CHRYSLER VOYAGER 2002 Service Manual

CONDITION POSSIBLE CAUSES CORRECTION
3. BLADE STRUCTURE BENT. 3. REPLACE BLADE.
4. BLADE ELEMENT HAS
PERMANENT SET.4. REPLACE BLADE.
WIPER KNOCK AT
REVERSAL1. LINKAGE BUSHINGS WORN. 1. REPLACE WORN LINK. REFER TO
WIPER LINKAGE REMOVAL AND
INSTALLATION.
2. ARMATURE ENDPLAY IN
MOTOR.2. REPLACE WIPER MOTOR. REFER TO
WIPER MOTOR REMOVAL AND
INSTALLATION.
WIPER MOTOR WILL NOT
RUN1. BLOWN FUSE. 1. REPLACE FUSE, AND RUN SYSTEM.
2. NEW FUSE BLOWS. 2. CHECK FOR SHORT IN WIRING OR
SWITCH.
3. NEW FUSE BLOWS. 3. REPLACE FUSE, REMOVE MOTOR
CONNECTOR, TURN SWITCH ON, FUSE
DOES NOT BLOW, REPLACE MOTOR.
4. NO VOLTAGE AT MOTOR. 4. CHECK SWITCH AND WIRING
HARNESS. REFER TO WIRING
DIAGRAMS.
5. POOR GROUND. 5. REPAIR GROUND WIRE CONNECTION
AS NECESSARY.
8R - 4 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)
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DIAGNOSIS AND TESTING - REAR WIPER
SYSTEM
The rear window wiper system operates in several
modes:
²Continuous wipe
²Intermittent wipe
²Wash
²Wipe after wash
The windshield wiper circuits are continuously
monitored and controlled by the Body Control Mod-ule (BCM). If a problem occurs in the electronic com-
ponents, wiring, switch (except integral motor park
switch) and wiper motor a Diagnostic Trouble Code
(DTC) will be stored in the BCM memory. The
DTC(s) can be retrieved using a DRB IIItscan tool.
DIAGNOSIS AND TESTING - WASHER SYSTEM
WASHER SYSTEM DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
WASHER MOTOR 1. IPM FUSE #33 BLOWN OR
DEFECTIVE.1. CHECK FUSE #33 IN THE IPM.
REPLACE IF NOT OK.
2. IPM FUSE #33 LOOSE. 2. PROPERLY INSTALL IPM FUSE #33 IN
SOCKET.
BLOWN FUSE WHEN
IGNITION SWITCH IS IN
THE RUN OR ACCESSORY
POSITION.1. SHORT IN IPM BETWEEN
FUSE #33 AND PIN 11 OR PIN
1.1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. SHORT IN MOTOR POWER
CIRCUIT.2. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 11 AND WASHER
MOTOR CONNECTOR POSITIVE
TERMINAL 2. IF NOT OK, REPAIR CIRCUIT.
3. SHORT IN WASHER PUMP
MOTOR.3. REPLACE WASHER PUMP MOTOR.
WASHER MOTOR RUNS
WHEN IGNITION SWITCH
IN RUN OR ACCESSORY
POSITION.1. SHORT IN IPM BETWEEN
WASHER PUMP MOTOR LSD
AND PIN 20.1. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
2. DEFECTIVE FRONT
WASHER LSD IN IPM.2. REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
3. SHORT IN MOTOR GROUND
CIRCUIT.3. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 20 AND MOTOR
CONNECTOR NEGATIVE TERMINAL 1. IF
NOT OK, REPAIR CIRCUIT.
RSWIPERS/WASHERS8R-5
WIPERS/WASHERS (Continued)
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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.
8R - 6 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)
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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.
2. NOZZLE JET(S) OUT OF
ADJUSTMENT.2. ADJUST NOZZLE JET(S) USING A
SAFETY PIN.
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.
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.
RSWIPERS/WASHERS8R-7
WIPERS/WASHERS (Continued)
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CONDITION POSSIBLE CAUSES CORRECTION
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.
8R - 8 WIPERS/WASHERSRS
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.
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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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.
8R - 12 WIPERS/WASHERSRS
HEADLAMP WASHERS - EXPORT (Continued)
ProCarManuals.com

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Hoist vehicle or support on jack stands.
(3) Disconnect the hose from the nozzle inlet. To
disconnect the headlamp washer hose, push down on
the latch with slight force and pull apart.
(4) Apply a regulated 20 psi of compressed air to
the inlet, so as to fully extend the telescopic unit.
WARNING: IF MORE THAN 20 PSI IS APPLIED TO
THE WASHER INLET, WASHER FLUID MAY SPRAY
OUT OF THE HEADLAMP WASHER. WEAR SAFETY
GLASSES AND DO NOT HAVE AIMING DIRECTLY
TOWARD FACE.
(5) Unsnap cover from telescopic assembly.
(6) Disconnect air supply from washer inlet to fully
retract the telescopic unit.
(7) Remove two screws holding the nozzle assem-
bly to the front fascia.
(8) Remove the nozzle assembly from behind fas-
cia.
INSTALLATION
(1) Place the nozzle assembly in behind the fascia.
(2) Install the two screws holding the nozzle
assembly to the front fascia.
(3) Snap cover onto telescopic assembly.
WARNING: IF MORE THAN 20 PSI IS APPLIED TO
THE WASHER INLET, WASHER FLUID MAY SPRAY
OUT OF THE HEADLAMP WASHER. WEAR SAFETY
GLASSES AND DO NOT HAVE AIMING DIRECTLY
TOWARD FACE.
On the new washer unit, there is a white tab with
pull ring holding the telescopic unit up approxi-
mately an inch. This is to ease the installation pro-
cess. Once cover is snapped on, you may either pull
up on the unit to remove the tab, or apply regulated
compressed air.
(4) Apply a regulated 20 psi of compressed air the
inlet, so as to fully extend the telescopic unit.
(5) With unit extended, pull white tab out from the
bottom of the telescopic unit and discard.
(6) Remove the air supply from the washer unit.
(7) Connect the washer hose to the telescopic unit.
Press firmly until snap is heard.
(8) Remove vehicle from hoist or jack stands.
(9) Connect the battery negative cable.
(10) Verify vehicle and system operation.
HEADLAMP WASHER HOSE -
EXPORT
REMOVAL
The headlamp washer hose is a special high pres-
sure hose with specific fittings, and must be replaced
as a unit.
(1) Disconnect and isolate the battery negative
cable.
(2) Hoist vehicle or support on jack stands.
(3) Remove parts as necessary to replace high
pressure headlamp washer hose. When disconnecting
hose, press down firmly on latch at headlamp washer
pump motor and telescopic washer assembly and pull
apart.
INSTALLATION
The headlamp washer hose is a special high pres-
sure hose with specific fittings, and must be replaced
as a unit.
(1) Install the new high pressure headlamp
washer hose assembly. Push fitting on until a snap is
heard.
(2) Install the parts that were removed to replace
high pressure headlamp washer hose.
(3) Remove vehicle from hoist or jack stands.
(4) Connect the battery negative cable.
(5) Verify vehicle and system operation.
HEADLAMP WASHER PUMP
MOTOR - EXPORT
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).
RSWIPERS/WASHERS8R-13
HEADLAMP WASHERS - EXPORT (Continued)
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