JEEP YJ 1995 Service And Repair Manual

CHIME/BUZZER WARNING SYSTEMS
CONTENTS
page page
DIAGNOSIS............................. 2
GENERAL INFORMATION.................. 1SERVICE PROCEDURES................... 4
GENERAL INFORMATION
This group covers the buzzer warning system,
which is standard equipment on XJ (Cherokee)/YJ
(Wrangler) models. The system provides an audible
warning to the driver when it monitors the following
conditions:
²key is in ignition switch with the driver's door
open
²head or park lamps are on with driver's door open
(XJ only)
²driver's seat belt is not buckled with ignition
switch in ON position.
Following are general descriptions of the major
components in the buzzer warning system. Refer to
Group 8W - Wiring Diagrams for complete circuit de-
scriptions and diagrams.
BUZZER MODULE
The buzzer module is located in the fuseblock mod-
ule under the left end of the instrument panel. It re-
ceives battery voltage at all times from (fuse 15 - XJ,
fuse 3 - YJ) the fuseblock module. It also receives a
second battery feed (fuse 17 - XJ, fuse 9 - YJ) when
the ignition switch is in the ON or START position.
Other inputs to the module include the driver's door
jamb switch, the driver's seat belt switch, the ignition
key-in switch, and the headlamp switch (XJ only). The
only output of the module is a timed 4 to 8 second feed
to the seat belt reminder lamp in the message center of
the instrument cluster. The timer function begins after
the ignition switch is turned to the ON position.
The buzzer module can not be repaired. If faulty, it
must be replaced.
DRIVER'S DOOR JAMB SWITCH
The driver's door jamb switch is mounted to the
driver's door hinge pillar. The switch closes a path to
ground for the buzzer module through the key-in
switch or headlamp switch (XJ only) when the driv-
er's door is opened, and opens when the driver's door
is closed. This switch can not be repaired. If faulty, it
must be replaced.
IGNITION KEY-IN SWITCH
XJ MODELS
The key-in switch is integral to the ignition switch,
which is mounted on the right side of the steering col-
umn. It closes a path to ground for the buzzer module
when the ignition key is inserted in the ignition lock cyl-
inder and the driver's door jamb switch is closed (door
open). The switch opens when the key is removed from
the ignition lock cylinder. This switch can not be re-
paired. If faulty, the entire ignition switch must be re-
placed. Refer to Group 8D - Ignition Systems for service
procedures.
YJ MODELS
The key-in switch is mounted within the steering col-
umn in the lock cylinder housing. It closes a path to
ground for the buzzer module when the ignition key is
inserted in the ignition lock cylinder and the driver's
door jamb switch is closed (door open). The switch opens
when the key is removed from the ignition lock cylinder.
This switch is available for service replacement. Refer
to Group 19 - Steering for service procedures.
HEADLAMP SWITCH (XJ ONLY)
The headlamp switch is located in the instrument
panel. It closes a path to ground for the buzzer module
when the park or headlamps are on and the driver's
door jamb switch is closed (door open). The switch opens
the ground path when the park and headlamps are
turned off. The headlamp switch can not be repaired. If
faulty, it must be replaced. Refer to Group 8E - Instru-
ment Panel and Gauges for service procedures.
DRIVER'S SEAT BELT SWITCH
The driver's seat belt switch is integral to the driv-
er's seat belt buckle-half assembly. The switch is nor-
mally closed, providing a ground path to the buzzer
module. When the tip-half of the seat belt is inserted
into the seat belt buckle, the switch opens the buzzer
module ground path. The seat belt switch can not be
repaired. If faulty, the entire driver's seat belt buck-
le-half must be replaced. Refer to Group 23 - Body
Components for service procedures.
JCHIME/BUZZER WARNING SYSTEMS 8U - 1

