windshield wipers CHRYSLER CARAVAN 2002 User Guide

FRONT WASHER PUMP
MOTOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the washer hose at the in-line con-
nector forward of the cowl grille so that the in-line
connector remains with the washer hose from the
fresh air plenum.
(4) Disconnect the washer hose from the hose clip
located on the front fender side shield.
(5) Remove the filler tube screw.
(6) Hoist and support vehicle on hoist or jack
stands.
(7) Remove the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - REMOVAL).
(8) Disconnect the left right front wheelhouse
splash shield and move aside (Refer to 23 - BODY/
EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(11) Remove the two reservoir mounting screws.
(12) Disconnect the reservoir from the body mount
by raising the reservoir upward slightly and then
down so that the reservoir filler neck and front
washer hose pull through the opening in the front
fender side shield.
(13) Remove pump from reservoir by pulling pump
upper retention tab away from reservoir cavity and
then lifting pump up from mounting grommet. Do
not damage reservoir/pump sealing surface or punc-
ture reservoir during removal.
(14) Remove pump grommet and discard.
INSTALLATION
(1) Use new grommet when installing a new pump
assembly.
(2) Assure pump upper retention tab is pressed
into reservoir slot and that pump is rotated flatagainst the reservoir and that pump connector is fac-
ing up in the fully seated position. Assure the pump
is aligned to and fully seated in the reservoir cavity.
(3) Push filler neck and front washer hose through
the opening in the front fender side shield. Connect
the reservoir to the body mount by lowering the res-
ervoir down.
(4) Install the two reservoir mounting screws.
Torque screws to 8.5 - 11.3 N´m (75 - 100 in. lbs.).
(5) Connect the electrical body harness connectors
to the washer pump motors and the fluid level sen-
sor. Slide the red lock on the connector to the closed
or locked position.
(6) Assure that washer hose is properly routed to
prevent pinching and possible inoperative washers.
(7) Connect the left right front wheelhouse splash
shield and move aside (Refer to 23 - BODY/EXTERI-
OR/WHEELHOUSE SPLASH SHIELD - INSTALLA-
TION).
(8) Install the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - INSTALLATION).
(9) lower vehicle from hoist or jack stands.
(10) Install the filler tube screw. Torque screw to
8.5 - 11.3 N´m (75 - 100 in. lbs.).
(11) Connect the washer hose to the hose clip
located on the front fender side shield.
(12) Connect the washer hose at the in-line con-
nector forward of the cowl grille.
(13) Install the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(14) Connect the battery negative cable.
(15) Verify system operation.
FRONT WIPER ARMS
STANDARD PROCEDURE - FRONT WIPER ARM
ALIGNMENT
(1) Verify wiper blade element condition and wiper
arm spring tension. Run wipers in low speed mode
while applying water to the windshield. Observe the
wiper blade that is chattering or skipping across the
windshield. If the wiper element is not rolling over
when the wiper direction reverses, align the wiper
arm. The extension bar portion of the wiper arm
must be twisted in the proper direction to allow the
wiper element to roll over when the direction
reverses.
(2) Place two small adjustable wrenches placed 50
mm (2 in.) apart on the wiper arm extension rod.
(3) Twist the extension rod slightly in the opposite
direction that the element is laying on the wind-
shield while holding the wrench closest to the pivot
stationary.
RSWIPERS/WASHERS8R-9
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(4) Repeat Step 1, and align as necessary until
wiper stops chattering and wipes the windshield
clear.
REMOVAL
CAUTION: The driver side wiper arm must be
parked above the passenger side. Failure to do so
will result in damage to the arms, blades or system.
(1) Lift the arm cap upward.
(2) Remove the nut holding wiper arm to the wiper
pivot.
(3) Using a suitable two jaw puller, separate the
wiper arm from the wiper pivot (Fig. 1).
INSTALLATION
(1) Verify that the wiper motor and linkage are in
the park position.
(2) Place the wiper arm in position over the wiper
pivot (Fig. 2).
(3) Install the nut to hold the wiper arm to the
wiper pivot. Torque nut to 35 N´m (26 ft. lbs.).
CAUTION: It is important to torque the wiper arm
nut properly to insure that the wiper arm head does
not strip and damage the arm, blade, and pivot of
both wiper arms.
(4) Push the arm cap cover down.
