washer fluid CHRYSLER CARAVAN 2003 User Guide
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2003Pages: 2177, PDF Size: 59.81 MB
Page 322 of 2177
OPERATION
The data link connector (diagnostic connector)
links the DRB scan tool with the Powertrain Control
Module (PCM). Refer to On-Board Diagnostics in the
General Diagnosis section of this group.
FRONT CONTROL MODULE
DESCRIPTION
The Front Control Module (FCM) is a micro con-
troller based module located in the engine compart-
ment. This FCM mates to the power distribution
center to form the Integrated Power Module (IPM).
The IPM connects directly to the battery and pro-
vides the primary means of circuit protection and
power distribution for all vehicle electrical systems.
The FCM controls power to some of these vehicle sys-
tems electrical and electromechanical loads based on
inputs received from hard wired switch inputs and
data received on the Programmable Communications
Interface (PCI) data bus.
For information on the IPM, (Refer to 8 - ELEC-
TRICAL/POWER DISTRIBUTION/INTEGRATED
POWER MODULE - DESCRIPTION)
OPERATION
As messages are sent over the Programmable Com-
munications Interface (PCI) data bus, the Front Con-
trol Module (FCM) reads these messages and controls
power to some of the vehicles electrical systems by
completing the circuit to ground (low side driver) or
completing the circuit to 12 volt power (high side
driver).
The following functions arecontrolledby the
Front Control Module:²Accessory Relay Actuation
²Brake Transmission Shift Interlock Functions
(BTSI)
²Diesel Cabin Heater (Diesel Engine Vehicles)
²Electronic Back Light (EBL) Rear Defogger
²Electronic Transaxle (Gasoline engine Vehicles)
²Front and Rear Blower Motor Relay Actuation
²Front Fog Lamp Relay Actuation
²Front Washer Motor
²Front Windshield Wiper ªHIº & ªLOº Relay
Actuation
²Front Windshield Wiper ªONº Relay Actuation
²Headlamp Power with Voltage Regulation
²Horn Relay Actuation
²Headlamp Washer Relay Actuation
²Name Brand Speaker (NBS) Relay Actuation
²Occupant Restraint Controller Voltage
²Park Lamp Relay Actuation
²Rear Washer Motor
²Side Airbag Voltage
The following inputs areReceived/Monitoredby
the Front Control Module:
²Ambient Temperature Sensing
²Back-Up switch
²Brake Fluid Level
²B+ Connection Detection
²Engine Crank Signal (Diesel Engine Vehicles)
²Horn Input
²Ignition Switch Start Only
²Ignition Switch Run and Start Only
²Stop Lamp Sense
²Washer Fluid Level
²Windshield Wiper Park
DIAGNOSIS AND TESTING - FRONT CONTROL
MODULE
The Front Control Module (FCM) is a printed cir-
cuit board based module with a on-board micro-pro-
cessor. The FCM interfaces with other electronic
modules in the vehicle via the Programmable Com-
munications Interface (PCI) data bus. In order to
obtain conclusive testing the PCI data bus and all of
the electronic modules that provide inputs to, or
receive outputs from the FCM must be checked. All
PCI communication faults must be resolved prior to
further diagnosing any front control module related
issues.
The FCM was designed to be diagnosed with an
appropriate diagnostic scan tool, such as the DRB
IIIt. The most reliable, efficient, and accurate means
to diagnose the front control module requires the use
of a DRB IIItscan tool and the proper Body Diag-
nostic Procedures manual.
Before any testing of the FCM is attempted, the
battery should be fully charged and all wire harness
Fig. 4 DATA LINK CONNECTOR
RSELECTRONIC CONTROL MODULES8E-7
DATA LINK CONNECTOR (Continued)
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Page 406 of 2177
INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS.........................2
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS...........................2REMOVAL.............................10
INSTALLATION.........................10
CLUSTER LENS
REMOVAL.............................10
INSTALLATION.........................10
INSTRUMENT CLUSTER
DESCRIPTION
The instrumentation gauges are contained in a
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.