DIAGNOSIS
BUZZER MODULE
(1) Check fuses (15 and 17 - XJ, 3 and 9 - YJ) in
the fuseblock module. If fuses are OK, go to next
step. If not OK, replace fuses as required.
(2) Check for battery voltage at fuse (15 - XJ, 3 -
YJ) in fuseblock module. If OK, go to next step. If not
OK, repair feed circuit from power distribution center
as required.
(3) Turn ignition switch to ON position. Check for
battery voltage at fuse (17 - XJ, 9 - YJ) in the fuse-
block module. If OK, go to next step. If not OK, re-
pair feed from ignition switch as required.
(4) Turn ignition switch to OFF position. Replace
buzzer module with a known good unit and test op-
eration. If not OK, remove buzzer module and go to
next step.
(5) Check for battery voltage at cavity for buzzer
terminal 7 in buzzer module connector (Fig. 1). If
OK, go to next step. If not OK, repair circuit to fuse
(15 - XJ, 3 - YJ).
(6) Turn ignition switch to ON position. Check for
battery voltage at cavity for buzzer terminal 1 in
buzzer module connector. If OK, go to next step. If
not OK, repair circuit to fuse (17 - XJ, 9 - YJ) in fuse-
block module.
(7) Turn ignition switch to OFF position. Check for
continuity between cavity for buzzer terminal 3 and
a good ground. There should be continuity. If OK, go
to diagnosis for switch that is related to buzzer mal-
function. If not OK, repair circuit to ground as re-
quired.
DRIVER'S DOOR JAMB SWITCH
(1) Open driver's door and note whether interior
lamps light. They should light. If OK, see diagnosis
for Ignition Key-In Switch (XJ or YJ) or Headlamp
Switch (XJ only). If not OK, go to next step.
(2) Check for continuity between door jamb switch
body and a good ground. There should be continuity.
If OK, go to next step. If not OK, tighten or clean
switch attachment to hinge pillar as required to re-
store ground path.
(3) Remove switch from hinge pillar and check
wire connections for clean and tight engagement. If
OK, replace faulty switch. If not OK, clean and
tighten connections as required.
IGNITION KEY-IN SWITCH
XJ MODELS
(1) Remove steering column shrouds (refer to
Group 8D - Ignition Systems for procedure). Unplug
ignition key-in switch connector from ignition switch
(Fig. 3). Open driver's door. Check for continuity be-
tween cavity 4 (black/light blue wire) and a good
ground. There should be continuity. If OK, go to next
step. If not OK, repair circuit to driver's door jamb
switch as required.
(2) Insert ignition key in ignition lock cylinder.
Check for continuity between key-in switch cavities 3
and 4 (Fig. 4). There should be continuity until key is
removed. If OK, go to next step. If not OK, replace
ignition switch.
(3) Check for continuity between key-in switch har-
ness connector cavity 3 (light blue wire) and cavity
for terminal 6 of buzzer module in buzzer module
connector. There should be continuity. If not OK, re-
pair circuit from switch to buzzer module as re-
quired.
Fig. 1 Buzzer Module Connector
Fig. 2 Buzzer Module Terminals
8U - 2 CHIME/BUZZER WARNING SYSTEMSJ

YJ MODELS
(1) Unplug steering column connector from instru-
ment panel wiring. Open driver's door. Check for con-
tinuity between cavity E (black/light blue wire) in
instrument panel half of steering column connector
and a good ground. There should be continuity. If
OK, go to next step. If not OK, repair circuit to driv-
er's door jamb switch as required.
(2) Insert ignition key in ignition lock cylinder.
Check for continuity between cavities E (pink wire)
and F (black wire) in steering column half of connec-
tor. There should be continuity until key is removed.
If OK, go to next step. If not OK, repair steering col-
umn wiring or replace key-in switch as required.
(3) Check for continuity between cavity F (light
blue wire) in instrument panel half of steering col-
umn connector and cavity for terminal 6 of buzzer
module in buzzer module connector. There should be
continuity. If not OK, repair circuit from switch to
buzzer module as required.
HEADLAMP SWITCH (XJ ONLY)
(1) Remove headlamp switch from instrument
panel (refer to Group 8E - Instrument Panel and
Gauges for procedure). Unplug headlamp switch con-
nector. Open driver's door. Check for continuity be-
tween headlamp switch connector cavity with light
blue wire and a good ground. There should be conti-
nuity until driver's door is closed. If OK, go to next
step. If not OK, repair circuit from headlamp switch
to driver's door jamb switch as required.
(2) Check for continuity between headlamp switch
connector cavity with pink/light blue wire and cavity
for terminal 6 of buzzer module in buzzer module
connector. There should be continuity. If OK, go to
next step. If not OK, repair circuit from headlamp
switch to buzzer module as required.
(3) Check continuity between headlamp switch ter-
minal for connector cavity with pink/light blue wire
and terminal for cavity with light blue wire. There
should be no continuity with switch in off position,
and there should be continuity with switch in park
lamps or headlamps on position. If not OK, replace
headlamp switch.
DRIVER'S SEAT BELT SWITCH
(1) Unplug seat belt switch connector on floor un-
der driver's seat riser near seat belt anchor. Check
for continuity between two cavities of seat belt half of
connector. There should be continuity with seat belt
unbuckled, and no continuity with seat belt buckled.
If OK, go to next step. If not OK, replace seat belt
buckle-half assembly.
(2) Check for continuity between cavity with black
wire in harness half of seat belt switch connector and
a good ground. There should be continuity. If OK, go
to next step. If not OK, repair circuit to ground as re-
quired.
(3) Check for continuity between cavity with light
green wire in harness half of seat belt switch connec-
tor and cavity for terminal 4 of buzzer module con-
nector. There should be continuity. If not OK, repair
circuit from seat belt switch connector to buzzer mod-
ule as required.
Fig. 3 Key-In Switch Connector
Fig. 4 Key-In Switch Continuity
JCHIME/BUZZER WARNING SYSTEMS 8U - 3

