Engine wiring JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

GROUP TAB LOCATOR
Introduction
0Lubrication & Maintenance
2Suspension
3Driveline
5Brakes
7Cooling
8AAudio
8BChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8LLamps
8MMessage Systems
8NPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WWiring
9Engine
11Exhaust System
13Frame & Bumpers
14Fuel System
19Steering
21Transaxle
22Tires/Wheels
23Body
24Heating & Air Conditioning
25Emissions Control
Service Manual Comment Forms (Rear of Manual)

CONDITION POSSIBLE CAUSES CORRECTION
17. Viscous fan drive not operating
properly.17. Check fan drive operation and replace as
necessary. (Refer to 7 - COOLING/ENGINE/
FAN DRIVE VISCOUS CLUTCH -
DIAGNOSIS AND TESTING).
18. Cylinder head gasket leaking. 18. Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS AND
TESTING). For repair, (Refer to 9 -
ENGINE/CYLINDER HEAD - REMOVAL).
19. Heater core leaking. 19. Check heater core for leaks. (Refer to 24
- HEATING & AIR CONDITIONING/
PLUMBING/HEATER CORE - REMOVAL).
Repair as necessary.
20. Hydraulic fan speed too low or
inopertive.20. Check for
DTC code.
Check fan operation speeds.
Refer to fan speed operation table.
Low power steering pump output. Refer to
power steering pump diagnosis - 4.7L engine.
TEMPERATURE GAUGE
READING IS
INCONSISTENT
(FLUCTUATES, CYCLES
OR IS ERRATIC)1. During cold weather operation,
with the heater blower in the high
position, the gauge reading may
drop slightly.1. A normal condition. No correction is
necessary.
2. Temperature gauge or engine
mounted gauge sensor defective or
shorted. Also, corroded or loose
wiring in this circuit.2. Check operation of gauge and repair if
necessary. Refer to Group 8J, Instrument
cluster.
3. Gauge reading rises when vehicle
is brought to a stop after heavy use
(engine still running)3. A normal condition. No correction is
necessary. Gauge should return to normal
range after vehicle is driven.
4. Gauge reading high after
re-starting a warmed up (hot)
engine.4. A normal condition. No correction is
necessary. The gauge should return to
normal range after a few minutes of engine
operation.
5. Coolant level low in radiator (air
will build up in the cooling system
causing the thermostat to open late).5. Check and correct coolant leaks. (Refer to
7 - COOLING - DIAGNOSIS AND TESTING).
6. Cylinder head gasket leaking
allowing exhaust gas to enter
cooling system causing a thermostat
to open late.6. (a) Check for cylinder head gasket leaks.
(Refer to 7 - COOLING - DIAGNOSIS AND
TESTING).
(b) Check for coolant in the engine oil.
Inspect for white steam emitting from the
exhaust system. Repair as necessary.
WJCOOLING 7 - 7
COOLING (Continued)

REMOVAL
REMOVALÐ4.0L ENGINE
WARNING: DO NOT LOOSEN THE RADIATOR
DRAINCOCK WITH THE SYSTEM HOT AND PRES-
SURIZED. SERIOUS BURNS FROM THE COOLANT
CAN OCCUR.
Do not waste reusable coolant. If the solution is
clean, drain the coolant into a clean container for
reuse.
(1) Drain the coolant from the radiator until the
level is below the thermostat housing (Refer to 7 -
COOLING - STANDARD PROCEDURE).
WARNING: CONSTANT TENSION HOSE CLAMPS
ARE USED ON MOST COOLING SYSTEM HOSES.
WHEN REMOVING OR INSTALLING, USE ONLY
TOOLS DESIGNED FOR SERVICING THIS TYPE OF
CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER
6094) (Fig. 52). SNAP-ON CLAMP TOOL (NUMBER
HPC-20) MAY BE USED FOR LARGER CLAMPS.
ALWAYS WEAR SAFETY GLASSES WHEN SERVIC-
ING CONSTANT TENSION CLAMPS.
CAUTION: A number or letter is stamped into the
tongue of constant tension clamps. If replacement
is necessary, use only an original equipment clamp
with matching number or letter.