The Mechanical Instrument Cluster (MIC) with a
tachometer is equipped with a electronic vacuum flu-
orescent transmission range indicator (PRND3L),
odometer, and trip odometer display.
The MIC without a tachometer is equipped with a
Light Emitting Diode (LED) transmission range indi-
cator (PRND3L) and a vacuum fluorescent odometer
display.
The MIC is equipped with the following warning
lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
²Coolant Temperature
²Anti-Lock Brake
²Brake
²Oil Pressure
²MIL (Malfunction Indicator Lamp)
²VTSS/SKIS Indicator
²Airbag
²Traction Control
²Autostick
The MIC without a tachometer also has the follow-
ing warning lamps:
²Turns Signals
²High Beam
WATER IN FUEL LAMP - EXPORT
The Water In Fuel Lamp is located in the message
center. When moisture is found within the fuel sys-
tem, the sensor sends a message via the PCI data
bus to the instrument cluster. The MIC illuminates
the bulb in the message center, The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
Refer to the vehicle Owner's Manual for operation
instructions and conditions for the Instrument Clus-
ter Gauges.
WATER IN FUEL LAMP - EXPORT
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RSINSTRUMENT CLUSTER8J-1
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Page 440 of 2177
LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS.....................25
CENTER CONSOLE LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
CLUSTER ILLUMINATION LAMPS
REMOVAL.............................26
INSTALLATION.........................26
COURTESY LAMP
REMOVAL.............................26
INSTALLATION.........................26
DOME/CARGO LAMP
REMOVAL.............................26INSTALLATION.........................26
GLOVE BOX LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
LIFTGATE LAMP
REMOVAL.............................27
INSTALLATION.........................27
READING LAMP
REMOVAL.............................27
INSTALLATION.........................28
VANITY LAMP
REMOVAL.............................28
INSTALLATION.........................28
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
ABS LED
AIRBAG LED
ALARM SET PC74
AUTOSTICK VFD*
BRAKE SYSTEM
WARNINGLED
CONSOLE 194
CRUISE INDICATOR VFD*
DOME/RAIL LAMPS 578
DOOR AJAR INDICATOR LED
DOOR COURTESY
LAMP578
FRONT DOOR
COURTESY567
GLOVE BOX 194
HIGH BEAM INDICATOR
(BASE CLUSTER)LED
HIGH BEAM INDICATOR PC74
LAMP BULB
CLUSTER
ILLUMINATIONPC74
LIFTGATE 578
LIFTGATE AJAR LED
LOW FUEL INDICATOR LED
LOW WASHER FLUID
INDICATORLED
MIL (BASE CLUSTER) LED
MIL PC74
OIL INDICATOR (BASE
CLUSTER)LED
OIL INDICATOR PC74
OVERHEAD CONSOLE
READINGPC579
OVERDRIVE OFF
INDICATORVFD*
READING 578
SEAT BELT INDICATOR LED
TEMPERATURE
INDICATORLED
TRAC OFF INDICATOR VFD*
TURN SIGNAL
INDICATOR (BASE
CLUSTER)LED
TURN SIGNAL
INDICATORPC74
VISOR VANITY 6501966
RSLAMPS/LIGHTING - INTERIOR8L-25
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Page 552 of 2177
WIPERS/WASHERS
TABLE OF CONTENTS
page page
WIPERS/WASHERS
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT WIPER
SYSTEM.............................2
DIAGNOSIS AND TESTING - FRONT
WIPER/WASHER SWITCH................2
DIAGNOSIS AND TESTING - FAILED PARK
SWITCH.............................2
DIAGNOSIS AND TESTING - REAR WIPER
SYSTEM.............................4
DIAGNOSIS AND TESTING - WASHER
SYSTEM.............................4
FRONT WASHER PUMP MOTOR
REMOVAL.............................8
INSTALLATION..........................8
