lock CHRYSLER CARAVAN 2002 Service Manual

CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Rear Blower Motor Power Module
C2Right Quarter N/S
Rear Blower Rear Control Switch
C1Overhead N/S
Rear Blower Rear Control Switch
C2Overhead N/S
Rear Power Outlet RD Left Quarter Panel 40
Rear Temperature Motor Right Quarter N/S
Rear Washer Pump Motor BK Right Fender Well 3
Rear Wiper Motor GY At Motor 42
Recirculation Door Actuator GY Right Side of HVAC N/S
Remote Keyless Entry Antenna
(JAPAN)BK Right Upper Instrument Panel 23
Remote Keyless Entry Module BK/RD Top Left of I.P. 15, 16
Right B-Pillar Switch GY Right B Pillar 33
Right Cinch/Release Motor GY Rear of Sliding Door 38
Right Combination Relay BK Left Quarter Panel N/S
Right Cylinder Lock Switch BK Right Front Door 37
Right Door Speaker BK/RD At Speaker N/S
Right Fog Lamp WT At Lamp 3
Right Front Door Ajar Switch BK At B Pillar N/S
Right Front Door Lock Motor/Ajar
SwitchBK Right Front Door 37
Right Front Park/Turn Signal Lamp BK At Lamp 1, 3
Right Front Wheel Speed Sensor GY Right Fender Side Shield 9, 12, 13
Right Full Open Switch BK Right Sliding Door 38
Right Headlamp BK At Lamp 1, 3
Right Headlamp Leveling Motor WT At Right Headlamp N/S
Right High Beam Lamp BK At Right Headlamp N/S
Right Instrument Panel Speaker BK At Speaker 15, 18, 19
Right Liftgate Flood Lamp BK At Lamp 42
Right Low Beam Lamp BK At Right Headlamp N/S
Right Mid Reading Lamp GY At Lamp N/S
Right Park Lamp BK AT Lamp N/S
Right Power Mirror BK At Mirror 15, 19, 23
Right Rear Lamp Assembly BK At Lamp 41
Right Rear Pillar Speaker BK At Speaker 41
Right Rear Reading Lamp GY At Lamp N/S
Right Rear Speaker BK/RD At Speaker 41
Right Rear Vent Motor NAT At Motor 41
Right Rear Wheel Speed Sensor BK Center Rear of Floor Pan 41
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater Lamp GY Right Front Fender 33
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-9
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Right Seat Airbag YL At Passenger Seat N/S
Right Side Impact Airbag Control
ModuleYL/RD Right B Pillar 33
Right Sliding Door Control Module
C1BK Rear of Door 38, 39
Right Sliding Door Control Module
C2BK/RD Rear of Door 38, 39
Right Sliding Door Latch Sensing
SwitchBK At Sliding Door 38
Right Sliding Door Lock Motor BK Rear of Door 38
Right Sliding Door Lock Motor/Ajar
SwitchBK At Latch N/S
Right Sliding Door Motor BK At Sliding Door 38
Right Speed Control Switch BK At Steering Wheel N/S
Right Stop/Turn Signal Relay BK LT Quarter Panel N/S
Right Turn Signal Lamp OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Immobilizer Module BK At Steering Column 15, 16, 17, 18, 26
Siren (United Kingdom) BK Left Front Body N/S
Solenoid/Pressure Switch
Assembly (EATX)BK Side of Transmission N/S
Speed Control Servo BK Near Controller Antilock Brake 14
Thatcham Alarm Module C1 BK Top Right Side of Instrument Panel
Near SpeakerN/S
Thatcham Alarm Module C1 WT Top Right Side of Instrument Panel
Near SpeakerN/S
Throttle Position Sensor GY On Throttle Body 9, 13
Torque Converter Clutch Solenoid BK Front of Transmission 10
Traction Control Switch BK Rear of Swtich 16, 17, 26
Trailer Tow Connector BK Left Quarter Panel N/S
Transmission Control Module BK Top of Transmission 14
Transmission Range Sensor GY Top of Transmission 14
Vehicle Speed Sensor BK Rear of Transmission 9, 12
Washer Fluid Level Switch BK Bottom of Reservoir 3
Water in Fuel Sensor (Diesel) Left Rear Engine Compartment N/S
Wiper Module BK Left Side Cowl 6
8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPLICE NUMBER LOCATION FIG.
