wiring diagram CHRYSLER CARAVAN 2002 Owner's Manual

²Heated Seat Switch- Two heated seat
switches are used per vehicle, one for the driver and
one for the passenger side front seats. The switches
are mounted to in the instrument panel center stack.
Refer to the description of the heated seat switch
later in this section for additional information.
Hard wired circuitry connects the heated seat sys-
tem components to each other through the electrical
system of the vehicle. These hard wired circuits are
integral to several wire harnesses, which are routed
throughout the vehicle and retained by many differ-
ent methods. These circuits may be connected to each
other, to the vehicle electrical system and to the
heated seat system components through the use of a
combination of soldered splices and splice block con-
nectors. Refer to Wiring for complete system wiring
schematics. The wiring information also includes the
proper wire and connector repair procedures, further
details on wire harness routing and retention, as well
as pin-out and location views for the various wire
harness connectors, splices and grounds.
OPERATION
The heated seat system components operate on
battery current received through a fuse in the Inte-
grated Power Module (IPM) on a fused ignition
switch output (run-acc) circuit so that the system willonly operate when the ignition switch is in the On or
Accessory positions. The heated seat system will be
turned Off automatically whenever the ignition
switch is turned to any position except On or Acces-
sory. Also, the heated seat system will not operate
when the surface temperature of the seat cushion
cover at either heated seat sensor is above the
designed temperature set points of the system. The
heated seat system has a self-diagnostic capability.
When certain failures are detected within the heated
seat system, the system will provide a visual indica-
tion of the failure by flashing the Light Emitting
Diode (LED) indicator lamps located in the heated
seat switches. See the owner's manual in the vehicle
glove box for more information on the features, use
and operation of the heated seat system.
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM
Refer toWiring Diagramsfor complete wiring
schematics. The wiring information also includes the
proper wire and connector repair procedures, further
details on wire harness routing and retention, as well
as pin-out and location views for the various wire
harness connectors, splices and grounds.
HEATED SEAT SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO HEATED SEAT SWITCH
ILLUMINATION WITH
IGNITION ON (SYSTEM ON)1. Faulty fuse 1. Check heated seat fuse in Integrated Power
Module. Replace fuse, repair short if required.
2. Faulty components 2. Refer to individual Heated Seat System
components for the proper diagnosis and testing
procedures.
3. Ground faulty 3. Check for ground at heated seat switch and
module. Repair, if required.
4. Wiring faulty 4. Check fused ignition switch output (run-acc)
circuits at switch and module. Repair, if required.
8G - 8 HEATED SEAT SYSTEMRS
HEATED SEAT SYSTEM (Continued)
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DRIVER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 2). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switch
assembly that also includes the hazard, rear window
wiper and washer switches. The heated seat switches
provide a resistor multiplexed signal to the Heated
Seat Module (HSM) through separate hard wired cir-
cuits. Each switch has an Off, Low, and High position
so that both the driver and the front seat passenger
can select a preferred seat heating mode. Each
switch has two Light-Emitting Diodes (LED) which
light to indicate that the heater for the seat is turned
on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
OPERATION
There are three positions that can be selected with
each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
depressed, the Low position is selected and the low
position LED indicator illuminates. When the right
side of the switch rocker is fully depressed, the High
position is selected and the high position LED indi-cator illuminates. When the switch rocker is moved
to its neutral position (middle), Off is selected and
both LED indicators are extinguished.
Both switches provide separate resistor multi-
plexed hard wire inputs to the Heated Seat Module
(HSM) to indicate the selected switch position. The
heated seat module responds to the heated seat
switch status messages by controlling the output to
the seat heater elements of the selected seat. The
Low heat position set point is about 36É C (97É F),
and the High heat position set point is about 41É C
(105É F).
DIAGNOSIS AND TESTING - DRIVER HEATED
SEAT SWITCH
For complete circuit diagrams, refer toWiring
Diagrams.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, SEAT 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.
CHECKING SWITCH SIGNAL AND WIRING AT THE
MODULE
(1) Disconnect and isolate the battery negative
cable.
(2) Access and disconnect the gray 4-way connector
from the heated seat module. Visually inspect wiring
terminals for damage that would prevent positive
connection. If not OK, repair or replace the necessary
components.