(2) Remove radiator upper hose and heater hose at
thermostat housing.
(3) Disconnect wiring connector at engine coolant
temperature sensor.
(4) Remove thermostat housing mounting bolts,
thermostat housing, gasket and thermostat (Fig. 24).
Discard old gasket.
(5) Clean the gasket mating surfaces.
REMOVALÐ4.7L ENGINE
WARNING: DO NOT LOOSEN RADIATOR DRAIN-
COCK WITH SYSTEM HOT AND PRESSURIZED.
SERIOUS BURNS FROM COOLANT CAN OCCUR.
Do not waste reusable coolant. If solution is clean,
drain coolant into a clean container for reuse.
If thermostat is being replaced, be sure that
replacement is specified thermostat for vehicle model
and engine type.
(1) Disconnect negative battery cable at battery.
(2) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(3) Raise vehicle on hoist.
(4) Remove splash shield.(5) Remove lower radiator hose clamp and lower
radiator hose at thermostat housing.
(6) Remove thermostat housing mounting bolts,
thermostat housing and thermostat (Fig. 25).
INSTALLATION
INSTALLATIONÐ4.0L ENGINE
(1) Install the replacement thermostat so that the
pellet, which is encircled by a coil spring, faces the
engine. All thermostats are marked on the outer
flange to indicate the proper installed position.
(a) Observe the recess groove in the engine cyl-
inder head (Fig. 26).
(b) Position thermostat in groove with arrow and
air bleed hole on outer flange pointing up.
(2) Install replacement gasket and thermostat
housing.
CAUTION: Tightening the thermostat housing
unevenly or with the thermostat out of its recess,
may result in a cracked housing.
(3) Tighten the housing bolts to 22 N´m (16 ft. lbs.)
torque.
(4) Install hoses to thermostat housing.
Fig. 24 Thermostat
1 - LONG BOLT
2 - GASKET
3 - THERMOSTAT
4 - THERMOSTAT HOUSING
5 - SHORT BOLT
7 - 38 ENGINEWJ
ENGINE COOLANT THERMOSTAT (Continued)

AUDIO
DESCRIPTION
An audio system is standard factory-installed
equipment on this model. The standard equipment
audio system includes an AM/FM/cassette (RBB sales
code) radio receiver, and speakers in six locations.
Several combinations of radio receivers and speaker
systems are offered as optional equipment on this
model. The audio system uses an ignition switched
control of battery current so that the system will only
operate when the ignition switch is in the On or
Accessory positions.
A Compact Disc (CD) changer with a ten disc mag-
azine, remote radio switches with six functions
mounted to the backs of the steering wheel spokes,
and a memory system that automatically stores and
recalls up to twenty radio station presets (ten AM
and ten FM) and the last station listened to for two
drivers are optional factory-installed equipment on
this model. Refer to Electrical, Power Seats for more
information on the memory system.
The audio system includes the following compo-
nents:
²Antenna
²Compact disc changer (available with RBP sales
code radio receivers only)
²Power amplifier (with premium speaker system
only)
²Radio noise suppression components
²Radio receiver
²Remote radio switches
²Speakers
Certain functions and features of the audio system
rely upon resources shared with other electronic
modules in the vehicle over the Programmable Com-
munications Interface (PCI) data bus network. The
PCI data bus network allows the sharing of sensor
information. This helps to reduce wire harness com-
plexity, internal controller hardware, and component
sensor current loads. At the same time, this system
provides increased reliability, enhanced diagnostics,
and allows the addition of many new feature capabil-
ities. For diagnosis of these electronic modules or of
the PCI data bus network, the use of a DRB scan
tool and the proper Diagnostic Procedures manual
are recommended.
The other electronic modules that may affect audio
system operation are as follows:
²Body Control Module (BCM)- (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/BODY CONTROL/CENTRAL TIMER MODUL
- DESCRIPTION) for more information.
²Driver Door Module (DDM)(Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-ULES/DRIVER DOOR MODULE - DESCRIPTION)
for more information.