S117 (2.4L) Neat T/O for G101 and G103 10
S117 (3.3L/3.8L) Near T/O for Output Speed Sensor 14
S118 (2.4L) Near T/O for Knock Sensor 10
S119 (2.5L) Near T/O for Engine Starter Motor 11
S120 (2.4L) Near T/O for Oxygen Sensors 9
S120 (3.3L/3.8L) Near T/O for Oxygen Sensors 14
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 14
S122 (2.4L) In T/O to Engine Starter Motor 10
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 14
S123 In T/O to Low Note Horn 5
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S126 In Right Headlamp Leveling Assembly N/S
S127 (2.5L) Near T/O for Engine Starter Motor N/S
S128 (2.5L) Near T/O for Engine Starter Motor 11
S129 (2.5L) Near T/O for Battery (+) N/S
S130 (2.5L) Near T/O for Battery (+) N/S
S131 (3.3L/3.8L) Near T/O for Transmission Control Module N/S
S132 (2.5L) Near T/O for Battery (+) N/S
S133 (2.5L) Near T/O for Intelligent Power Module C3 N/S
S134 Near T/O for Controller Antilock Brake N/S
S135 (2.5L) Near T/O for Glow Plug No.2 11
S136 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S137 (2.5L) Near T/O for A/C Compressor Clutch 11
S138 (2.5L) Between T/O for Radiator Fan No.2 and T/O for G102 N/S
S139 (2.5L) Between T/O for Engine Starter Motor and T/O for
Engine Control Module C112
S141 (2.4L) Near T/O for Powertrain Control Module N/S
S141 (2.5L) Near /t/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 14
S143 (2.5L) Near T/O for Engine Control Module C1 11
S143 (3.3L/3.8L) Near T/O for Intelligent Power Module - C3 N/S
S144 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C10311
S145 (2.5L) Near T/O for Battery (+) N/S
S148 (2.5L) Near T/O for Engine Starter Motor 11
S150 (2.5L) Between T/O for Battery Temperature Sensor and T/O
for C103N/S
S151 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S152 (2.5L) Near T/O for Left Fog Lamp N/S
S157 (2.5L) Near T/O for Glow Plug No.1 11
8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPLICE NUMBER LOCATION FIG.
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (2.5L) Near T/O for Engine Control Module C1 11
S188 (2.5L) Near T/O for Radiator Fan Relay No.1 2
S201 In T/O to Instrument Panel Speaker 15, 21
S202 Near T/O for Instrument Panel Switch Bank 15, 21
S203 Near T/O for Instrument Panel Switch Bank 15, 21
S204 Near T/O to Instrument Panel Speaker 15, 21
S205 Near T/O for C201 15
S206 Near T/O for Instrument Cluster 15
S207 In A/C Unit Assembly N/S
S208 (RHD) Between T/O for Antenna Connector and T/O for Front
Cigar Lighter21
S209 (RHD) Between T/O for Front Cigar Lighter and T/O for Brake
Transmission Shift Interlock Solenoid21
S210 (RHD) Near T/O for C203 21
S211 In Steering Column Wiring Assembly N/S
S212 In Steering Column Wiring Assembly N/S
S302 In Floor Pan Track Wiring 31
S303 In T/O to Data Link Connector 31
S304 Near T/O for C307 32
S305 Near T/O for Memory Seat/Mirror Module - C2 N/S
S306 In Floor Pan Track Wiring 32
S307 Near T/O for Memory Power Seat Switch N/S
S308 In Floor Pan Track Wiring 31
S309 In Floor Pan Track Wiring 31
S310 Near T/O for C301 30
S311 In Floor Pan Track Wiring 29
S312 Near T/O for C320 N/S
S313 Near T/O for Power Liftgate Module 40
S314 In Floor Pan Track Wiring 29
S315 In Floor Pan Track Wiring 29
S316 In Floor Pan Track Wiring 29
S317 Near T/O for C101 30
S318 Near T/O for Power Seat Circuit Breaker N/S
S319 In Floor Pan Track Wiring 32
S320 Near T/O for C200 31
S321 In T/O to Data Link Connector 31
S322 Near T/O for C301 30
S323 In Floor Pan Track Wiring 31
S324 In Floor Pan Track Wiring 29
S325 In Floor Pan Track Wiring 29
S326 Near T/O for C101 30
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-13
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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SPLICE NUMBER LOCATION FIG.