(3) Reconnect the negative battery cable and Turn
heated seat ON in the LO position. Using an Ohm-
meter, check the resistance between cavities 2 and 3
of the gray connector noted above. Resistance should
be about 3.5 kiloohms (3500 ohms). If not OK, check
resistance directly at switch, as noted below. If OK,
proceed. If NOT OK replace the switch or faulty wir-
ing.
(4) Turn heated seat ON in the HI position. Using
an Ohmmeter, check the resistance between cavities
2 and 3 of the gray connector noted above. Resistance
should be about 1.4 kiloohms (1400 ohms). If not OK,
check resistance directly at switch, as noted below. If
OK, proceed. If NOT OK replace the switch or faulty
wiring.
(5) With the system ON in the HI position, Check
for battery voltage and ground at cavities 4 and 1. If
OK, proceed with testing remaining components. If
NOT OK, repair open or wiring short.
Fig. 2 HEATED SEAT SWITCH LOCATION
1 - HEATED SEAT SWITCHES
RSHEATED SEAT SYSTEM8G-9
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(2) Install and tighten the three screws that secure
the heated seat switch to the back of the instrument
panel center bezel. Tighten the screws to 1.5 N´m (13
in. lbs.) (Fig. 4).
(3) Install the center bezel onto the instrument
panel. Refer toInstrument Panel Center Bezelin
the Body section for the procedure.
(4) Reconnect the battery negative cable.
HEATED SEAT ELEMENT
DESCRIPTION
The heated seat system includes two seat heating ele-
ments in each front seat, one for the seat cushion and
the other for the seat back. The two elements for each
seat that are connected in series with the Heated Seat
Module (HSM). The temperature sensor is a Negative
Temperature Coefficient (NTC) thermistor. One temper-
ature sensor is used for each seat, and it is located on
the seat cushion heating element for all models.
The seat heating elements are sewn into the seat
cushion cover trim and seat back cover trim units.
The heated seat elements and the temperature sen-
sor cannot be adjusted or repaired and, if faulty or
damaged, the seat element assembly must be
replaced. Refer to the procedure in this section.
OPERATION
The heated seat elements resist the flow of electrical
current. When battery current is passed through the
elements, the energy lost by the resistance of the ele-
ments to the current flow is released in the form of
heat. The temperature sensor is a NTC thermistor.
When the temperature of the seat cushion cover rises,
the resistance of the sensor decreases. The heated seat
module supplies a five-volt current to one side of each
sensor, and monitors the voltage drop through the
sensor on a return circuit. The heated seat module
uses this temperature sensor input to monitor the
temperature of the seat, and regulates the current
flow to the seat heating elements accordingly.
DIAGNOSIS AND TESTING - HEATED SEAT
ELEMENTS
The wire harness connectors for the seat cushion and
seat back heating elements are located under the seat,
at the heated seat module. For circuit descriptions and
diagrams, refer to section 8W, Wiring Diagrams.
In order to access and test the heated seat ele-
ments it will be necessary to remove the appropriate
front seat retaining bolts and lay the seat rearward,
up against one of the rear seats. It is not necessary
to disconnect the seat electrical connectors, just use
care not to damage the attached wire harnesses
while testing.NOTE: WHEN CHECKING HEATED SEAT ELE-
MENTS FOR CONTINUITY, BE CERTAIN TO MOVE
THE HEATING ELEMENT BEING CHECKED. MOV-
ING THE ELEMENT, SUCH AS SITTING IN THE SEAT
WILL ELIMINATE THE POSSIBILITY OF AN INTER-
MITTENT OPEN IN THE ELEMENT WHICH WOULD
ONLY BE EVIDENT IF THE ELEMENT WAS MOVED
IN A CERTAIN DIRECTION. FAILURE TO CHECK
THE ELEMENT IN VARIOUS POSITIONS COULD
RESULT IN AN INCOMPLETE TEST.
SEAT CUSHION ELEMENT
(1) From under the vehicle, remove the appropri-
ate seats four retaining nuts.
(2) From inside the vehicle, pull the seat up, off
the mounting studs and lay it back, up against one of
the rear seats.
(3) Locate the heated seat module, attached to the
bottom of the seat cushion pan. Remove the heated
seat module from the seat cushion pan. Do not dis-
connect the electrical connectors at this time.
(4) Locate the green 4-way electrical connector,
connected to the heated seat module. Disconnect the
green 4-way connector from the heated seat module.