SERVICE PROCEDURES
Service procedures for components of the buzzer
system can be found in the appropriate group as fol-
lows:
²driver's door jamb switch - refer to Group 8L -
Lamps
²ignition key-in switch (XJ) - refer to Group 8D -
Ignition Systems²ignition key-in switch (YJ) - refer to Group 19 -
Steering
²headlamp switch - refer to Group 8E - Instrument
Panel and Gauges
²driver's seat belt switch - refer to Group 23 - Body
Components.
BUZZER MODULE SCHEMATIC - XJBUZZER MODULE SCHEMATIC - YJ
8U - 4 CHIME/BUZZER WARNING SYSTEMSJ

WIRING DIAGRAMSÐGENERAL INFORMATION
INDEX
page page
Circuit Identification......................... 1
Connector and Terminal Replacement........... 7
Connector Replacement..................... 6
Connectors............................... 2
Diode Replacement........................ 8
Electrostatic Discharge (ESC) Sensitive Devices . . . 2
General Information......................... 1
Intermittent and Poor Connections.............. 4
Notes, Cautions, and Warnings................ 1Symbols................................. 2
Take Outs................................ 2
Terminal Replacement....................... 8
Terminal/Connector RepairÐMolex Connectors.... 6
Troubleshooting Tests....................... 4
Troubleshooting Tools....................... 4
Troubleshooting Wiring Problems.............. 5
Wire Code Identification..................... 1
Wiring Repair............................. 6
GENERAL INFORMATION
This Group is divided into three stand alone sec-
tions; XJ, YJ, and XJ Right Hand Drive (XJ-RHD).
Separate circuit descriptions and wiring diagrams are
provided for each vehicle. Each section contains a
Contents list for the wiring diagrams and circuit de-
scriptions for that vehicle.
The complete XJ circuit descriptions and diagrams
are printed first, followed by those for the YJ and
then the XJ-RHD. The heading at the top of each
page identifies the vehicle covered in the section.
NOTES, CAUTIONS, and WARNINGS
Throughout this group additional important infor-
mation is presented in three ways; Notes, Cautions,
and Warnings.
NOTESare used to help describe how switches or
components operate to complete a particular circuit.
They are also used to indicate different conditions
that may appear on the vehicle. For example, an
up-to and after condition.
CAUTIONSare used to indicate information that
could prevent making an error that may damage the
vehicle.
WARNINGSprovide information to prevent per-
sonal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a
vehicle is being serviced.
ALWAYS WEAR SAFETY GLASSES FOR EYE PRO-
TECTION.
USE SAFETY STANDS ANYTIME A PROCEDURE RE-
QUIRES BEING UNDER A VEHICLE.
BE SURE THAT THE IGNITION SWITCH ALWAYS IS
IN THE OFF POSITION, UNLESS THE PROCEDURE
REQUIRES IT TO BE ON.SET THE PARKING BRAKE WHEN WORKING ON
ANY VEHICLE. AN AUTOMATIC TRANSMISSION
SHOULD BE IN PARK. A MANUAL TRANSMISSION
SHOULD BE IN NEUTRAL.
OPERATE THE ENGINE ONLY IN A WELL-VENTI-
LATED AREA.
KEEP AWAY FROM MOVING PARTS WHEN THE EN-
GINE IS RUNNING, ESPECIALLY THE FAN AND BELTS.
TO PREVENT SERIOUS BURNS, AVOID CONTACT
WITH HOT PARTS SUCH AS THE RADIATOR, EX-
HAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CON-
VERTER, AND MUFFLER.
DO NOT ALLOW FLAME OR SPARKS NEAR THE
BATTERY. GASES ARE ALWAYS PRESENT IN AND
AROUND THE BATTERY.
ALWAYS REMOVE RINGS, WATCHES, LOOSE
HANGING JEWELRY, AND LOOSE CLOTHING.
WIRE CODE IDENTIFICATION
Each wire shown in the diagrams contains a code
(Fig. 1) which identifies the main circuit, part of the
main circuit, gauge of wire, and color. The color is
shown as a two letter code which can be identified by
referring to the Wire Color Code Chart (Fig. 2).
CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric
code to identify the wire and its function (Fig. 3). To
identify which circuit code applies to a system, refer
to the Circuit Identification Code Chart. This chart
shows the main circuits only and does not show the
secondary codes that may apply to some models.
JWIRING DIAGRAMSÐGENERAL INFORMATION 8W - 1

