Battery cable JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

HORN SWITCH
DESCRIPTION
A center-blow, normally open, resistive membrane-
type horn switch is secured in a plastic tray that is
inserted in a pocket sewn on the front of the driver
side airbag retainer strap. The horn switch is con-
cealed behind the driver side airbag module trim
cover in the center of the steering wheel. The switch
consists of two plastic membranes, one that is flat
and one that is slightly convex. These two mem-
branes are secured to each other around the perime-
ter. Inside the switch, the centers of the facing
surfaces of these membranes each has a grid made
with an electrically conductive material applied to it.
One of the grids is connected to a circuit that pro-
vides it with continuity to ground at all times. The
grid of the other membrane is connected to the horn
relay control circuit.
The steering wheel and steering column must be
properly grounded in order for the horn switch to
function properly. The horn switch and plastic tray
are serviced as a unit. If the horn switch is damaged
or faulty, or if the driver side airbag is deployed, the
horn switch and tray must be replaced as a unit.
OPERATION
When the center area of the driver side airbag trim
cover is depressed, the electrically conductive grids
on the facing surfaces of the horn switch membranes
contact each other, closing the switch circuit. The
completed horn switch circuit provides a ground for
the control coil side of the horn relay, which activates
the relay. When the horn switch is released, the
resistive tension of the convex membrane separates
the two electrically conductive grids and opens the
switch circuit.
DIAGNOSIS AND TESTING - HORN SWITCH
For complete circuit diagrams, refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
WARNING: 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) Disconnect and isolate the battery negative
cable. Remove the steering column opening cover
from the instrument panel.
(2) Check for continuity between the metal steer-
ing column jacket and a good ground. There should
be continuity. If OK, go to Step 3. If not OK, refer to
Steering, Column for proper installation of the steer-
ing column.
(3) Remove the driver side airbag module from the
steering wheel. Disconnect the horn switch wire har-
ness connectors from the driver side airbag module.
(4) Remove the horn relay from the Power Distri-
bution Center (PDC). Check for continuity between
the steering column half of the horn switch feed wire
harness connector and a good ground. There should
be no continuity. If OK, go to Step 5. If not OK,
repair the shorted horn relay control circuit to the
horn relay in the PDC as required.
(5) Check for continuity between the steering col-
umn half of the horn switch feed wire harness con-
nector and the horn relay control circuit cavity for
the horn relay in the PDC. There should be continu-
ity. If OK, go to Step 6. If not OK, repair the open
horn relay control circuit to the horn relay in the
PDC as required.
Fig. 3 Power Distribution Center
1 - RIGHT FENDER
2 - BATTERY
3 - POWER DISTRIBUTION CENTER
4 - COVER
8H - 6 HORNWJ
HORN RELAY (Continued)

(6) Check for continuity between the horn switch
feed wire and the horn switch ground wire on the
driver side airbag module. There should be no conti-
nuity. If OK, go to Step 7. If not OK, replace the
faulty horn switch.
(7) Depress the center of the driver side airbag
module trim cover and check for continuity between
the horn switch feed wire and the horn switch
ground wire on the driver side airbag module. There
should now be continuity. If not OK, replace the
faulty horn switch.
REMOVAL
WARNING:
²ON VEHICLES EQUIPPED WITH AIRBAGS,
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 ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
²THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the trim cover from the driver side air-
bag module. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - REMOVAL) for the
procedure.
(3) Remove the horn switch and tray as a unit
from the pouch on the retaining strap of the driver
side airbag module (Fig. 4).
INSTALLATION
WARNING:
²ON VEHICLES EQUIPPED WITH AIRBAGS,
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 ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.²THE HORN SWITCH IS INTEGRAL TO THE
DRIVER SIDE AIRBAG MODULE. SERVICE OF THIS
COMPONENT SHOULD BE PERFORMED ONLY BY
CHRYSLER-TRAINED AND AUTHORIZED DEALER
SERVICE TECHNICIANS. FAILURE TO TAKE THE
PROPER PRECAUTIONS OR TO FOLLOW THE
PROPER PROCEDURES COULD RESULT IN ACCI-
DENTAL, INCOMPLETE, OR IMPROPER AIRBAG
DEPLOYMENT AND POSSIBLE OCCUPANT INJU-
RIES.