FRONT WIPER ARMS
STANDARD PROCEDURE - FRONT WIPER
ARM ALIGNMENT......................8
REMOVAL.............................9
INSTALLATION..........................9
FRONT WIPER MOTOR
REMOVAL.............................9
INSTALLATION..........................9
HEADLAMP WASHERS - EXPORT
DESCRIPTION.........................10
OPERATION...........................10
DIAGNOSIS AND TESTING - HEADLAMP
WASHERS - EXPORT..................10
REMOVAL.............................12
INSTALLATION.........................12
HEADLAMP WASHER HOSE - EXPORT
REMOVAL.............................12
INSTALLATION.........................12HEADLAMP WASHER PUMP MOTOR - EXPORT
REMOVAL.............................12
INSTALLATION.........................13
REAR WASHER PUMP MOTOR
REMOVAL.............................13
INSTALLATION.........................14
REAR WIPER ARM
REMOVAL.............................14
INSTALLATION.........................14
REAR WIPER MOTOR
REMOVAL.............................14
INSTALLATION.........................15
REAR WIPER/WASHER SWITCH
DESCRIPTION.........................15
OPERATION...........................15
WASHER FLUID LEVEL SWITCH
REMOVAL.............................15
INSTALLATION.........................16
WASHER HOSES
REMOVAL.............................16
INSTALLATION.........................16
WASHER RESERVOIR
REMOVAL.............................16
INSTALLATION.........................17
WIPER BLADES
REMOVAL.............................17
CLEANING............................17
INSTALLATION.........................17
WIPER LINKAGE
REMOVAL.............................17
INSTALLATION.........................18
WIPER MODULE
REMOVAL.............................18
INSTALLATION.........................18
WIPERS/WASHERS
DESCRIPTION
FRONT WIPER/WASHER SYSTEM
The windshield wipers can be operated with the
windshield wiper switch when the ignition switch is
in the RUN or ACCESSORY positions. The wind-
shield wiper system is protected by a 30 amp fuse (9)
located in the Power Distribution Center (PDC) part
of the Integrated Power Module (IPM) in the engine
compartment. The wiper/washer switch is integral tothe multi-function switch. It is a resistive MUX
switch that sends inputs to the BCM to operate the
wiper/washer system.
REAR WIPER/WASHER SYSTEM
The rear windshield wiper and washers can be
operated when the ignition switch is in the RUN or
ACCESSORY positions.
RSWIPERS/WASHERS8R-1
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CONDITION POSSIBLE CAUSES CORRECTION
WASHER SYSTEM WILL
NOT FLOW WASHER
FLUID.1. NO WASHER FLUID IN
RESERVOIR.1. FILL WASHER RESERVOIR.
2. IPM FUSE #33 BLOWN. 2. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 11 AND WASHER
PUMP MOTOR CONNECTOR POSITIVE
TERMINAL 2. INTERNAL SHORT IN IPM. IF
NOT OK, REPAIR CIRCUIT OR REFER TO
IPM DIAGNOSTIC PROCEDURES IN
WIRING DIAGRAMS.
3. WASHER HOSE NOT
FLOWING WASHER FLUID.3. ASSURE WASHER HOSE IS NOT
PINCHED, LOOSE, BROKEN OR
DISCONNECTED. IF NOT OK, PROPERLY
ROUTE OR REPAIR WASHER HOSE.
4. MOTOR CONNECTOR
LOOSE.4. PROPERLY SEAT AND LOCK
CONNECTOR TO MOTOR.
5. MOTOR CONNECTOR
TERMINALS BENT.5. REPAIR TERMINALS AND PROPERLY
SEAT CONNECTOR TO MOTOR.
6. OPEN CIRCUIT TO OR
FROM WASHER SELECT
SWITCH.6. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM BODY CONTROLLER PIN
27 AND WASHER SELECT SWITCH PIN 4,
OR OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM BODY CONTROLLER PIN
22 AND WASHER SELECT SWITCH PIN 2.
IF NOT OK, REPAIR CIRCUIT.