S327 Near Left Side Impact Airbag Module 31
S328 (RS) In Floor Pan Track Wiring 32
S329 Near T/O to Left Rear Pillar Speaker 40
S330 Near T/O for Power Liftgate Module 40
S331 Near T/O for Power Liftgate Motor 40
S332 In Floor Pan Track Wiring 29
S333 (RS) In Floor Pan Track Wiring 32
S334 Near T/O to G301 29
S335 Near T/O for Left Rear Reading Lamp N/S
S336 Near T/O for Left Rear Reading Lamp 29
S337 Near T/O for Right Mid Reading Lamp N/S
S338 Near T/O for Right Visor/Vanity Lamp N/S
S339 Near T/O for C312 N/S
S340 Near T/O for Passenger Power Window Switch 37
S342 (LHD) Near T/O for Passenger Power Window Motor 37
S343 (LHD) Near T/O for Driver Power Window Motor 37
S344 In T/O to Right Sliding Door Control Module C2 39
S345 Near T/O for Right Sliding Door Motor 39
S346 Near T/O for Driver Power Window Switch 37
S347 Near T/O for Right Sliding Door Lock Motor 39
S348 Near T/O for Left Sliding Door Lock Motor 39
S349 In T/O to Left Sliding Door Control Module - C2 39
S350 Near T/O for Left Sliding Door Motor 39
S351 Near T/O for Liftgate Cylinder Lock Switch 42
S352 Near T/O for Liftgate Cinch/Release Motor 42
S353 Near T/O for C318 40
S354 (RG) Near T/O for C301 31
S354 (RS) Near T/O for Driver Heated Seat Module N/S
S355 Near T/O for Passenger Heated Seat Module N/S
S356 (RG) In Floor Pan Track Wiring 31
S356 (RS) Near T/O for Passenger Heated Seat Back N/S
S358 (RG) In T/O for Data Link Connector N/S
S364 (RHD) Near T/O for Passenger Power Window Window 37
S365 (LHD) Near T/O for Driver Power Window Window 37
S366 In Passenger Power Heated Seat Wiring Assembly N/S
S368 Near T/O for C101 30
S370 In T/O to Pedal Adjust Module N/S
S371 In T/O to Power Window Switch N/S
8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATIONRS
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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8W-97 POWER DISTRIBUTION SYSTEM
TABLE OF CONTENTS
page page
POWER DISTRIBUTION SYSTEM
DESCRIPTION..........................1
OPERATION............................1
SPECIAL TOOLS
POWER DISTRIBUTION SYSTEMS.........2
ACCESSORY RELAY
DESCRIPTION..........................2
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - ACCESSORY
RELAY...............................2
REMOVAL.............................3
INSTALLATION..........................3
INTEGRATED POWER MODULE
DESCRIPTION..........................3OPERATION............................3
REMOVAL.............................4
INSTALLATION..........................4
IOD FUSE
DESCRIPTION..........................4
OPERATION............................5
REMOVAL.............................5
INSTALLATION..........................5
POWER OUTLET
DESCRIPTION..........................5
OPERATION............................5
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET . . 5
REMOVAL.............................6
INSTALLATION..........................6
POWER DISTRIBUTION
SYSTEM
DESCRIPTION
This group covers the various standard and
optional power distribution components used on this
model. The power distribution system for this vehicle
consists of the following components:
²Integrated Power Module (IPM)
²Front Control Module (FCM)
²Power Outlets
Refer to Wiring Diagrams for complete circuit sche-
matics.
The power distribution system also incorporates
various types of circuit control and protection fea-
tures, including:
²Automatic resetting circuit breakers
²Blade-type fuses
²Bus bars
²Cartridge fuses
²Circuit splice blocks
²Flashers
²Fusible links
²Relays
Following are general descriptions of the major
components in the power distribution system. See the
owner's manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components.