(1) Install the horn switch and tray as a unit into
the pouch on the retaining strap of the driver side
airbag module. Be certain that the tray is facing the
airbag module, that the horn switch is facing the
trim cover, that the horn switch feed wire is on the
left, and that the horn switch ground wire is on the
right.
(2) Install the trim cover onto the driver side air-
bag module. (Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - INSTALLATION) for
the procedure.
(3) Reconnect the battery negative cable.
Fig. 4 Horn Switch Remove/Install
1 - HORN SWITCH GROUND WIRE EYELET
2 - HORN SWITCH
3 - AIRBAG RETAINING STRAP
4 - POUCH
5 - DRIVER SIDE AIRBAG MODULE (TRIM COVER REMOVED)
6 - TRAY
7 - HORN SWITCH FEED WIRE CONNECTOR
WJHORN 8H - 7
HORN SWITCH (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)

INSTALLATION
(1) Connect engine harness connector to coil by
snapping into position. Move slide tab towards
engine (Fig. 15) for a positive lock.
(2) Position ignition coil rubber boots to all spark
plugs. Push down on coil assembly until bolt bases
have contacted cylinder head
(3) Install 4 coil mounting bolts. Loosely tighten 4
bolts just enough to allow bolt bases to contact cylin-
der head. Do a final tightening of each bolt in steps
down to 29 N´m (250 in. lbs.) torque. Do not apply
full torque to any bolt first.
(4) Connect negative battery cable to battery.
IGNITION COIL
DESCRIPTION
The 4.7L V±8 engine uses 8 dedicated, and individ-
ually fired coil (Fig. 16) for each spark plug. Each
coil is mounted directly to the top of each spark plug
(Fig. 17).
Fig. 15 Ignition Coil Electrical ConnectorÐ4.0L
6±Cylinder Engine
1 - REAR OF VALVE COVER
2 - COIL RAIL
3 - SLIDE TAB
4 - RELEASE LOCK
5 - COIL CONNECTOR
Fig. 16 Ignition CoilÐ4.7L Engine
1 - O-RING
2 - IGNITION COIL
3 - ELECTRICAL CONNECTOR
Fig. 17 Ignition Coil LocationÐ4.7L Engine
1 - IGNITION COIL
2 - COIL ELECTRICAL CONNECTOR
3 - COIL MOUNTING STUD/NUT
WJIGNITION CONTROL 8I - 11
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)

an input from the auto headlamp light sensor to
determine the ambient light levels. If the BCM
decides that the exterior lighting is turned on in the
daylight, it overrides the selected panel dimmer
switch signal by sending a message over the PCI
data bus to illuminate all vacuum fluorescent dis-
plays at full brightness for improved visibility in day-
time light levels. The automatic parade mode has no
effect on the incandescent bulb illumination intensity.
The hard wired cluster illumination circuits
between the left (lighting) multi-function switch and
the BCM may be diagnosed using conventional diag-
nostic tools and methods. The electro-luminescent
lamp is diagnosed using the EMIC self-diagnostic
actuator test. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - DIAGNOSIS AND TESTING).
However, proper testing of the EMIC and the elec-
tronic dimming level messages sent by the BCM over
the PCI data bus requires the use of a DRBIIItscan
tool. Refer to the appropriate diagnostic information.