7. OPEN OR DEFECTIVE
WASHER SELECT SWITCH.7. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/MULTI-FUNCTION
SWITCH - DIAGNOSIS AND TESTING).
8. OPEN POWER CIRCUIT TO
MOTOR.8. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM CONNECTOR TERMINAL 11
AND WASHER MOTOR CONNECTOR
POSITIVE TERMINAL 2. INTERNAL OPEN
IN IPM. IF NOT OK, REPAIR CIRCUIT OR
REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
9. OPEN OR DEFECTIVE
MOTOR GROUND CIRCUIT.9. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM CONNECTOR TERMINAL
20 AND WASHER MOTOR CONNECTOR
NEGATIVE TERMINAL 1. INTERNAL OPEN
IN IPM. IF NOT OK, REPAIR CIRCUIT OR
REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
10. OPEN CIRCUIT IN MOTOR. 10. CHECK FOR OPEN CIRCUIT IN MOTOR
BETWEEN POSITIVE TERMINAL 2 AND
NEGATIVE TERMINAL 1. IF NOT OK,
REPLACE WASHER MOTOR.
11. SEIZED MOTOR BEARINGS. 11. APPLY DIRECT BATTERY VOLTAGE TO
MOTOR TERMINALS. IF MOTOR DOES
NOT RUN, REPLACE MOTOR.
RSWIPERS/WASHERS8R-5
WIPERS/WASHERS (Continued)
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Page 557 of 2177
CONDITION POSSIBLE CAUSES CORRECTION
COWL GRILLE NOZZLE
WILL NOT FLOW.1. FROZEN NOZZLE. 1. MOVE VEHICLE INTO HEATED AREA TO
ALLOW TIME TO THAW NOZZLE. ASSURE
WASHER FLUID IS PROPERLY BLENDED
FOR AMBIENT OUTSIDE TEMPERATURES.
2. NOZZLE HOSE NOT
FLOWING.2. ASSURE NOZZLE HOSE IS NOT
PINCHED, LOOSE, BROKEN, OR
DISCONNECTED. IF NOT OK, PROPERLY
ROUTE OR REPAIR NOZZLE HOSE.
3. NOZZLE HOSE PLUGGED
BY CONTAMINATION.3. CLEAN NOZZLE HOSE OF
CONTAMINATION. DETERMINE SOURCE
OF CONTAMINATION. INSPECT
RESERVOIR FOR EXCESSIVE
CONTAMINATION. CLEAN SYSTEM AS
REQUIRED.
4. NOZZLE PLUGGED BY
CONTAMINATION.4. CLEAN NOZZLE OF CONTAMINATION
OR REPLACE NOZZLE. DETERMINE
SOURCE OF CONTAMINATION. INSPECT
RESERVOIR FOR EXCESSIVE
CONTAMINATION. CLEAN SYSTEM AS
REQUIRED.
5. DEFECTIVE WASHER HOSE
CHECK VALVE.5. REPLACE COWL GRILLE PANEL
WASHER HOSE/CHECK VALVE ASSEMBLY.
WASHER FLUID OUTPUT IS
LOW.1. PARTIALLY PINCHED HOSE. 1. ASSURE WASHER HOSE IS NOT
PARTIALLY PINCHED. IF NOT OK,
PROPERLY ROUTE HOSE.
2. REVERSE POLARITY TO
PUMP.2. CHECK FOR CROSSED CIRCUIT TO
PUMP. IF NOT OK, REPAIR CIRCUIT.
3. WORN OUT WASHER PUMP. 3. REPLACE WASHER PUMP.
COWL GRILLE NOZZLE
STREAM OVERSHOOTS
WINDSHIELD.1. NOZZLE NOT SEATED IN
COWL GRILLE.1. ASSURE NOZZLE IS SNAPPED IN
PLACE.