²Passenger Door Module (PDM)(Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/DRIVER DOOR MODULE - DESCRIPTION)
for more information.
The audio system includes the following major
components, which are described in further detail
elsewhere in this service information:
²Amplifier- On models equipped with the
optional premium speaker system, an audio power
amplifier is located on the rear floor panel under-
neath the right end of the rear seat cushion in the
passenger compartment.
²Antenna Body and Cable- The most visible
component of the antenna body and cable are the
antenna adapter and the antenna cap nut, which are
located on the top of the right front fender panel of
the vehicle, near the right end of the cowl plenum.
²Antenna Mast- The antenna mast is a metal
rod that extends upward from the antenna body and
cable on the top of the right front fender panel of the
vehicle, near the right end of the cowl plenum.
²Radio- The radio for this model is located in
the instrument panel center stack area, inboard of
the instrument cluster and above the heater and air
conditioner controls.
²Radio Noise Suppression Ground Strap-A
radio noise suppression ground strap is installed
between the rear of the engine cylinder head(s) and
the dash panel sheet metal in the engine compart-
ment.
²Speaker- The standard speaker system
includes six speakers in six locations, while the pre-
mium speaker system includes an amplifier for the
six speakers in six locations.
Hard wired circuitry connects the audio system
components to each other through the electrical sys-
tem 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
audio system components through the use of a com-
bination of soldered splices, splice block connectors
and many different types of wire harness terminal
connectors and insulators. Refer to the appropriate
wiring information in this service manual for com-
plete standard and premium audio system circuit
diagrams. The wiring information includes 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 har-
ness connectors, splices, and grounds.
8A - 2 AUDIOWJ

BCM programming then performs those tasks and
provides features through both PCI data bus commu-
nication with other electronic modules and hard
wired outputs to a number of relays. These relays
provide the BCM with the ability to control numer-
ous high current accessory systems in the vehicle.
The BCM circuitry operates on battery current
received through fuses in the Junction Block (JB) on a
non-switched fused B(+) circuit, a fused ignition switch
output (start-run) circuit, and a fused ignition switch
output (run-accessory) circuit. This arrangement allows
the BCM to provide some features regardless of the
ignition switch position. The BCM circuitry is grounded
through the chassis beneath the center console.
The BCM monitors its own internal circuitry as
well as many of its input and output circuits, and
will store a Diagnostic Trouble Code (DTC) in elec-
tronic memory for any failure it detects. These DTCs
can be retrieved and diagnosed using a DRBIIItscan
tool. Refer to the appropriate diagnostic information.
HARD WIRED INPUTS
The hard wired inputs to the BCM include the fol-
lowing:
²A/C switch signal
²Ambient temperature sensor signal
²Body control module flash enable
²Coolant level switch sense
²Door ajar switch sense (two circuits - one left
rear, and one right rear)
²Driver seat heater switch mux
²Fog lamp switch sense
²Fused B(+)
²Fused ignition switch output (run-acc)
²Fused ignition switch output (st-run)
²Ground (five circuits - two Z1, and three Z2)
²Hazard switch sense
²Headlamp switch mux
²High beam switch sense
²Hood ajar switch sense (export)
²Key-in ignition switch sense
²Liftgate ajar switch sense
²Liftgate courtesy disable
²Liftgate flip-up ajar switch sense
²Panel lamps dimmer signal
²Park lamp relay output
²Passenger seat heater switch mux
²PCI bus