FRONT WIPER MOTOR
REMOVAL
(1) Remove the front wiper motor from vehicle
(Refer to 8 - ELECTRICAL/WIPERS/WASHERS/
WIPER MODULE - REMOVAL).
(2) Remove four backwall bolts and four brace
nuts.
(3) Remove wiper linkage from wiper module.
(4) Disconnect wire connectors from back of wiper
motor.
(5) Remove wiper linkage from motor crank. DO
NOT remove crank from motor.
(6) Remove bolts holding wiper motor and remove
motor.
INSTALLATION
(1) Place wiper module on a suitable work surface.
(2) Install wiper linkage into wiper unit.
(3) Connect wire connectors to wiper motor.
(4) Place the wiper module into engine compart-
ment and connect wiper module wire connector to
engine wire harness (Fig. 10).
(5) Install the four backwall bolts and four brace
nuts to wiper module.
(6) Operate wiper motor and verify that the wiper
motor parks when wiper switch is turned OFF.
Fig. 1 WIPER ARM REMOVAL
1 - WASHER NOZZLE
2 - HOOD
3 - COWL COVER
4 - WINDSHIELD
5 - TWO JAW PULLER
6 - ARM CAP
7 - WINDSHIELD WIPER ARM
Fig. 2 WIPER ARM ADJUSTMENT
1 - WIPER BLADES
2 - WINDSHIELD
3 - WASHER NOZZLES
4 - WIPER ARMS
8R - 10 WIPERS/WASHERSRS
FRONT WIPER ARMS (Continued)
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HEADLAMP WASHERS -
EXPORT
DESCRIPTION
The headlamp washers (Fig. 3) work in conjunction
with the windshield washers. The headlamp washers
are enabled with the headlamps ON and the wind-
shield washers activated. With the windshield wash-
ers activated, the headlamp washers will spray twice
for a predetermined amount of time.
OPERATION
The headlamp washer system utilizes a separate
high pressure pump that is attached to the wind-
shield washer reservoir. The headlamp washer pump
feeds nozzles that are mounted in the front fascia of
the vehicle. The nozzle bodies have a telescopic
action that will extend the nozzles in front of the
headlamp assembly. These nozzles spray the head-
lamps when the system is activated.
To activate the headlamp washers, turn ON the
headlamps and them press the windshield washer
control knob (Fig. 4). The switch sends an input to
the Body Control Module (BCM), and then the BCM
will signal the windshield washers to operate and
direct two timed high pressure sprays onto the head-
lamp lens. When the criteria is met to activate the
headlamp washers (headlamps ON and windshield
washer control depressed), the headlamp washerswill spray its two timed pulses every fourth request
from the washer control.
DIAGNOSIS AND TESTING - HEADLAMP
WASHERS - EXPORT
The headlamp washer pump pick-up is located
above the low washer fluid level sensor. First of all
check the fluid level in the reservoir.
(1) Check fuse #30 for continuity. If no continuity,
go to Step 3.
(2) If the headlamp washers do not pop up when a
headlamp wash is requested, disconnect the head-
lamp washer hose. To disconnect the headlamp
washer hose, push down on the latch at any connec-
tor with slight force and pull apart. When reattach-
ing, push till you hear a snap. With a regulated 20
psi of air pressure, apply it to the washer hose. The
headlamp washers should pop up out of the front fas-
cia. If not, check for leaks/connections in the hose.
WARNING: IF MORE THAN 20 PSI IS APPLIED TO
THE WASHER HOSE, WASHER FLUID MAY SPRAY
OUT OF THE HEADLAMP WASHER. WEAR SAFETY
GLASSES AND DO NOT HAVE AIMING DIRECTLY
TOWARD FACE.
(3) If the hose and washer spray assembly are OK,
check the washer pump for ground and 12v power
during a washer request. If defective, repair circuit
as necessary.
Fig. 3 HEADLAMP WASHER LOCATION
Fig. 4 WINDSHIELD WASHER CONTROL
RSWIPERS/WASHERS8R-11
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(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the rear washer pump hose from
washer pump.
(11) Disconnect the high pressure headlamp
washer pump hose by pressing down firmly on latch
and pulling hose off.
(12) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(13) Remove the two reservoir mounting screws.
(14) Disconnect the reservoir from the body mount
by raising the reservoir upward slightly and then
down so that the reservoir filler neck and front
washer hose pull through the opening in the front
fender side shield.