CONNECTORS
Connectors shown in the diagrams are identified
using the international standard arrows for male and
female terminals (Fig. 4). A connector identifier is
placed next to the arrows to indicate the connector
number (Fig. 4).
For viewing connector pin outs, with two terminals
or greater, refer to section 8W-80. This section identi-
fies the connector by number and provides terminal
numbering, circuit identification, wire colors, and
functions.
All connectors are viewed from the terminal end un-
less otherwise specified. To find the connector location in
the vehicle refer to section 8W-90. This section uses the
connector identification number from the wiring dia-
grams to provide a figure number reference.
TAKE OUTS
The abbreviation T/O is used in the component
location section to indicate a point in which the wir-
ing harness branches out to a component.
SYMBOLS
Various symbols are used throughout the Wiring
Diagrams. These symbols can be identified by refer-
ring to the symbol identification chart (Fig. 5).
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 6) is used to indicate this. When han-
dling any component with this symbol, comply with
Fig. 1 Wire Color Code Identification
Fig. 2 Wire Color Code Chart
Fig. 3 Circuit Identification
Fig. 4 Connector Identification
8W - 2 WIRING DIAGRAMSÐGENERAL INFORMATIONJ

Fig. 5 Symbol Identification
JWIRING DIAGRAMSÐGENERAL INFORMATION 8W - 3

the following procedures to reduce the possibility of
electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
known whether the part is ESD sensitive, assume
that it is.
(1) Always touch a known good ground before han-
dling the part. This should be repeated while han-
dling the part and more frequently after sliding
across a seat, sitting down from a standing position,
or walking a distance.
(2) Avoid touching electrical terminals of the part,
unless instructed to do so by a written diagnostic
procedure.
(3) When using a voltmeter, be sure to connect the
ground lead first.
(4) Do not remove the part from its protective pack-
ing until it is time to install the part.
(5) Before removing the part from its package,
ground the package to a known good ground on the
vehicle.
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit
there are several common tools necessary. These tools
are listed and explained below.
²Jumper Wire - This is a test wire used to connect
two points of a circuit. It can be used to bypass an
open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A
LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN
A BATTERY FEED AND GROUND.
²Voltmeter - Used to check for voltage on a circuit.
Always connect the black lead to a known good
ground and the red lead to the positive side of the
circuit.
CAUTION: Most of the electrical components used
in today's vehicle are solid state. When checking
voltages in these circuits use a meter with a 10-
megohm or greater impedance.
²Ohmmeter - Used to check the resistance between
two points of a circuit. Low or no resistance in a
circuit means good continuity.CAUTION: - Most of the electrical components used
in today's vehicle are Solid State. When checking
resistance in these circuits use a meter with a 10-
megohm or greater impedance. In addition, make
sure the power is disconnected from the circuit.
Circuits that are powered up by the vehicle electrical
system can cause damage to the equipment and
provide false readings.
²Probing Tools - These tools are used for probing
terminals in connectors (Fig. 7). Select the proper size
tool from Special Tool Package 6807, and insert it into
the terminal being tested. Use the other end of the
tool to insert the meter probe.
INTERMITTENT AND POOR CONNECTIONS
Most intermittent electrical problems are caused by
faulty electrical connections or wiring. It is also pos-
sible for a sticking component or relay to cause a
problem. Before condemning a component or wiring
assembly check the following items.
²Connectors are fully seated
²Spread terminals, or terminal push out
²Terminals in the wiring assembly are fully seated
into the connector/component and locked in position
²Dirt or corrosion on the terminals. Any amount of
corrosion or dirt could cause an intermittent problem
²Damaged connector/component casing exposing the
item to dirt and moisture
²Wire insulation that has rubbed through causing a
short to ground
²Wiring broke inside of the insulation
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicle's electrical
system, use the Wiring Diagrams and study the cir-
cuit. Also refer to the Troubleshooting Wiring Prob-
lems section in this section.
TESTING FOR VOLTAGE
(1) Connect the ground lead of a voltmeter to a
known good ground (Fig. 8).
Fig. 6 Electrostatic Discharge Symbol
Fig. 7 Probing Tool
8W - 4 WIRING DIAGRAMSÐGENERAL INFORMATIONJ