²Radio control mux
²Rear window defogger switch sense
²Seat belt switch sense
²Ultralight sensor signal
²Washer fluid switch sense
²Washer pump switch sense
²Windshield wiper switch mux
²Wiper park switch sense
MESSAGING
The BCM uses the following messages received
from other electronic modules over the PCI data bus:
²Accessory Delay Control (DDM/PDM)
²Battery Temperature (PCM)
²Chime Request (EMIC, EVIC, SKIM)
²Cylinder Lock Switch Status (DDM)
²Door Ajar Status/Front Doors (DDM/PDM)
²Door Lock Status (DDM/PDM)
²Engine Model (PCM)
²Engine RPM (PCM)
²Engine Temperature (PCM)
²English/Metric Default (EMIC)
²Fuel Tank Level (PCM)
²Fuel Used/Injector Pulses (PCM)
²Panic Control (PDM)
²Programmable Features Preferences/Audible &
Optical Chirps/Headlamp Delay (EVIC)
²RKE Status (PDM)
²Vehicle Identification Number (PCM)
²Vehicle Speed (PCM)
The BCM provides the following messages to other
electronic modules over the PCI data bus:
²A/C Switch Status (PCM)
²Ambient Temperature Data (AZC/EVIC/PCM)
²Average/Instantaneous Fuel Economy (EVIC)
²Country Code (EMIC)
²Courtesy Lamp Status (DDM/PDM)
²Distance To Empty (EVIC)
²Elapsed Ignition On Timer (EVIC)
²English/Metric Status (EMIC)
²Front & Rear Door Ajar Status (EVIC)
²Front & Rear Fog Lamp Status (EMIC)
²Heated Seat Switch Status (HSM/MHSM)
²High Beam Status (EMIC)
²Ignition Off Timer (EVIC)
²Ignition Switch Position (DDM/PDM)
²Key-In Ignition Status (DDM/PDM)
²Low Beam Status (EMIC)
²Panel Lamp Status (AZC/EMIC/Radio)
²Rear Window Defogger Relay Status (DDM/
PDM)
²Remote Radio Switch Status (Radio)
²Seatbelt Status (EMIC/MHSM/MSM)
DIAGNOSIS AND TESTING - BODY CONTROL
MODULE
The hard wired inputs to and outputs from the
Body Control Module (BCM) may be diagnosed and
tested using conventional diagnostic tools and proce-
dures. Refer to the appropriate wiring information.
Conventional diagnostic methods may not prove
conclusive in the diagnosis of the BCM. In order to
obtain conclusive testing of the BCM, the Program-
mable Communications Interface (PCI) data bus net-
work and all of the electronic modules that provide
8E - 4 ELECTRONIC CONTROL MODULESWJ
BODY CONTROL MODULE (Continued)

INSTALLATION
(1) Install the MHSM,HSM into the bracket.
(2) Position the heated seat module and mounting
bracket onto the power seat track.
(3) Reconnect the power seat wiring harness con-
nectors to the heated seat module.
(4) Install the driver side front bucket seat onto
the power seat track unit (Refer to 23 - BODY/
SEATS/SEAT TRACK ADJUSTER - INSTALLA-
TION).
(5) Reconnect the battery negative cable.
NOTE: If the vehicle is equipped with the optional
Memory System, following installation, it will be
necessary to initialize the Memory Heated Seat
Module (MHSM). In order to function properly, the
MHSM must ªlearnº the sensor values of each of
the power seat motor position transducers in each
of the adjuster hard stop positions. This is done by
performing the ªReset Guard Bandº procedure
using a DRBIIITscan tool and the proper Diagnostic
Procedures manual.
WARNING: THE ªRESET GUARD BANDº PROCE-
DURE WILL CAUSE THE DRIVER SIDE FRONT
SEAT TO AUTOMATICALLY ADJUST TO EACH OF
ITS TRAVEL LIMITS. BE CERTAIN THAT NO ONE IS
SEATED IN THE VEHICLE AND THAT THERE IS
NOTHING IN THE VEHICLE THAT WILL OBSTRUCT
SEAT MOVEMENT. FAILURE TO OBSERVE THIS
WARNING COULD RESULT IN PERSONAL INJURIES
AND/OR VEHICLE DAMAGE.
POWERTRAIN CONTROL
MODULE
DESCRIPTION
DESCRIPTION - PCM
The Powertrain Control Module (PCM) is located
in the engine compartment (Fig. 11). The PCM is
referred to as JTEC.
MODES OF OPERATION
As input signals to the Powertrain Control Module
(PCM) change, the PCM adjusts its response to the
output devices. For example, the PCM must calculate
different injector pulse width and ignition timing for
idle than it does for wide open throttle (WOT).
The PCM will operate in two different modes:
Open Loop and Closed Loop.