(5) Check for continuity between the two outboard
circuit cavities of the wire harness connector (Pins
1&4). There should be continuity. If OK, refer to
Heated Seat Module Diagnosis and Testing in the
Electronic Control Modules section of the service
manual for complete system testing procedures. If
not OK, install a replacement heated seat cushion
element. Refer to the procedure in this section.
SEAT BACK ELEMENT
(1) From under the vehicle, remove the appropri-
ate seats four retaining nuts.
(2) From inside the vehicle, pull the seat up and
off the mounting studs and lay it back, up against
one of the rear seats.
(3) Locate the heated seat module, attached to the
bottom of the seat cushion pan. Remove the heated
seat module from the seat cushion pan. Do not dis-
connect the electrical connectors at this time.
(4) Locate the gray 2-way electrical connector, con-
nected to the heated seat module. Disconnect the
2-way connector from the heated seat module.
(5) Check for continuity between the two circuit
cavities of the 2-way wire harness connector. There
should be continuity. If OK, refer to Heated Seat
Module Diagnosis and Testing in the Electronic Con-
trol Modules section of the service manual for com-
plete system testing procedures. If not OK, install a
replacement heated seat back element. Refer to the
procedure in this section.
RSHEATED SEAT SYSTEM8G-11
DRIVER HEATED SEAT SWITCH (Continued)
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REMOVAL
Do not remove the OEM heating element from the
seat or seat back cushion/trim covers. The original
element is permanently attached and cannot be
removed without permanent damage. The service
replacement heating element is designed to be
applied directly on the seat cushion.
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the appropriate seat cushion or seat
back trim cover. Refer to the Body section of the ser-
vice manual for the procedures.
(3) Disconnect the inoperative heated seat cushion
or seat back element electrical connectors.
(4) Locate the wires leading from the inoperative
heating element and cut them off flush with the edge
of the original heating element.
INSTALLATION
(1) Peel off the adhesive backing on the back of the
replacement heating element and stick directly on
the foam cushion.
CAUTION: During the installation of the replace-
ment heating element, be careful not to fold or
crease the element assembly. Folds or creases will
cause premature failure.
(2) Connect the new heating element electrical
connectors (Fig. 5).
(3) Connect the negative battery cable.
(4) Verify heated seat system operation.
(5) Install the appropriate seat cushion or seat
back trim cover. Make certain the seat wire harness
is correctly routed through the seat and seat back.
The excess wire between the cushion and back ele-
ments should be securely tucked between the rear of
the cushion foam and the rear carpet flap of the trim
cover.
HEATED SEAT SENSOR
DESCRIPTION
Two heated seat sensors are used per vehicle, one
in each front seat cushion heating element. The
heated seat temperature sensor is a Negative Tem-
perature Coefficient (NTC) thermistor.
The heated seat sensors cannot be repaired or
adjusted and if found to be faulty, the complete
heated seat cushion element must be replaced.
OPERATION
The temperature sensor is a NTC thermistor.
When the temperature of the seat cushion cover
rises, the resistance of the sensor decreases. The
heated seat module supplies a five-volt current to one
side of each sensor, and monitors the voltage drop
through the sensor on a return circuit. The heated
seat module uses this temperature sensor input to
monitor the temperature of the seat, and regulates
the current flow to the seat heating elements accord-
ingly.
DIAGNOSIS AND TESTING - HEATED SEAT
SENSOR
For complete circuit diagrams, refer toWiring
Diagrams.
(1) Disconnect and isolate the battery negative
cable. Disconnect the green 4-way heated seat mod-
ule wire harness connector.
(2) Using an ohmmeter, check the resistance
between cavities 2 and 3. The sensor resistance
should be between 2 kilohms at 15É C (60É F) and 50
kilohms at 30É C (85É F). If not OK, replace the
faulty seat element and sensor assembly.