(15) Remove pump from reservoir by pulling pump
up and away from reservoir cavity and out of mount-
ing grommet. Do not damage reservoir/pump sealing
surface or puncture reservoir during removal.
(16) Remove pump grommet and discard.
INSTALLATION
(1) Use new grommet when installing a new pump
assembly.
(2) Assure pump upper retention tab is pressed
into reservoir slot and assure the pump is aligned to
and fully seated in the reservoir cavity.
(3) Push filler neck and front washer hose through
the opening in the front fender side shield. Connect
the reservoir to the body mount by lowering the res-
ervoir down.
(4) Install the two reservoir mounting screws.
Torque screws to 8.5 - 11.3 N´m (75 - 100 in. lbs.).
(5) Connect the electrical body harness connectors
to the washer pump motors and the fluid level sen-
sor. Slide the red lock on the connector to the closed
or locked position.
(6) Connect front and rear washer pump hoses and
assure that they are properly routed to prevent
pinching and possible inoperative washers.
(7) Connect the high pressure headlamp washer
hose by firmly pushing hose onto inlet until a snap is
heard.
(8) Connect the left right front wheelhouse splash
shield and move aside (Refer to 23 - BODY/EXTERI-
OR/WHEELHOUSE SPLASH SHIELD - INSTALLA-
TION).(9) Install the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - INSTALLATION).
(10) lower vehicle from hoist or jack stands.
(11) Install the filler tube screw. Torque screw to
8.5 - 11.3 N´m (75 - 100 in. lbs.).
(12) Connect the washer hose to the hose clip
located on the front fender side shield.
(13) Connect the washer hose at the in-line con-
nector forward of the cowl grille.
(14) Install the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(15) Connect the battery negative cable.
(16) Verify vehicle and system operation.
REAR WASHER PUMP MOTOR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the washer hose at the in-line con-
nector forward of the cowl grille so that the in-line
connector remains with the washer hose from the
fresh air plenum.
(4) Disconnect the washer hose from the hose clip
located on the front fender side shield.
(5) Remove the filler tube screw.
(6) Hoist and support vehicle on hoist or jack
stands.
(7) Remove the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - REMOVAL).
(8) Disconnect the left right front wheelhouse
splash shield and move aside (Refer to 23 - BODY/
EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(11) Remove the two reservoir mounting screws.
8R - 14 WIPERS/WASHERSRS
HEADLAMP WASHER PUMP MOTOR - EXPORT (Continued)
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(6) Hoist and support vehicle on hoist or jack
stands.
(7) Remove the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - REMOVAL).
(8) Disconnect the left right front wheelhouse
splash shield and move aside (Refer to 23 - BODY/
EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(11) Remove the two reservoir mounting screws.
(12) Disconnect the reservoir from the body mount
by raising the reservoir upward slightly and then
down so that the reservoir filler neck and front
washer hose pull through the opening in the front
fender side shield.
(13) Remove the sensor from reservoir by using a
side foot to gently pry the sensor from the body of
the reservoir. Do not damage the reservoir/sensor
sealing surface or puncture reservoir during removal.
CAUTION: To avoid damage to the sensor, assure
the reservoir is in an upright position before remov-
ing the sensor from the reservoir. Do not rotate the
sensor during removal.
INSTALLATION
(1) Use a new grommet when installing a new sen-
sor assembly.
(2) Assure that the flat of the sensor is aligned
under the ridge of the reservoir and that the sensor
connector is facing down in the fully seated position.
This will allow for proper operation of the sensor
float switch.
(3) Push filler neck and front washer hose through
the opening in the front fender side shield. Connect
the reservoir to the body mount by lowering the res-
ervoir down.
(4) Install the two reservoir mounting screws.
Torque screws to 8.5 - 11.3 N´m (75 - 100 in. lbs.).(5) Connect the electrical body harness connectors
to the washer pump motors and the fluid level sen-
sor. Slide the red lock on the connector to the closed
or locked position.
(6) Assure that washer hose is properly routed to
prevent pinching and possible inoperative washers.
(7) Connect the left right front wheelhouse splash
shield and move aside (Refer to 23 - BODY/EXTERI-
OR/WHEELHOUSE SPLASH SHIELD - INSTALLA-
TION).
(8) Install the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - INSTALLATION).