During Open Loop modes, the PCM receives input
signals and responds only according to preset PCMprogramming. Input from the oxygen (O2S) sensors
is not monitored during Open Loop modes.
During Closed Loop modes, the PCM will monitor
the oxygen (O2S) sensors input. This input indicates
to the PCM whether or not the calculated injector
pulse width results in the ideal air-fuel ratio. This
ratio is 14.7 parts air-to-1 part fuel. By monitoring
the exhaust oxygen content through the O2S sensor,
the PCM can fine tune the injector pulse width. This
is done to achieve optimum fuel economy combined
with low emission engine performance.
The fuel injection system has the following modes
of operation:
²Ignition switch ON
²Engine start-up (crank)
²Engine warm-up
²Idle
²Cruise
²Acceleration
²Deceleration
²Wide open throttle (WOT)
²Ignition switch OFF
The ignition switch On, engine start-up (crank),
engine warm-up, acceleration, deceleration and wide
open throttle modes are Open Loop modes. The idle
and cruise modes, (with the engine at operating tem-
perature) are Closed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
This is an Open Loop mode. When the fuel system
is activated by the ignition switch, the following
actions occur:
Fig. 11 PCM Location
1 - PCM
2 - COOLANT TANK
8E - 12 ELECTRONIC CONTROL MODULESWJ
MEMORY HEATED SEAT/MIRROR MODULE (Continued)

Certain mechanical failures within the input clutch
assembly can cause inadequate or out-of-range ele-
ment volumes. Also, defective Input/Output Speed
Sensors and wiring can cause these conditions. The
following chart identifies the appropriate clutch vol-
umes and when they are monitored/updated:
CLUTCH VOLUMES
Clutch When UpdatedProper Clutch
Volume
L/R2-1 or 3-1
downshift45 to 134
2C3-2 kickdown
shift25 to 85
OD 2-3 upshift 30 to 100
4C 3-4 upshift 30 to 85
UD4-3 kickdown
shift30 to 100
SHIFT SCHEDULES
As mentioned earlier, the TCM has programming
that allows it to select a variety of shift schedules.
Shift schedule selection is dependent on the follow-
ing:
²Shift lever position
²Throttle position
²Engine load
²Fluid temperature
²Software level
As driving conditions change, the TCM appropri-
ately adjusts the shift schedule. Refer to the follow-
ing chart to determine the appropriate operation
expected, depending on driving conditions.
Schedule Condition Expected Operation
Extreme ColdOil temperature below -16É F -Park, Reverse, Neutral and 1st and
3rd gear only in D position, 2nd
gear only in Manual 2 or L
-No EMCC
Super ColdOil temperature between -12É F and
10É F- Delayed 2-3 upshift
- Delayed 3-4 upshift - Early 4-3
coastdown shift
- High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
-Shifts at high throttle openings willl
be early.
- No EMCC
ColdOil temperature between 10É F and
36É F-Shift schedule is the same as
Super Cold except that the 2-3
upshifts are not delayed.
WarmOil temperature between 40É F and
80É F- Normal operation (upshift,
kickdowns, and coastdowns)
- No EMCC
HotOil temperature between 80É F and
240É F- Normal operation (upshift,
kickdowns, and coastdowns) -
Normal EMCC operation
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F- Delayed 2-3 upshift
- Delayed 3-4 upshift
- 3rd gear FEMCC from 30-48 mph
- 3rd gear PEMCC above 35 mph
- Above 25 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
WJELECTRONIC CONTROL MODULES 8E - 21
TRANSMISSION CONTROL MODULE (Continued)

The battery cables (Fig. 17) or (Fig. 18) are large
gauge, stranded copper wires sheathed within a
heavy plastic or synthetic rubber insulating jacket.
The wire used in the battery cables combines excel-
lent flexibility and reliability with high electrical cur-
rent carrying capacity. Refer toWiring Diagrams
for battery cable wire gauge information.