Fig. 5 HEATING ELEMENT INSTALLED - TYPICAL
1 - SEAT BACK WIRE HARNESS
2 - HEATED SEAT WIRE HARNESS CONNECTOR
3 - HEATED SEAT CUSHION ELEMENT
8G - 12 HEATED SEAT SYSTEMRS
HEATED SEAT ELEMENT (Continued)
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PASSENGER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 6). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switch
assembly that also includes the hazard, rear window
wiper and washer switches. The heated seat switches
provide a resistor multiplexed signal to the Heated
Seat Module (HSM) through separate hard wired cir-
cuits. Each switch has an Off, Low, and High position
so that both the driver and the front seat passenger
can select a preferred seat heating mode. Each
switch has two Light-Emitting Diodes (LED) which
light to indicate that the heater for the seat is turned
on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
OPERATION
There are three positions that can be selected with
each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
depressed, the Low position is selected and the low
position LED indicator illuminates. When the right
side of the switch rocker is fully depressed, the High
position is selected and the high position LED indi-cator illuminates. When the switch rocker is moved
to its neutral position (middle), Off is selected and
both LED indicators are extinguished.
Both switches provide separate resistor multi-
plexed hard wire inputs to the Heated Seat Module
(HSM) to indicate the selected switch position. The
heated seat module responds to the heated seat
switch status messages by controlling the output to
the seat heater elements of the selected seat. The
Low heat position set point is about 36É C (97É F),
and the High heat position set point is about 41É C
(105É F).
DIAGNOSIS AND TESTING - PASSENGER
HEATED SEAT SWITCH
For complete circuit diagrams, refer toWiring
Diagrams.
WARNING: REFER TO THE RESTRAINTS SECTION
OF THIS MANUAL BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, SEAT 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.
CHECKING SWITCH SIGNAL AND WIRING AT THE
MODULE
(1) Disconnect and isolate the battery negative
cable.
(2) Access and disconnect the gray 4-way connector
from the heated seat module. Visually inspect wiring
terminals for damage that would prevent positive
connection. If not OK, repair or replace the necessary
components.
(3) Reconnect the negative battery cable and Turn
heated seat ON in the LO position. Using an Ohm-
meter, check the resistance between cavities 2 and 3
of the gray connector noted above. Resistance should
be about 3.5 kiloohms (3500 ohms). If not OK, check
resistance directly at switch, as noted below. If OK,
proceed. If NOT OK replace the switch or faulty wir-
ing.
(4) Turn heated seat ON in the HI position. Using
an Ohmmeter, check the resistance between cavities
2 and 3 of the gray connector noted above. Resistance
should be about 1.4 kiloohms (1400 ohms). If not OK,
check resistance directly at switch, as noted below. If
OK, proceed. If NOT OK replace the switch or faulty
wiring.
(5) With the system ON in the HI position, Check
for battery voltage and ground at cavities 4 and 1. If
OK, proceed with testing remaining components. If
NOT OK, repair open or wiring short.
Fig. 6 HEATED SEAT SWITCH LOCATION
1 - HEATED SEAT SWITCHES
RSHEATED SEAT SYSTEM8G-13
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HORN
TABLE OF CONTENTS
page page
HORN SYSTEM
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING - HORN SYSTEM . . . 1
HORN
DIAGNOSIS AND TESTING - HORN..........3
REMOVAL.............................4INSTALLATION..........................4
HORN RELAY
DIAGNOSIS AND TESTING - HORN RELAY....5
REMOVAL.............................5
INSTALLATION..........................5
HORN SWITCH
DESCRIPTION..........................5
HORN SYSTEM
DESCRIPTION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, REFER TO ELECTRICAL, RESTRAINTS FOR
SAFETY PRECAUTIONS. DISCONNECT THE NEGA-
TIVE CABLE FROM THE BATTERY BEFORE SER-
VICING COMPONENTS INVOLVING THE AIRBAG
SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG
AND PERSONAL INJURY CAN RESULT.
The horn circuit consists of a horn switch, clock-
spring, horn relay, horns and Integrated Power Mod-
ule (IPM). The horn switch is a membrane switch
located in the airbag trim cover. The horns are
located forward of the left front wheel behind the
bumper fascia.
OPERATION
The horn relay plugs into the Integrated Power
Module (IPM) which is located in the engine com-
partment. For circuit information and component
locations, refer to the appropriate 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 connectors, splices and grounds.
The horns will not function if the switch is
ªCLOSEDº for more than 30 seconds. Once the
switch is ªOPENº, a 20±30 second delay will occur
before the horns are functional again.
DIAGNOSIS AND TESTING - HORN SYSTEM
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.