OPERATION
The power distribution system for this vehicle is
designed to provide safe, reliable, and centralized dis-
tribution points for the electrical current required to
operate all of the many standard and optional facto-
ry-installed electrical and electronic powertrain,
chassis, safety, security, comfort and convenience sys-
tems. At the same time, the power distribution sys-
tem was designed to provide ready access to these
electrical distribution points for the vehicle techni-
cian to use when conducting diagnosis and repair of
faulty circuits. The power distribution system can
also prove useful for the sourcing of additional elec-
trical circuits that may be required to provide the
electrical current needed to operate many accessories
that the vehicle owner may choose to have installed
in the aftermarket.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-1
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(4) The coil ground terminal (85) is connected to
the electromagnet in the relay. It receives battery
feed to energize the accessory relay when the ignition
switch is in the Accessory or On positions. Turn the
ignition switch to the On position. Check for battery
voltage at the fused ignition switch output (acc/run)
circuit cavity for relay terminal 85 in the IPM recep-
tacle for the accessory relay. If OK, go to Step 5. If
not OK, repair the open fused ignition switch output
(acc/run) circuit to the ignition switch as required.
(5) The coil battery terminal (86) is connected to
the electromagnet in the relay. The IPM cavity for
this terminal should have continuity to ground at all
times. If not OK, repair the open ground circuit to
ground as required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Integrated Power Module (IPM)
cover from the IPM.
(3) Remove the accessory relay from the IPM.
Refer to the IPM cover for relay location.
INSTALLATION
(1) Position the accessory relay in the proper
receptacle in the Integrated Power Module (IPM).
(2) Push in firmly on the accessory relay until the
terminals are fully seated in the terminal cavities in
the IPM receptacle.
(3) Install the IPM cover.
(4) Reconnect the battery negative cable.
INTEGRATED POWER MODULE
DESCRIPTION
The Integrated Power Module (IPM) is a combina-
tion of the Power Distribution Center (PDC) and the
Front Control Module (FCM). The IPM is located in
the engine compartment, next to the battery on this
model (Fig. 2). The power distribution center mates
directly with the Front Control Module (FCM) to
form the IPM Fuse and Relay Center. The power dis-
tribution center (PDC) is a printed circuit board
based module that contains fuses and relays, while
the front control module contains the electronics con-
trolling the IPM and other functions. This IPM con-
nects directly to the battery positive via a four pin
connector. The ground connection is via two other
connectors. The IPM provides the primary means of
voltage distribution and protection for the entire
vehicle.
The molded plastic IPM housing includes a base
and cover. The IPM cover is easily opened or removed
for service access by squeezing the two marked coverlatches and has a fuse and relay layout map integral
to the inside surface of the cover. This IPM housing
base and cover are secured in place by an IPM
mounting bracket. This mounting bracket is designed
to allow the IPM to rotate counter-clockwise once the
locking tab is disengaged. The IPM mounting bracket
is secured in place by bolts threaded into the left
front wheel house.
Replaceable components of the IPM assembly are
broken down into the following components: the
Power Distribution Center (PDC) (without fuses or
relays), the IPM cover, the Front Control Module
(FCM), the IPM mounting bracket, IPM bracket
retaining clips and the IPM assembly which includes
the power distribution center, the cover and FCM.
Refer to the Front Control Module in the Elec-
tronic Control Module sectionof this service
manual for information on the FCM.
OPERATION
All of the current from the battery and the gener-
ator output enters the Integrated Power Module
(IPM) via a four- pin connector on the bottom of the
module. The IPM cover is unlatched and opened or
removed to access the fuses or relays. Internal con-
nections of all of the power distribution center cir-
cuits is accomplished by a combination of bus bars
and a printed circuit board. Refer to the Wiring sec-
Fig. 2 BATTERY THERMAL GUARD
1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
3 - FRONT CONTROL MODULE
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-3
ACCESSORY RELAY (Continued)
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tion of the service manual for complete IPM circuit
schematics.
REMOVAL
(1) Disconnect the negative and positive battery
cables.
(2) Remove the battery thermal guard from the
vehicle. Refer to the Battery section for the proce-
dure.