WIPER WILL NOT CYCLE
WHEN WASHER SELECT
SWITCH IS DEPRESSED.1. DEFECTIVE IPM. 1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. DEFECTIVE IPM/BODY
CONTROLLER.2. REFER TO IPM/BODY CONTROLLER
DIAGNOSTIC PROCEDURES IN WIRING
DIAGRAMS.
3. REAR WIPER OUTPUT
SHORT FAULT.3. A GROUND SHORT DETECTED
BETWEEN BCM AND REAR WIPER
MOTOR. CLEAR FAULT. IF IT WON'T
CLEAR, REPAIR SHORT
4. REAR WIPER OUTPUT
OPEN FAULT.4. AN OPEN CIRCUIT DETECTED
BETWEEN BCM AND REAR WIPER
MOTOR. CLEAR FAULT. IF IT WON'T
CLEAR, REPAIR OPEN CIRCUIT.
8R - 6 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)
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Page 558 of 2177
CONDITION POSSIBLE CAUSES CORRECTION
WASHER OPERATES
INTERMITTENTLY.1. INTERMITTENT MOTOR
GROUND.INTERMITTENT GROUND BETWEEN
MOTOR CONNECTOR TERMINAL 1 AND
IPM PIN 20.
2. INTERMITTENT OPEN IN
WASHER SELECT SWITCH.2. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/MULTI-FUNCTION
SWITCH - DIAGNOSIS AND TESTING).
3. DEFECTIVE WASHER
MOTOR.3. REPLACE WASHER MOTOR.
LOW WASHER FLUID
LEVEL INDICATOR
INOPERATIVE.1. LOOSE FLUID LEVEL
SENSOR CONNECTOR.1. PROPERLY SEAT CONNECTOR TO LOW
FLUID LEVEL SENSOR AND LOCK.
2. OPEN POWER CIRCUIT TO
FLUID LEVEL SENSOR.2. OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM CONNECTOR TERMINAL 7
AND THE LOW FLUID LEVEL SENSOR
CONNECTOR TERMINAL 2. IF NOT OK,
REPAIR CIRCUIT.
3. OPEN GROUND CIRCUIT. 3. OPEN OR DEFECTIVE CIRCUIT
BETWEEN FLUID LEVEL SENSOR
CONNECTOR TERMINAL 1 AND FLOOR
GROUND 1.
4. DEFECTIVE IPM. 4. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
5. FLUID LEVEL SENSOR
SWITCH OPEN OR
DEFECTIVE.5. APPLY OHMMETER TO THE SWITCH
TERMINALS TO CHECK FOR COMPLETE
CIRCUIT. CYCLE SWITCH FLOAT BACK
AND FORTH BY FILLING AND DEPLETING
RESERVOIR OF WASHER FLUID TO
CHECK FOR PROPER SWITCH FUNCTION.
IF NOT OK, REPLACE LOW FLUID LEVEL
SENSOR SWITCH.
LEAKING WASHER FLUID. 1. PUMP OR SENSOR
GROMMET DEFECTIVE.1. PROPERLY SEAT PUMP OR SENSOR IN
GROMMET. IF NOT OK, REPLACE PUMP
OR SENSOR GROMMET.
2. LEAKING WASHER PUMP. 2. REPLACE WASHER PUMP.
3. LEAKING FLUID LEVEL
SENSOR.3. REPLACE FLUID LEVEL SENSOR.
4. LEAKING OR DEFECTIVE
RESERVOIR BODY.4. REPLACE RESERVOIR BODY.
RSWIPERS/WASHERS8R-7
WIPERS/WASHERS (Continued)
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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.
8R - 8 WIPERS/WASHERSRS
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Page 561 of 2177
HEADLAMP WASHERS -
EXPORT
DESCRIPTION
The headlamp washers on this vehicle (Fig. 3)
work in conjunction with the windshield washers.
The headlamp washers are enabled with the head-
lamps ªONº and the windshield washers activated.
With the windshield washers 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. This will operate the windshield wash-
ers and direct two timed high pressure sprays onto
the headlamp lens.