Refer to Horn System Test below. If the horn does
not sound, check horn fuse located in the Integrated
Power Module (IPM). If the fuse is blown, replace
with the correct fuse. If the horns fail to sound and
the new fuse blows when depressing the horn switch,
a short circuit in the horn or the horn wiring
between the fuse terminal and the horn is responsi-
ble, or a defective horn switch allowed the horn to
burn out is responsible.
If the fuse is OK, test horn relay (Refer to 8 -
ELECTRICAL/HORN/HORN RELAY - DIAGNOSIS
AND TESTING).
If the relay is OK, test horn. Refer to Horn System
Test.
CAUTION: Continuous sounding of horn may
cause horn failure.
Should the horn sound continuously:
²Unplug the horn relay from IPM.
²Refer to (Refer to 8 - ELECTRICAL/HORN/
HORN RELAY - DIAGNOSIS AND TESTING).
Refer to the appropriate 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 connectors, splices and grounds.
RSHORN8H-1
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CONDITION POSSIBLE CAUSE CORRECTION
(5) FAULTY HORN SWITCH. (5) REPLACE DRIVER AIRBAG
MODULE TRIM COVER.
(6) FAULTY CLOCKSPRING. (6) REPLACE CLOCKSPRING.
(7) FAULTY FRONT
CONTROL MODULE.(7) REFER TO ELECTRONIC
CONTROL MODULES/FRONT
CONTROL MODULE.
FUSE BLOWS WHEN HORN SOUNDS (1) SHORT CIRCUIT IN
HORN OR HORN WIRING.(1) REMOVE HORN RELAY, CHECK
FOR SHORTED HORN OR HORN
WIRING. DISCONNECT HORN WIRE
HARNESS TO ISOLATE SHORT
AND REPAIR AS NECESSARY.
(2) FAULTY CLOCKSPRING. (2) REPLACE CLOCKSPRING.
FUSE BLOWS WITHOUT BLOWING
HORN(1) SHORT CIRCUIT. (1) REMOVE RELAY, INSTALL NEW
FUSE, IF FUSE DOES NOT BLOW
REPLACE HORN RELAY. IF FUSE
BLOWS WITH RELAY REMOVED,
CHECK FOR SHORT TO GROUND
WITH OHMMETER ON CIRCUIT
BETWEEN TERMINALS 30 & 86
AND THE FUSE TERMINAL. REPAIR
AS NECESSARY.
(2) FAULTY CLOCKSPRING. (2) REPLACE CLOCKSPRING.
HORN
DIAGNOSIS AND TESTING - HORN
HORN
(1) Disconnect wire connector at horn.
(2) Using a voltmeter, connect one lead to ground
terminal and the other lead to the positive wire ter-
minal (Fig. 1).
(3) Depress the horn switch, battery voltage
should be present.
(4) If no voltage, refer toHORNS WILL NOT
SOUND. If voltage is OK, go to step Step 5.
(5) Using ohmmeter, test ground wire for continu-
ity to ground.
(6) If no ground repair as necessary.
(7) If wires test OK and horn does not sound,
replace horn.
HORNS SOUND CONTINUOUSLY
CAUTION: Continuous sounding of horns may
cause relay to fail.The horn switch (membrane) sometimes can be the
cause without the switch being depressed.
(1) Remove the horn relay from the intelligent
power module.
(2) Using a continuity tester, test continuity from
the X3 cavity of the horn relay to ground. Refer to
the appropriate wiring information. The wiring infor-
mation includes wiring diagrams, proper wire and
connector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
(a) If continuity is detected, proceed to step Step
3.
(b) If NO continuity, replace the horn relay.
(3) Remove the airbag trim cover from the steering
wheel and disengage horn connector.
(4) Install horn relay into Integrated Power Mod-
ule (IPM).
(a) If horn does not sound, replace airbag trim
cover.
(b) If horn sounds, repair grounded X3 circuit
from IPM to clockspring in the steering column.
HORNS WILL NOT SOUND
Check horn fuse#8intheIPM. If fuse is blown,
check for a shorted switch in the airbag module. and
refer to FUSE BLOWN section. If fuse is OK, refer to
FUSE OK section.
RSHORN8H-3
HORN SYSTEM (Continued)
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NOTE: Always check the functionality of the cluster
by running the self test prior to troubleshooting.
INSTRUMENT CLUSTER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
INSTRUMENT CLUSTER
INOPERATIVE. NO
RESPONSE FROM
INSTRUMENT CLUSTER.NO PCI BUS MESSAGES
FROM THE BCM.USE A DRB IIITSCAN TOOL TO CHECK THE BCM.
IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE
FOR CLUSTER FAILURE. IF NOT OK, REFER TO
THE PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL.
SPREAD TERMINAL(S)
ON WIRING HARNESS
CLUSTER CONNECTOR.REMOVE CLUSTER FROM INSTRUMENT PANEL
AND CHECK WIRING HARNESS CONNECTOR FOR
SPREAD TERMINAL. IF OK, LOOK FOR ANOTHER
POSSIBLE CAUSE FOR THE CLUSTER FAILURE. IF
NOT OK, REPAIR CONNECTOR.
BCM IS NOT RECEIVING
PROPER INPUT FROM
THE IGNITION SWITCH.1. USE A DRB IIITSCAN TOOL TO VERIFY IGNITION
SWITCH STATUS INTO THE BCM. IF NOT OK, GO
TO STEP (2). IF OK, LOOK AT ANOTHER POSSIBLE
CAUSE OF FAILURE.
2. CHECK IGNITION SWITCH FUNCTION AND
WIRING.
INTERNAL CLUSTER
FAILURE.REPLACE CLUSTER.
WAKE UP CIRCUIT
FAULTY.VERIFY CONTINUITY OF WAKE UP CIRCUIT FROM
BCM TO MIC. CIRCUIT SHALL BE LOW WHENEVER
BCM IS AWAKE.
POWER OR GROUND
MISSING.IF NO RESPONSE FROM THE MIC, CHECK FOR
POWER AND GROUND AT THE MIC CONNECTOR.
REFER TO WIRING DIAGRAMS FOR CONNECTOR
CALL OUTS.
RSINSTRUMENT CLUSTER8J-3
INSTRUMENT CLUSTER (Continued)
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(4) Install the headlamp unit.
(5) Connect the battery negative cable.
HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, fuses, charging system, headlamp bulbs,
wire connectors, relay, high beam switch, dimmer
switch, and headlamp switch. Refer to the appropri-
ate wiring information.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING
OR IGNITION TURNED
OFF.1. Loose or corroded battery
cables.1. Clean and secure battery cable clamps and
posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery
System.
6. Poor lighting circuit Z343/Z344-
ground.6. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS
BURN OUT
FREQUENTLY.1. Integrated Power Module (IPM)
not controlling voltage.1. Test and repair Integrated Power Module.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
Fig. 11 FRONT POSITION LAMP
1 - TURN SIGNAL LAMP
2 - HIGH BEAM LAMP
3 - FRONT POSITION LAMP
4 - LOW BEAM LAMP
8L - 12 LAMPS/LIGHTING - EXTERIORRS
FRONT POSITION LAMP - EXPORT (Continued)
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HEADLAMP LEVELING MOTOR
- EXPORT
DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT
HEADLAMP LEVELING MOTOR DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
ONE MOTOR DOES NOT
OPERATE.1. Poor electrical connection at
motor1. Check for proper electrical connection at
motor
2. No voltage at motor 2. Repair no voltage condition. Refer to
Wiring Diagrams
3. No ground at motor 3. Repair no ground condition. Refer to
Wiring Diagrams
4. Defective motor 4. Replace leveling motor
BOTH MOTORS DO NOT
OPERATE1. No voltage at or from headlamp
leveling switch1. Repair no voltage condition. Check for
proper headlamp leveling switch operation
2. No voltage at leveling motors 2. Repair no voltage condition. Refer to
Wiring Diagrams
3. No ground at leveling motors 3. Repair no ground condition. Refer to
Wiring Diagrams
4. Both motors defective 4. Replace both motors
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit.
(3) Disconnect electrical connector from headlamp
leveling motor.
(4) Remove the two mounting screws.
(5) Gently pry motor from headlamp unit (Fig. 14).
INSTALLATION
(1) Press motor into position.
(2) Install the two mounting screws.
(3) Connect the electrical connector to motor.
(4) Install the headlamp unit.
(5) Connect the battery negative cable.
Fig. 14 HEADLAMP LEVELING MOTOR - EXPORT
1 - HIGH BEAM HEADLAMP
2 - HEADLAMP LEVELING MOTOR
3 - LOW BEAM HEADLAMP
RSLAMPS/LIGHTING - EXTERIOR8L-15
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