(3) Remove the battery from the vehicle. Refer to
the Battery section for the procedure.
(4) Using a flat-bladed screwdriver, twist the Inte-
grated Power Module (IPM) bracket retaining latch
outward to free the intelligent power module from its
mounting bracket (Fig. 3).
(5) Rotate the IPM counter-clockwise to access and
disconnect the various electrical connectors (Fig. 4).
(6) Free the IPM from its mounting bracket by
removing the IPM bracket clips from the hinge. A
screwdriver slipped up from under the hinge will free
the clips.
INSTALLATION
(1) Snap the left side of the Integrated Power Mod-
ule (IPM) housing in its mounting bracket and con-
nect the various electrical connectors. Care must be
taken that the Connector Positive Assurance (CPA)
on the five-pin B+ connector is positively engaged to
prevent generating a Diagnostic Trouble Code (DTC).
NOTE: IPM electrical connectors are color coded to
ease location reference.(2) Being certain no wires are stressed or pinched,
rotate the IPM clock-wise until secured in mounting
bracket. An audible click may be heard.
(3) Install the battery in the vehicle. Refer to the
Battery section for the procedure.
(4) Install the battery thermal guard in the vehi-
cle. Refer to the Battery section for the procedure.
(5)
Connect the negative and positive battery cables.
(6) Using a diagnostic scan tool, check for any
stored diagnostic trouble codes and correct, check
that all vehicle options are operational before return-
ing the vehicle to service.
IOD FUSE
DESCRIPTION
All vehicles are equipped with an Ignition-Off
Draw (IOD) fuse that is removed from its normal
cavity in the Integrated Power Module (IPM) when
the vehicle is shipped from the factory. Dealer per-
sonnel are to remove the IOD fuse from the storage
location and install it into the IPM fuse cavity
marked IOD as part of the preparation procedures
performed just prior to new vehicle delivery.
The IPM has a molded plastic cover that can be
removed to provide service access to all of the fuses
and relays in the IPM. An integral latch and hinges
are molded into the IPM cover for easy removal. A
fuse layout map is integral to the underside of the
IPM cover to ensure proper fuse and relay identifica-
Fig. 3 RELEASING INTEGRATED POWER MODULE
FROM ITS MOUNTING BRACKET
Fig. 4 DISCONNECTING IPM
1 - INTEGRATED POWER MODULE FUSE & RELAY CENTER
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEMRS
INTEGRATED POWER MODULE (Continued)
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tion. The IOD fuse is a 15 ampere blade-type car-
tridge fuse and, when removed, it is stored in a fuse
cavity adjacent to the washer fuse within the IPM.
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
removed is to reduce the normal IOD of the vehicle
electrical system during new vehicle transportation
and pre-delivery storage to reduce battery depletion,
while still allowing vehicle operation so that the
vehicle can be loaded, unloaded and moved as needed
by both vehicle transportation company and dealer
personnel.
The IOD fuse is removed from the IPM fuse cavity
when the vehicle is shipped from the assembly plant.
Dealer personnel must install the IOD fuse when the
vehicle is being prepared for delivery in order to
restore full electrical system operation. Once the
vehicle is prepared for delivery, the IOD function of
this fuse becomes transparent and the fuse that has
been assigned the IOD designation becomes only
another Fused B(+) circuit fuse. The IOD fuse serves
no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
other than the same purpose as that of any other
standard circuit protection device.
The IOD fuse can be used by the vehicle owner as
a convenient means of reducing battery depletion
when a vehicle is to be stored for periods not to
exceed about thirty days. However, it must be
remembered that removing the IOD fuse will not
eliminate IOD, but only reduce this normal condition.
If a vehicle will be stored for more than about thirty
days, the battery negative cable should be discon-
nected to eliminate normal IOD; and, the battery
should be tested and recharged at regular intervals
during the vehicle storage period to prevent the bat-
tery from becoming discharged or damaged. Refer to
Battery Systemfor additional service information.
REMOVAL
(1) Turn the ignition switch to the Off position.
(2) Unlatch and open the cover of the intelligent
power module.
(3) Remove the IOD fuse from fuse location
markedIODof the Integrated Power Module (IPM).