CHIME SERVICE
The EMIC is programmed to request chime service
from the Body Control Module (BCM) when certain
indicators are illuminated. The EMIC chime request
for illumination of the low fuel indicator is a cus-
tomer programmable feature. When the programmed
conditions are met, the EMIC generates an electronic
chime request message and sends it over the PCI
data bus to the BCM. Upon receiving the proper
chime request, the BCM activates an integral chime
tone generator to provide the audible chime tone to
the vehicle operator. (Refer to 8 - ELECTRICAL/
CHIME WARNING SYSTEM - OPERATION). Proper
testing of the PCI data bus and the electronic chime
request message outputs from the EMIC requires the
use of a DRBIIItscan tool. Refer to the appropriate
diagnostic information.
DIAGNOSIS AND TESTING - INSTRUMENT
CLUSTER
If all of the instrument cluster gauges and/or indi-
cators are inoperative, refer to PRELIMINARY
DIAGNOSIS . If an individual gauge or Programma-
ble Communications Interface (PCI) data bus mes-
sage-controlled indicator is inoperative, refer to
ACTUATOR TEST . If an individual hard wired indi-
cator is inoperative, refer to the diagnosis and testing
information for that specific indicator. If the base
instrument cluster incandescent illumination lighting
is inoperative, refer to CLUSTER ILLUMINATION
DIAGNOSIS . If the premium instrument cluster
electro-luminescent illumination lighting is inopera-
tive, refer to ACTUATOR TEST . Refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connectorrepair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
NOTE: Occasionally, a condition may be encoun-
tered where the gauge pointer for the speedometer
or the tachometer becomes caught on the wrong
side of the pointer stop. To correct this condition,
the technician should use a DRBIIITscan tool and
the appropriate diagnostic information to perform
the instrument cluster self-diagnostic actuator test
procedure. When performed, the actuator test pro-
cedure will automatically return the pointer to the
correct side of the pointer stop.
PRELIMINARY DIAGNOSIS
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) Check the fused B(+) fuse (Fuse 17 - 10
ampere) in the Junction Block (JB). If OK, go to Step
2. If not OK, repair the shorted circuit or component
as required and replace the faulty fuse.
(2) Check for battery voltage at the fused B(+) fuse
(Fuse 17 - 10 ampere) in the JB. If OK, go to Step 3.
If not OK, repair the open fused B(+) circuit between
WJINSTRUMENT CLUSTER 8J - 7
INSTRUMENT CLUSTER (Continued)

the JB and the Power Distribution Center (PDC) as
required.
(3) Check the fused ignition switch output (run-
start) fuse (Fuse 22 - 10 ampere) in the JB. If OK, go
to Step 4. If not OK, repair the shorted circuit or
component as required and replace the faulty fuse.
(4) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run-start) fuse (Fuse 22 - 10 ampere) in the
JB. If OK, go to Step 5. If not OK, repair the open
fused ignition switch output (run-start) circuit
between the JB and the ignition switch as required.
(5) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Remove the instrument cluster. Reconnect the bat-
tery negative cable. Check for battery voltage at the
fused B(+) circuit cavity of the instrument panel wire
harness connector for the instrument cluster. If OK,
go to Step 6. If not OK, repair the open fused B(+)
circuit between the instrument cluster and the JB as
required.
(6) Turn the ignition switch to the On position.
Check for battery voltage at the fused ignition switch
output (run-start) circuit cavity of the instrument
panel wire harness connector for the instrument clus-
ter. If OK, go to Step 7. If not OK, repair the open
fused ignition switch output (run-start) circuit
between the instrument cluster and the JB as
required.
(7) Turn the ignition switch to the Off position.
Disconnect and isolate the battery negative cable.
Check for continuity between each of the ground cir-
cuit cavities of the instrument panel wire harness
connector for the instrument cluster and a good
ground. There should be continuity. If OK, refer to
the ACTUATOR TEST . If not OK, repair the open
ground circuit(s) between the instrument cluster and
ground (G200) as required.
ACTUATOR TEST
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.