(9) lower vehicle from hoist or jack stands.
(10) Install the filler tube screw. Torque screw to
8.5 - 11.3 N´m (75 - 100 in. lbs.).
(11) Connect the washer hose to the hose clip
located on the front fender side shield.
(12) Connect the washer hose at the in-line con-
nector forward of the cowl grille.
(13) Install the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(14) Connect the battery negative cable.
(15) Verify system operation.
WASHER HOSES
REMOVAL
(1) Remove washer reservoir from vehicle (Refer to
8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - REMOVAL).
(2) Disconnect washer hose front the reservoir cav-
ity.
(3) Disconnect the washer hose from the reservoir
pump.
(4) Remove parts as necessary to replace washer
hose (engine compartment, interior components, etc.).
INSTALLATION
(1) Install parts as necessary to after replacing
washer hose (engine compartment, interior compo-
nents, etc.).
(2) Connect the washer hose to the reservoir
pump.
(3) Connect washer hose to the reservoir cavity.
(4) Install the washer reservoir into vehicle (Refer
to 8 - ELECTRICAL/WIPERS/WASHERS/WASHER
RESERVOIR - INSTALLATION).
RSWIPERS/WASHERS8R-17
WASHER FLUID LEVEL SWITCH (Continued)
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WASHER RESERVOIR
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the washer hose at the in-line con-
nector forward of the cowl grille so that the in-line
connector remains with the washer hose from the
fresh air plenum.
(4) Disconnect the washer hose from the hose clip
located on the front fender side shield.
(5) Remove the filler tube screw.
(6) Hoist and support vehicle on hoist or jack
stands.
(7) Remove the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - REMOVAL).
(8) Disconnect the left right front wheelhouse
splash shield and move aside (Refer to 23 - BODY/
EXTERIOR/WHEELHOUSE SPLASH SHIELD -
REMOVAL).
(9) Drain washer fluid from the reservoir and into
a suitable clean container. This can be done by dis-
connecting the windshield washer hose from the
front (outboard) washer pump and allowing the
washer fluid to drain into a container through a tem-
porary jumper hose connected to the front washer
pump.
(10) Disconnect the electrical body harness connec-
tors to the washer pump motors and the fluid level
sensor. Slide the red lock on the connector to the
release position, then, depress the black tab and pull
the connector off the pump or sensor.
(11) Remove the two reservoir mounting screws.
(12) Disconnect the reservoir from the body mount
by raising the reservoir upward slightly and then
down so that the reservoir filler neck and front
washer hose pull through the opening in the front
fender side shield.
INSTALLATION
(1) Push filler neck and front washer hose through
the opening in the front fender side shield. Connect
the reservoir to the body mount by lowering the res-
ervoir down.
(2) Install the two reservoir mounting screws.
Torque screws to 8.5 - 11.3 N´m (75 - 100 in. lbs.).
(3) Connect the electrical body harness connectors
to the washer pump motors and the fluid level sen-
sor. Slide the red lock on the connector to the closed
or locked position.
(4) Assure that washer is properly routed to pre-
vent pinching and possible inoperative washers.(5)
Connect the left right front wheelhouse splash
shield and move aside (Refer to 23 - BODY/EXTERIOR/
WHEELHOUSE SPLASH SHIELD - INSTALLATION).
(6) Install the right front wheel and tire assembly
(Refer to 22 - TIRES/WHEELS - INSTALLATION).
(7) lower vehicle from hoist or jack stands.
(8) Install the filler tube screw. Torque screw to 8.5
- 11.3 N´m (75 - 100 in. lbs.).
(9) Connect the washer hose to the hose clip
located on the front fender side shield.
(10) Connect the washer hose at the in-line con-
nector forward of the cowl grille.
(11) Install the engine fresh air housing inside the
engine compartment (Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(12) Connect the battery negative cable.
(13) Verify system operation.
WIPER BLADES
REMOVAL
(1) Lift the wiper arm away from the glass.
(2) Disengage the release tab holding the wiper
blade to the wiper arm and remove the wiper blade
from the wiper arm (Fig. 8) and (Fig. 9).
Fig. 8 WINDSHIELD WIPER BLADE
1 - RELEASE TAB
Fig. 9 REAR WIPER
1 - WIPER ARM
2 - BLADE LATCH
8R - 18 WIPERS/WASHERSRS
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CLEANING
Wiper blades exposed to the weather for a long
period of time tend to lose their wiping effectiveness.