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
8R - 10 WIPERS/WASHERSRS
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HEADLAMP WASHER TEST
CONDITION POSSIBLE CAUSE CORRECTION
HEADLAMP WASHER
SYSTEM WILL NOT FLOW
WASHER FLUID.1. NO WASHER FLUID IN
RESERVOIR.1. FILL RESERVOIR.
2. JUNCTION BLOCK FUSE
#5 BLOWN.2. SHORT CIRCUIT BETWEEN JUNCTION BLOCK
FUSE #5 AND WIPER SWITCH TERMINAL #1.
SHORT IN WIPER SWITCH. IF NOT OK, REPAIR
CIRCUIT OR REFER TO WIPER/WASHER
SWITCH DIAGNOSTIC PROCEDURES.
3. HEADLAMP WASHER
HOSE NOT FLOWING FLUID.3. ASSURE WASHER HOSE IS NOT PINCHED,
LOOSE, BROKEN, OR DISCONNECTED. IF NOT
OK, PROPERLY ROUTE OR REPAIR WASHER
HOSE.
4. MOTOR CONNECTOR
LOOSE.4. PROPERLY SEAT CONNECTOR TO MOTOR.
5. MOTOR CONNECTOR
TERMINALS BENT.5. REPAIR TERMINALS AND PROPERLY SEAT
CONNECTOR TO MOTOR.
6. OPEN POWER CIRCUIT
TO SWITCH.6. OPEN OR DEFECTIVE CIRCUIT BETWEEN
JUNCTION BLOCK FUSE #5 AND WASHER
SWITCH CONNECTOR TERMINAL #1. IF NOT OK,
REPAIR CIRCUIT.
7. OPEN OR DEFECTIVE
WIPER/WASHER SWITCH.7. CONNECT AN OHMMETER ACROSS WIPER/
WASHER SWITCH TERMINAL #1 AND #2 AND
DEPRESS WASHER BUTTON AND CHECK FOR
CONTINUITY. IF NOT OK, REFER TO WIPER/
WASHER SWITCH DIAGNOSTIC PROCEDURES.
8. OPEN POWER CIRCUIT
TO MOTOR.8. OPEN OR DEFECTIVE CIRCUIT BETWEEN
WIPER/WASHER SWITCH CONNECTOR
TERMINAL #2 AND MOTOR CONNECTOR
TERMINAL #1. IF NOT OK, REPAIR CIRCUIT.
9. OPEN OR DEFECTIVE
MOTOR GROUND CIRCUIT.9. OPEN OR DEFECTIVE CIRCUIT BETWEEN
WASHER MOTOR CONNECTOR GROUND
TERMINAL #2 AND LEFT HEADLAMP GROUND
#5 OR ENGINE GROUND #1 OR 2.
10. OPEN CIRCUIT IN
HEADLAMP WASHER
MOTOR.10. CHECK FOR AN OPEN CIRCUIT ON MOTOR
BETWEEN POWER TERMINAL #1 AND GROUND
TERMINAL #2. IF NOT OK, REPLACE WASHER
MOTOR.
11. SEIZED MOTOR
BEARINGS.11. APPLY DIRECT BATTERY VOLTAGE TO
MOTOR TERMINALS. IF MOTOR DOES NOT
RUN, REPLACE MOTOR.
12. DEFECTIVE HEADLAMP
WASHER RELAY.12. REPLACE THE HEADLAMP WASHER RELAY.
ONE HEADLAMP WASHER
NOZZLE WILL NOT FLOW
WASHER FLUID.1. HEADLAMP WASHER
HOSE NOT FLOWING FLUID.1. REPAIR OR REPLACE THE HEADLAMP
WASHER HOSE.
2. PLUGGED HEADLAMP
WASHER NOZZLE.2. REPLACE HEADLAMP WASHER NOZZLE.
RSWIPERS/WASHERS8R-11
HEADLAMP WASHERS - EXPORT (Continued)
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