The instrument cluster actuator test will put the
instrument cluster into its self-diagnostic mode. In
this mode the instrument cluster can perform a self-
diagnostic test that will confirm that the instrument
cluster circuitry, the gauges, the PCI data bus mes-
sage controlled indicators, and the electro-lumines-
cent illumination lamp (if equipped) are capable of
operating as designed. During the actuator test the
instrument cluster circuitry will sweep each of the
gauge needles across the gauge faces, illuminate each
of the segments in the Vacuum-Fluorescent Display
(VFD), turn all of the PCI data bus message-con-
trolled indicators on and off again, and turn the elec-
tro-luminescent illumination lamp (if equipped) on
and off again.
Successful completion of the actuator test will con-
firm that the instrument cluster is operational. How-
ever, there may still be a problem with the PCI data
bus, the Powertrain Control Module, the Airbag Con-
trol Module (ACM), the Body Control Module (BCM),
the Controller Anti-lock Brake (CAB), the Sentry Key
Immobilizer Module (SKIM), or the inputs to one of
these electronic control modules. Use a DRBIIItscan
tool to diagnose these components. Refer to the
appropriate diagnostic information.
If an individual indicator lamp or the electro-lumi-
nescent illumination lamp do not illuminate during
the actuator test, the instrument cluster should be
removed. However, check that the incandescent lamp
bulb is not faulty, that the bulb holder is properly
installed on the instrument cluster electronic circuit
board, or that the electro-luminescent lamp pigtail
wire connector is properly connected to the instru-
ment cluster electronic circuit board before consider-
ing instrument cluster replacement. If the bulb and
bulb holder, or the electro-luminescent lamp connec-
tion check OK, replace the faulty instrument cluster
unit.
(1) Begin the test with the ignition switch in the
Off position.
(2) Depress the odometer/trip odometer switch but-
ton.
8J - 8 INSTRUMENT CLUSTERWJ
INSTRUMENT CLUSTER (Continued)

(3) While still holding the odometer/trip odometer
switch button depressed, turn the ignition switch to
the On position, but do not start the engine.
(4) Release the odometer/trip odometer switch but-
ton.
(5) The instrument cluster will automatically
begin the actuator test sequence, as follows:
(a) The cluster will turn on, then off again each
of the PCI data bus message controlled indicators
(except Airbag) to confirm the functionality of the
indicator and the cluster control circuitry:
(b) The cluster will sweep the needles for each of
the gauges from minimum to maximum and back
to minimum to confirm the functionality of the
gauge and the cluster control circuitry:
(c) Only on models with a premium version of
the cluster, the cluster will illuminate the electro-
luminescent lamp and turn it off again to confirm
the functionality of the lamp and the cluster con-
trol circuitry.
(d) The cluster will sequentially step the odome-
ter/trip odometer VFD display from all zeros
(000000) through all nines (999999) to confirm the
functionality of all VFD segments and their control
circuitry, then display the software version number,
followed by ªDONEº.
(6) The actuator test is now completed. The instru-
ment cluster will automatically exit the self-diagnos-
tic mode and return to normal operation at the
completion of the test, if the ignition switch is turned
to the Off position during the test, or if a vehicle
speed message indicating that the vehicle is moving
is received from the PCM over the PCI data bus dur-
ing the test.
(7) Go back to Step 1 to repeat the test, if
required.
CLUSTER ILLUMINATION DIAGNOSIS
On models equipped with a base version of the
instrument cluster, the EMIC has several incandes-
cent illumination lamps that are illuminated when-
ever the exterior lighting is turned On. If the
problem being diagnosed is a single inoperative illu-
mination lamp, be certain that the bulb and bulb
holder unit are properly installed in the instrument
cluster electronic circuit board. If no installation
problems are found replace the faulty bulb and bulb
holder unit. If all of the cluster illumination lamps
are inoperative, the most reliable, efficient, and accu-
rate means to diagnose the cluster illumination func-tion of the instrument cluster requires the use of a
DRBIIItscan tool. Refer to the appropriate diagnos-
tic information.
REMOVAL
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) Disconnect and isolate the battery negative
cable.