(2) Connect the other lead of the voltmeter to the
selected test point. The vehicle ignition may need to
be turned ON to check voltage. Refer to the appropri-
ate test procedure.
TESTING FOR CONTINUITY
(1) Remove the fuse for the circuit being checked or,
disconnect the battery.
(2) Connect one lead of the ohmmeter to one side of
the circuit being tested (Fig. 9).
(3) Connect the other lead to the other end of the
circuit being tested. Low or no resistance means good
continuity.
TESTING FOR A SHORT TO GROUND
(1) Remove the fuse and disconnect all items in-
volved with the fuse.
(2) Connect a test light or a voltmeter across the
terminals of the fuse.
(3) Starting at the fuse block, wiggle the wiring
harness about six to eight inches apart and watch the
voltmeter/test lamp.
(4) If the voltmeter registers voltage or the test
lamp glows, there is a short to ground in that general
area of the wiring harness.
TESTING FOR A SHORT TO GROUND ON
FUSES POWERING SEVERAL LOADS
(1) Refer to the wiring diagrams and disconnect or
isolate all items on the fused circuit.
(2) Replace the blown fuse.
(3) Supply power to the fuse by turning ON the
ignition switch or re-connecting the battery.(4) Start connecting the items in the fuse circuit
one at a time. When the fuse blows the circuit with
the short to ground has been isolated.
TESTING FOR A VOLTAGE DROP
(1) Connect the positive lead of the voltmeter to the
side of the circuit closest to the battery (Fig. 10).
(2) Connect the other lead of the voltmeter to the
other side of the switch or component.
(3) Operate the item.
(4) The voltmeter will show the difference in volt-
age between the two points.
TROUBLESHOOTING WIRING PROBLEMS
When troubleshooting wiring problems there are six
steps which can aid in the procedure. The steps are
listed and explained below. Always check for non-
factory items added to the vehicle before doing any
diagnosis. If the vehicle is equipped with these items,
disconnect them to verify these add-on items are not
the cause of the problem.
(1) Verify the problem.
(2) Verify any related symptoms. Do this by per-
forming operational checks on components that are in
the same circuit. Refer to the wiring diagrams.
(3) Analyze the symptoms. Use the wiring dia-
grams to determine what the circuit is doing, where
the problem most likely is occurring and where the
diagnosis will continue.
(4) Isolate the problem area.
(5) Repair the problem.
(6) Verify proper operation. For this step, check for
proper operation of all items on the repaired circuit.
Refer to the wiring diagrams.
Fig. 8 Testing for Voltage
Fig. 9 Testing for Continuity
JWIRING DIAGRAMSÐGENERAL INFORMATION 8W - 5

WIRING REPAIR
When replacing or repairing a wire, it is important
that the correct gauge be used as shown in the wiring
diagrams. The wires must also be held securely in
place to prevent damage to the insulation.
(1) Disconnect battery negative cable.
(2) Remove 1 inch of insulation from each end of
the wire.
(3) Place a piece of heat shrink tubing over one side
of the wire. Make sure the tubing will be long enough
to cover and seal the entire repair area.
(4) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1).
(5) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11
example 2).
(6) Twist the wires together (Fig. 11 example 3).
(7) Solder the connection together using rosin core
type solder only.Do not use acid core solder.
(8) Center the heat shrink tubing over the joint,
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
(9) Secure the wire to the existing ones to prevent
chafing or damage to the insulation.
(10) Connect battery and test all affected systems.
TERMINAL/CONNECTOR REPAIRÐMOLEX
CONNECTORS
(1) Disconnect battery.
(2) Disconnect the connector from its mating half/
component.
(3) Insert the terminal releasing special tool 6742
into the terminal end of the connector (Fig. 12).(4) Using special tool 6742, release the locking fin-
gers on the terminal (Fig. 13).
(5) Pull on the wire to remove it from the connec-
tor.
(6) Repair or replace the connector or terminal as
necessary.
CONNECTOR REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector that is to be repaired
from its mating half/component.
(3) Remove connector locking wedge, if required
(Fig. 14).
(4) Position the connector locking finger away from
the terminal using the proper pick from special tool
kit 6680. Pull on the wire to remove the terminal
from the connector (Fig. 15, and Fig. 16).
Fig. 10 Testing for Voltage DropFig. 11 Wire Repair
Fig. 12 Molex Connector Repair
8W - 6 WIRING DIAGRAMSÐGENERAL INFORMATIONJ