Periodic cleaning of the wiper blade is recommended
to remove the accumulation of salt and road grime.
The wiper blades, arms and windshield should be
cleaned with a sponge or cloth and a mild detergent
or nonabrasive cleaner. If the wiper blades continue
to streak or smear, they should be replaced. The
wiper blade should run smoothly across the wind-
shield in both directions. The wiper blade should
slightly roll over center when the blade reverses
direction. A wiper blade insert that has lost flexibility
or a wiper arm that has lost spring tension, will
cause the blade to skip or chatter across the wind-
shield. If the wiper blades are new and the wiper
arm spring tension is OK and a chattering sound is
emitted from the wiper(s), the wiper blade is not roll-
ing over center. If this condition exists, (refer to 8 -
ELECTRICAL/WIPERS/WASHERS/WIPER ARMS -
ADJUSTMENTS).
INSTALLATION
(1) Position the blade onto the arm.
(2) Engage the blade to the retainer by pulling up
on the blade until the tabs snap into position (Fig. 8).
WIPER LINKAGE
REMOVAL
(1) Remove the front windshield wiper unit from
vehicle (Refer to 8 - ELECTRICAL/WIPERS/WASH-
ERS/WIPER MODULE - REMOVAL).
(2) Place the wiper unit on a suitable work sur-
face.
(3) Remove nuts holding the cowl cover brackets to
the wiper unit.
(4) Remove cowl cover brackets from the wiper
unit.
(5) Remove nuts holding linkage to the wiper unit.
(6) Remove the wiper linkage from the wiper unit.
(7) Disconnect the wire connectors from back of
the wiper motor.
INSTALLATION
(1) Connect the wire harness connector.
(2) Install the linkage on the wiper unit.
(3) Install the nut holding the linkage to the wiper
unit.
(4) Install the cowl cover brackets to the wiper
nut.
(5) Install the front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).(6) Install the cowl cover.
(7) Install the wiper arms and blades.
WIPER MODULE
REMOVAL
(1) Release the hood latch and open hood.
(2) Disconnect and isolate the battery negative
cable.
(3) Remove the wiper arms.
(4) Remove the cowl cover (Refer to 23 - BODY/
EXTERIOR/COWL GRILLE - REMOVAL).
(5) Disconnect the positive lock on the wiper mod-
ule wire connector (Fig. 10).
(6) Disconnect the wiper module wire connector
from the engine compartment wire harness.
(7) Disconnect the windshield washer hose from
coupling outside the module.
(8) Disconnect the drain tubes from nipples on bot-
tom of the wiper module.
(9) Remove nuts holding wiper module to lower
windshield fence.
(10) Remove bolts holding the wiper module to the
dash panel (Fig. 11).
(11) Lift wiper module from weld-studs on lower
windshield fence.
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(12) Remove wiper module.
Fig. 10 WIPER MODULE WIRE CONNECTOR
1 - WIPER SYSTEM WIRE CONNECTOR
2 - LOCK TAB
3 - POSITIVE LOCK
4 - WIPER MODULE
RSWIPERS/WASHERS8R-19
WIPER BLADES (Continued)
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INSTALLATION
(1) Position the wiper module into the cowl.
(2) Install the bolts that secure the wiper module
to the dash (Fig. 11).
(3) Install the nuts that retain the wiper module.
(4) Connect the drain tubes to the nipples on the
wiper module.
(5) Connect the windshield washer tube.
(6) Connect the wire harness connector to the
wiper module (Fig. 11).
(7) Connect the positive lock on the wiper module
wire connector (Fig. 10).
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(8) Install the cowl cover (Refer to 23 - BODY/EX-
TERIOR/COWL GRILLE - INSTALLATION).
(9) Install the wiper arms and blades.
(10) Connect the battery negative cable.
(11) Close the hood.
Fig. 11 WIPER MODULE
1 - BOLT
2 - NUTS
3 - BOLT
4 - WIPER MODULE
5 - WINDSHIELD
8R - 20 WIPERS/WASHERSRS
WIPER MODULE (Continued)
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SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS
ACCESSORY RELAY
DESCRIPTION
The accessory relay is an electromechanical device
that switches fused battery current to the accessory
powered vehicle circuits when the ignition switch is
turned to the Accessory or On positions. The delay
feature will maintain power to the accessories for 45
seconds after the ignition is shut off or until a door is
opened. This allows sufficient time to close windows
and park the windshield wipers. The accessory relay
is located in the Integrated Power Module (IPM) in
the engine compartment.