A clamping type female battery terminal made of
soft lead is die cast onto one end of the battery cable
wire. A square headed pinch-bolt and hex nut are
installed at the open end of the female battery termi-
nal clamp. Large eyelet type terminals are crimped
onto the opposite end of the battery cable wire and
then solder-dipped. The battery positive cable wires
have a red insulating jacket to provide visual identi-
fication and feature a larger female battery terminal
clamp to allow connection to the larger battery posi-
tive terminal post. The battery negative cable wires
have a black insulating jacket and a smaller female
battery terminal clamp.
The battery cables cannot be repaired and, if dam-
aged or faulty they must be replaced. Both the bat-
tery positive and negative cables are available for
service replacement only as a unit with the battery
wire harness, which may include portions of the wir-
ing circuits for the generator and other components
on some models. Refer toWiring Diagramsfor more
information on the various wiring circuits included in
the battery wire harness for the vehicle being ser-
viced.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables
also provide a path back to the battery for electrical
current generated by the charging system for restor-
ing the voltage potential of the battery. The female
battery terminal clamps on the ends of the battery
cable wires provide a strong and reliable connection
of the battery cable to the battery terminal posts.
The terminal pinch bolts allow the female terminal
clamps to be tightened around the male terminal
posts on the top of the battery. The eyelet terminals
secured to the opposite ends of the battery cable
wires from the female battery terminal clamps pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.
The battery positive cable terminal clamp is die
cast onto the ends of two wires. One wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the Power Distribution
Center (PDC), and the other wire has an eyelet ter-
minal that connects the battery positive cable to the
B(+) terminal stud of the engine starter motor sole-
noid. The battery negative cable terminal clamp is
also die cast onto the ends of two wires. One wirehas an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the right side of the engine cylinder block. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the right front fender inner shield,
near the battery.
DIAGNOSIS AND TESTING - BATTERY CABLES
A voltage drop test will determine if there is exces-
sive resistance in the battery cable terminal connec-
tions or the battery cable. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion or foreign material, then reassembled.
Following reassembly, check the voltage drop for the
battery cable connection and the battery cable again
to confirm repair.
When performing the voltage drop test, it is impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached.EXAM-
PLE:When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive cable eyelet terminal at the starter solenoid
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
terminal at the starter solenoid B(+) terminal stud,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
post connection and the battery positive cable.
VOLTAGE DROP TEST
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing this
test, be certain that the following procedures are
accomplished:
²The battery is fully-charged and load tested.
Refer to Standard Procedures for the proper battery
charging and load test procedures.
²Fully engage the parking brake.
²If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position.
²Verify that all lamps and accessories are turned
off.
²To prevent the engine from starting, remove the
Automatic Shut Down (ASD) relay. The ASD relay is
located in the Power Distribution Center (PDC), in
the engine compartment. See the fuse and relay lay-
out label affixed to the underside of the PDC cover
for ASD relay identification and location.
8F - 18 BATTERY SYSTEMWJ
BATTERY CABLE (Continued)

CHARGING
TABLE OF CONTENTS
page page
CHARGING
DESCRIPTION.........................24
OPERATION...........................24
DIAGNOSIS AND TESTING - CHARGING
SYSTEM............................24
SPECIFICATIONS
GENERATOR RATINGS - GAS POWERED . . 25
TORQUE - GAS POWERED.............25
SPECIAL TOOLS.......................26
BATTERY TEMPERATURE SENSOR
DESCRIPTION.........................26OPERATION...........................26
REMOVAL.............................26
INSTALLATION.........................26
GENERATOR
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................28
VOLTAGE REGULATOR
DESCRIPTION.........................28
OPERATION...........................28
CHARGING
DESCRIPTION
The charging system consists of:
²Generator
²Electronic Voltage Regulator (EVR) circuitry
within the Powertrain Control Module (PCM)
²Ignition switch
²Battery (refer to 8, Battery for information)
²Battery temperature sensor
²Generator Lamp (if equipped)
²Check Gauges Lamp (if equipped)
²Voltmeter (refer to 8, Instrument Cluster for
information)
²Wiring harness and connections (refer to 8, Wir-
ing for information)
OPERATION
The charging system is turned on and off with the
ignition switch. The system is on when the engine is
running and the ASD relay is energized. When the
ASD relay is on, voltage is supplied to the ASD relay
sense circuit at the PCM. This voltage is connected
through the PCM and supplied to one of the genera-
tor field terminals (Gen. Source +) at the back of the
generator.
