it onto the cluster
housing.
(3) Work around the perimeter of the cluster hous-
ing to be certain that each of the eight latches that
secure the cluster lens, hood and mask unit to the
cluster housing is fully engaged.
(4) Reinstall the instrument cluster into the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(5) Reconnect the battery negative cable.CLUSTER HOUSING REAR COVER
(1) Position the rear cover onto the back of the
cluster housing (Fig. 6).
(2) Press firmly and evenly on the rear cover until
each of the eight latches (four on top, four on the bot-
tom) that secure the upper and lower edges of the
rear cover to the top and bottom of the cluster hous-
ing are fully engaged.
(3) Install and tighten the seven screws that
secure the rear cover to the back of the cluster hous-
ing. Tighten the screws to 2 N´m (20 in. lbs.).
(4) On models with a premium cluster only, recon-
nect the electro-luminescent illumination lamp pig-
tail wire connector to the receptacle on the cluster
electronic circuit board and engage the pigtail wire
under the integral routing clip on the rear cover.
(5) Reinstall the instrument cluster onto the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(6) Reconnect the battery negative cable.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SIDE CURTAIN AIRBAG,
FRONT IMPACT SENSOR, SIDE IMPACT SENSOR,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
WARNING: ON VEHICLES EQUIPPED WITH THE
PREMIUM INSTRUMENT CLUSTER, THE CLUSTER
CIRCUITRY PROVIDES AN ALTERNATING CURRENT
TO SUPPLY POWER TO THE ELECTRO-LUMINES-
CENT ILLUMINATION LAMP THROUGH A PIGTAIL
WIRE AND CONNECTOR THAT IS ACCESSIBLE AT
THE BACK OF THE CLUSTER HOUSING. USE
PROPER PRECAUTIONS WHEN HANDLING THIS
UNIT DURING DIAGNOSIS OR SERVICE TO AVOID
ELECTRICAL SHOCK AND POSSIBLE PERSONAL
INJURY.
(1) Position the instrument cluster to the instru-
ment panel.
8J - 12 INSTRUMENT CLUSTERWJ
INSTRUMENT CLUSTER (Continued)

ing the system voltage is high (system voltage is
about sixteen volts or higher), the gauge needle is
moved to the relative voltage position in the red zone
of the gauge scale and the check gauges indicator is
illuminated. The gauge needle remains in the red
zone and the check gauges indicator remains illumi-
nated until the cluster receives a message from the
PCM indicating there is no high system voltage con-
dition (system voltage is below about sixteen volts,
but higher than about eleven volts).
²Communication Error- If the cluster fails to
receive a system voltage message, it will hold the
gauge needle at the last indication for about twelve
seconds, until a new message is received, or until the
ignition switch is turned to the Off position, which-
ever occurs first. After twelve seconds, the cluster
will return the gauge needle to the low end of the
gauge scale.
²Actuator Test- Each time the cluster is put
through the actuator test, the gauge needle will be
swept across the entire gauge scale and back to con-
firm the functionality of the gauge and the cluster
control circuitry.
The PCM continually monitors the system voltage
to control the generator output. The PCM then sends
the proper system voltage messages to the instru-
ment cluster. For further diagnosis of the voltage
gauge or the instrument cluster circuitry that con-
trols the gauge, (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - DIAGNOSIS AND TESTING). If
the instrument cluster turns on the check gauges
indicator due to a system voltage low or high condi-
tion, it may indicate that the charging system
requires service. For proper diagnosis of the charging
system, the PCI data bus, or the electronic message
inputs to the instrument cluster that control the volt-
age gauge, a DRBIIItscan tool is required. Refer to
the appropriate diagnostic information.
WAIT-TO-START INDICATOR
DESCRIPTION
A wait-to-start indicator is only found in the
instrument clusters of vehicles equipped with an
optional diesel engine. The wait-to-start indicator is
located near the lower edge of the tachometer gauge
dial face, to the right of center. The wait-to-start
indicator consists of an International Control and
Display Symbol icon for ªDiesel Preheatº imprinted
on an amber lens. The lens is located behind a cutout
in the opaque layer of the tachometer gauge dial face
overlay. The dark outer layer of the gauge dial face
overlay prevents the icon from being clearly visible
when the indicator is not illuminated. The icon
appears silhouetted against an amber field throughthe translucent outer layer of the gauge dial face
overlay when the indicator is illuminated from
behind by a replaceable incandescent bulb and bulb
holder unit located on the instrument cluster elec-
tronic circuit board. The wait-to-start indicator lens
is serviced as a unit with the instrument cluster.
OPERATION
The wait-to-start indicator gives an indication to
the vehicle operator when the diesel engine glow
plugs are energized in their preheat operating mode.
This indicator is controlled by a transistor on the
instrument cluster circuit board based upon cluster
programming and electronic messages received by
the cluster from the Powertrain Control Module
(PCM) over the Programmable Communications
Interface (PCI) data bus. The wait-to-start indicator
bulb is completely controlled by the instrument clus-
ter logic circuit, and that logic will only allow this
indicator to operate when the instrument cluster
receives a battery current input on the fused ignition
switch output (run-start) circuit. Therefore, the indi-
cator will always be off when the ignition switch is in
any position except On or Start. The bulb only illu-
minates when it is switched to ground by the instru-
ment cluster transistor. The instrument cluster will
turn on the wait-to-start indicator for the following
reasons:
²Wait-To-Start Indicator Lamp-On Message-
Each time the cluster receives a wait-to-start indica-
tor lamp-on message from the PCM indicating the
glow plugs are heating and the driver must wait to
start the engine, the wait-to-start indicator will be
illuminated. The indicator remains illuminated until
the cluster receives a wait-to-start indicator lamp-off
message, or until the ignition switch is turned to the
Off position, whichever occurs first.
²Actuator Test- Each time the cluster is put
through the actuator test, the wait-to-start indicator
will be turned on for the duration of the test to con-
firm the functionality of the bulb and the cluster con-
trol circuitry.
The PCM continually monitors the ambient tem-
perature and the glow plug pre-heater circuits to
determine how long the glow plugs must be heated in
the pre-heat operating mode. The PCM then sends
the proper wait-to-start indicator lamp-on and lamp-
off messages to the instrument cluster. If the wait-to-
start indicator fails to light during the actuator test,
replace the bulb with a known good unit. For further
diagnosis of the wait-to-start indicator or the instru-
ment cluster circuitry that controls the indicator,
(Refer to 8 - ELECTRICAL/INSTRUMENT CLUS-
TER - DIAGNOSIS AND TESTING). For proper
diagnosis of the glow plug pre-heater control circuits,
the PCM, the PCI data bus, or the electronic message
WJINSTRUMENT CLUSTER 8J - 35
VOLTAGE GAUGE (Continued)