(4) Store the removed IOD fuse by installing it in
the unused fuse storage markedSPAREof the IPM.
(5) Close and latch the IPM.
INSTALLATION
(1) Be certain the ignition switch is in the Off posi-
tion.
(2) Unlatch and open the cover of the Integrated
Power Module (IPM).
(3) Remove the stored 15 amp IOD fuse from fuse
storage markedSPAREof the IPM.
(4) Use a thumb to press the IOD fuse firmly down
into IPM fuse cavity markedIOD.
(5) Close and latch the IPM cover.
POWER OUTLET
DESCRIPTION
Accessory power outlets are standard equipment on
this model. Two power outlets are installed in the
instrument panel center lower bezel, which is located
near the bottom of the instrument panel center stack
area. Two additional power outlets are also incorpo-
rated into the vehicle, one on the left rear C-pillar
trim and the other in the center console, if equipped.
The power outlets bases are secured by a snap fit in
the appropriate bezels. A hinged plug flips closed to
conceal and protect the power outlet base when the
power outlet is not being used.
The power outlet receptacle unit and the power
outlet plugs are each available for service replace-
ment.
OPERATION
The power outlet base or receptacle shell is con-
nected to ground, and an insulated contact in the
bottom of the shell is connected to battery current.
The power outlet on the instrument panel marked
with a battery receives battery voltage from a fuse in
the Integrated Power Module (IPM) at all times. The
other power outlet on the instrument panel marked
with a key receives battery voltage only when the
key is in the on position.
The power outlet located in the center console
receives battery voltage all the time when positioned
between thefront seatsand key-on voltage when
positioned between therear seats. The power outlet
located on the C-pillar receives battery voltage only
when the key is in the on position.
DIAGNOSIS AND TESTING
DIAGNOSIS & TESTING - POWER OUTLET
For complete circuit diagrams, refer toCigar
Lighter/Power Outletin Wiring Diagrams.
RS8W-97 POWER DISTRIBUTION SYSTEM8W-97-5
IOD FUSE (Continued)
ProCarManuals.com

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN,
SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
NOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Check the fused B(+) fuse in the Integrated
Power Module (IPM). 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
in the IPM. If OK, go to Step 3. If not OK, repair the
open fused B(+) circuit to the IPM fuse as required.
(3)
Open the power outlet door. Check for continuity
between the inside circumference of the power outlet
receptacle and a good ground. There should be continu-
ity. If OK, go to Step 4. If not OK, go to Step 5.
(4) Check for battery voltage at the insulated con-
tact located at the back of the power outlet recepta-
cle. If not OK, go to Step 5.
(5) Disconnect and isolate the battery negative
cable. Remove the appropriate bezel. Check for conti-
nuity between the ground circuit cavity of the power
outlet wire harness connector and a good ground.
There should be continuity. If OK, go to Step 6. If not
OK, repair the open ground circuit to ground as
required.
(6) Connect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
power outlet wire harness connector. If OK, replace
the faulty power outlet receptacle. If not OK, repair
the open fused B(+) circuit to the IPM fuse as
required.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Look inside and note position of the retaining
bosses (Fig. 5).
(3) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(4) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 6).
(5) Disconnect the base wires.
(6) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position the mounting ring on the instrument
panel and feed the wires through the ring. Index the
cap and the mounting ring with the index tab at the9 o'clock position to the key in the instrument panel.
Install the ring.
(2) Connect the wires to the base. Orientate the
base alignment rib at the 11 o'clock position to mate
the groove in the mounting ring to the base.
(3) Push the base into the bezel until it locks in
place.
(4) Check operation of outlet or element and
install the 12 volt outlet cap.
Fig. 5 Outlet Base Removal
1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
4 - PULL BASE OUT-THROUGH MOUNTING RING
Fig. 6 Tool For Outlet Removal
1 - 2.5MM (3/32 INS.)
2 - WELD
3 - 100MM (4 INS.)
4 - 22.25 TO 22.45MM (7/8 TO 57/64 INS.)
8W - 97 - 6 8W-97 POWER DISTRIBUTION SYSTEMRS
POWER OUTLET (Continued)
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