The amount of DC current produced by the gener-
ator is controlled by the EVR (field control) circuitry
contained within the PCM. This circuitry is con-
nected in series with the second rotor field terminal
and ground.
A battery temperature sensor, located in the bat-
tery tray housing, is used to sense battery tempera-
ture. This temperature data, along with data from
monitored line voltage, is used by the PCM to vary
the battery charging rate. This is done by cycling theground path to control the strength of the rotor mag-
netic field. The PCM then compensates and regulates
generator current output accordingly.
All vehicles are equipped with On-Board Diagnos-
tics (OBD). All OBD-sensed systems, including EVR
(field control) circuitry, are monitored by the PCM.
Each monitored circuit is assigned a Diagnostic Trou-
ble Code (DTC). The PCM will store a DTC in elec-
tronic memory for certain failures it detects. Refer to
Diagnostic Trouble Codes in; Powertrain Control
Module; Electronic Control Modules for more DTC
information.
The Check Gauges Lamp (if equipped) monitors:
charging system voltage,engine coolant tempera-
ture and engine oil pressure. If an extreme condition
is indicated, the lamp will be illuminated. This is
done as reminder to check the three gauges. The sig-
nal to activate the lamp is sent via the CCD bus cir-
cuits. The lamp is located on the instrument panel.
Refer to 8, Instrument Cluster for additional infor-
mation.
DIAGNOSIS AND TESTING - CHARGING
SYSTEM
The following procedures may be used to diagnose
the charging system if:
²the check gauges lamp (if equipped) is illumi-
nated with the engine running
²the voltmeter (if equipped) does not register
properly
²an undercharged or overcharged battery condi-
tion occurs.
Remember that an undercharged battery is often
caused by:
²accessories being left on with the engine not
running
8F - 24 CHARGINGWJ

SPECIAL TOOLS
BATTERY TEMPERATURE
SENSOR
DESCRIPTION
The Battery Temperature Sensor (BTS) is attached
to the battery tray located under the battery.
OPERATION
The BTS is used to determine the battery temper-
ature and control battery charging rate. This temper-
ature data, along with data from monitored line
voltage, is used by the PCM to vary the battery
charging rate. System voltage will be higher at colder
temperatures and is gradually reduced at warmer
temperatures.
The PCM sends 5 volts to the sensor and is
grounded through the sensor return line. As temper-
ature increases, resistance in the sensor decreases
and the detection voltage at the PCM increases.The BTS is also used for OBD II diagnostics. Cer-
tain faults and OBD II monitors are either enabled
or disabled, depending upon BTS input (for example,
disable purge and enable Leak Detection Pump
(LDP) and O2 sensor heater tests). Most OBD II
monitors are disabled below 20 degrees F.
REMOVAL
The battery temperature sensor is located under
the vehicle battery (Fig. 1) and is attached to a
mounting hole on the battery tray.
The battery temperature sensor is located under
the vehicle battery (Fig. 1) and is attached to a
mounting hole on the battery tray.
(1) Remove battery. Refer to Group 8A, Battery for
procedures.
(2) Remove battery tray.
(3) Pull sensor up from battery tray and discon-
nect engine wire harness.
(4) Remove sensor from battery tray.
INSTALLATION
The battery temperature sensor is located under
the vehicle battery (Fig. 1) and is attached to a
mounting hole on the battery tray.
(1) Position sensor into mounting hole and attach
wiring harness.
(2) Press sensor into top of battery tray.
(3) Install battery. Refer to Group 8A, Battery for
procedures.
GENERATOR DECOUPLER TOOL #8433
GENERATOR DECOUPLER TOOL #8823
Fig. 1 Battery Temperature Sensor Location
1 - BATTERY TEMPERATURE SENSOR
2 - ENGINE WIRE HARNESS
3 - BATTERY TRAY
8F - 26 CHARGINGWJ
CHARGING (Continued)