(2) Remove the cluster bezel from the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - REMOVAL).
(3) Remove the two screws that secure the upper
mounting tabs of the instrument cluster to the
underside of the instrument cluster hood formation of
the instrument panel top pad.
(4) Remove the two screws that secure the lower
mounting tabs of the instrument cluster to the
instrument panel structural duct.
WJINSTRUMENT CLUSTER 8J - 9
INSTRUMENT CLUSTER (Continued)

(5) Pull the upper mounting tabs of the instrument
cluster downward, then pull the instrument cluster
rearward far enough to access the instrument panel
wire harness connector for the instrument cluster
(Fig. 3).
(6) Disconnect the instrument panel wire harness
connector for the instrument cluster from the connec-
tor receptacle on the back of the instrument cluster
housing.
(7) Remove the instrument cluster from the instru-
ment panel.
DISASSEMBLY
Some of the components for the instrument cluster
used in this vehicle are serviced individually. The
serviced components include: the incandescent
instrument cluster indicator and illumination lamp
bulbs (including the integral bulb holders), the clus-
ter lens, hood and mask unit, and the cluster housing
rear cover. Following are the procedures for disas-
sembling these components from the instrument clus-
ter unit.
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.
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. Be certain
that any bulb holder removed from the electronic cir-
cuit board is reinstalled in the correct position.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument cluster from the instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(3) Turn the bulb holder counterclockwise about
sixty degrees on the cluster electronic circuit board
(Fig. 4).
(4) Pull the bulb and bulb holder straight back to
remove it from the bulb mounting hole in the cluster
electronic circuit board.
CLUSTER LENS, HOOD AND MASK
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the instrument cluster from the instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).
(3) Work around the perimeter of the cluster hous-
ing to disengage each of the eight latches that secure
the cluster lens, hood and mask unit to the cluster
housing (Fig. 5).
(4) Gently pull the cluster lens, hood and mask
unit away from the cluster housing.
CLUSTER HOUSING REAR COVER
(1) Disconnect and isolate the battery negative
cable.
Fig. 3 Instrument Cluster Remove/Install
1 - INSTRUMENT PANEL WIRE HARNESS CONNECTOR
2 - INSTRUMENT CLUSTER
8J - 10 INSTRUMENT CLUSTERWJ
INSTRUMENT CLUSTER (Continued)

(2) Remove the instrument cluster from the instru-
ment panel. (Refer to 8 - ELECTRICAL/INSTRU-
MENT CLUSTER - REMOVAL).(3) On models with a premium cluster only, discon-
nect the electro-luminescent illumination lamp pig-
tail wire connector from the receptacle on the cluster
electronic circuit board and disengage the pigtail
wire from the integral routing clip on the rear cover
(Fig. 6).
(4) Remove the seven screws that secure the rear
cover to the back of the cluster housing.
(5) Disengage the eight latch features (four on top,
four on the bottom) that secure the upper and lower
edges of the rear cover to the top and bottom of the
cluster housing.
(6) Remove the rear cover from the back of the
cluster housing.
ASSEMBLY
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.
Fig. 4 Cluster Bulb Locations - Typical
1 - ILLUMINATION LAMP BULBS AND HOLDERS (5)
2 - CLUSTER HOUSING REAR COVER
3 - CLUSTER HOUSING
Fig. 5 Instrument Cluster Components
1 - MINOR GAUGE SETS
2 - HOUSING REAR COVER
3 - TRIP ODOMETER RESET KNOB
4 - LENS, HOOD AND MASK
5 - MAJOR GAUGES
6 - CLUSTER HOUSING
Fig. 6 Cluster Housing Rear Cover Screws
1 - ELECTRO-LUMINESCENT LAMP PIGTAIL WIRE
CONNECTOR
2 - REAR COVER
3 - SCREW (7)
WJINSTRUMENT CLUSTER 8J - 11
INSTRUMENT CLUSTER (Continued)