The accessory relay is a International Standards
Organization (ISO) relay. Relays conforming to the
ISO specifications have common physical dimensions,
current capacities, terminal patterns, and terminal
functions.
The accessory 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 movable)
electrical contacts. The movable (common feed) relay
contact is held against one of the fixed contacts (normal-
ly closed) by spring pressure. When the electromagnetic
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
DIAGNOSIS & TESTING - ACCESSORY RELAY
The accessory relay (Fig. 1) is located in the Inte-
grated Power Module (IPM), in the engine compart-
ment. For complete circuit diagrams, refer toWiring
Diagrams.
(1) Remove the accessory relay from the IPM.
Refer toAccessory Relayin the Removal and
Installation section of this group for the procedure.
(2) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.
(3) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 75   5 ohms. If OK, go to Step
4. If not OK, replace the faulty relay.
(4) Connect a battery to terminals 85 and 86.
There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.
DIAGNOSIS & TESTING - RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) of
the IPM is connected to battery voltage and should
be hot at all times. Check for battery voltage at the
fused B(+) circuit cavity in the IPM receptacle for the
accessory relay. If OK, go to Step 2. If not OK, repair
the fused B(+) circuit to the IPM fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the IPM that feeds the
accessories when the relay is energized by the igni-
tion switch. There should be continuity between the
IPM cavity for relay terminal 87 and the fused B(+)
fuse in the IPM at all times. If OK, go to Step 4. If
not OK, repair the open fused B(+) circuit to the IPM
fuse as required.
Terminal Pick Kit 6680
Fig. 1 Accessory Relay
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER DISTRIBUTION SYSTEM (Continued)
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COWL GRILLE
REMOVAL
(1) Remove wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS -
REMOVAL)
(2) Remove four (4) screws securing cowl cover to
wiper module (Fig. 6).
(3) Disengage quarter turn fasteners at outboard
ends of cowl grill from body.
(4) Release hood latch and open hood.
CAUTION: To prevent hood scratching of cowl grille
before removal, cover outboard exterior ends of
cowl grille with masking tape or equivalent method.
NOTE: Do not over bend cowl grille during removal.
Bend cowl grille just enough to clear top of wiper
pivot shaft and bottom rear corner of hood.
(5) Remove cowl grill by raising above driver side
wiper pivot shaft and swinging away towards engine
compartment. The cowl grille will need to be bent on
outboard end to clear simultaneously top of wiper
pivot shaft and bottom corner of hood.
(6) Close hood. Do not latch. Remove outboard
screws. (Fig. 7).
(7) Disconnect washer hose in line connector.
(8) Disconnect washer hose and grommet from
hole in wiper module and pull out.
(9) Remove cowl grille by raising over opposite
wiper pivot shaft and removing away from vehicle.
(10) Remove cowl cover from vehicle.
INSTALLATION
(1) Reverse removal procedure.
(2) When installing cowl cover over wiper module,
make sure fore aft locator on the underside of cowl
grill seat into the locator grooves on top of wiper
module.
(3) Star all cowl grille mounting screws by hand
before torquing to specifications.
(4) Assure washer hose is properly routed and not
pinched.
(5) Center cowl grille to body and windshield.
(6) Assure ªarrowº indicator head of quarter turn
fasteners is pointing toward windshield.
(7) Tighten screw to 1.2 N´m (11 in. lbs.) torque.
(8) Install the wiper arms. (Refer to 8 - ELECTRI-
CAL/WIPERS/WASHERS/WIPER ARMS - INSTAL-
LATION)
(9) Check for proper spray pattern from washer
nozzles.
EXTERIOR NAME PLATES -
TAPE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) Using a nonmetallic prying device, such as a
plastic or wood trim stick gently pry up at corners
and remove.Fig. 6 COWL COVER
1 - COWL COVER
2 - WIPER PIVOT
3 - WASHER HOSES
4 - HOOD
Fig. 7 COWL COVER RETAINERS
1 - SCREW
2 - WINDSHIELD
3 - COWL COVER
4 - FRONT FENDER
23 - 50 EXTERIORRS
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