Windows control JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

POWER WINDOWS
TABLE OF CONTENTS
page page
POWER WINDOWS
DESCRIPTION.........................33
OPERATION...........................34
DIAGNOSIS AND TESTING - POWER
WINDOWS...........................34
POWER WINDOW SWITCH
DESCRIPTION.........................36
OPERATION...........................36
DIAGNOSIS AND TESTING - POWER
WINDOW SWITCH.....................37REMOVAL.............................37
INSTALLATION.........................38
WINDOW MOTOR
DESCRIPTION.........................38
OPERATION...........................38
DIAGNOSIS AND TESTING - WINDOW
MOTOR .............................38
REMOVAL.............................39
INSTALLATION.........................39
POWER WINDOWS
DESCRIPTION
Power operated driver side and passenger side
front and rear door windows are standard factory-in-
stalled equipment on this model. The power window
system allows each of the door windows to be raised
or lowered electrically by operating a switch on the
trim panel for that door. Additionally, the master
switches on the driver side front door trim panel
allow all of the windows to be operated from the
driver seat position. A power window lockout switch
on the driver side front door trim panel will allow the
driver to disable all of the passenger door window
switches.
The power window system functionally operates
when the ignition switch is in the On position. How-
ever, a unique feature of this system will allow the
power windows to be operated for up to forty-five sec-
onds after the ignition switch is turned to the Off
position, or until a front door is opened, whichever
occurs first.
An auto-down feature allows the driver side front
door window to be lowered all the way, even if the
window switch is released. The driver side front door
window switch must be depressed in the down direc-
tion to a second detent to begin an auto-down event.
Depressing the switch again in any direction cancel
the auto-down event and begin movement in the
direction specified.
This group covers the following components of the
power window system:
²Power window switches
²Power window motors.
Certain functions and features of the power win-
dow system rely upon resources shared with other
electronic modules in the vehicle over the Program-mable Communications Interface (PCI) data bus net-
work. The PCI data bus network allows the sharing
of sensor information. This helps to reduce wire har-
ness complexity, 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 fea-
ture capabilities. 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 power
window 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.
This group covers diagnosis and service of only the
electrical components in the power window system.
For service of mechanical components, such as the
regulator, lift plate, window tracks, or glass refer to
Body. Refer to the appropriate wiring information.
The wiring information includes wiring diagrams,
proper wire and connector repair procedures, details
of wire harness routing and retention, connector pin-
out information and location views for the various
wire harness connectors, splices and grounds. Follow-
ing are general descriptions of the major components
in the power window system.
WJPOWER WINDOWS 8N - 33

OPERATION
The power window system includes the Driver
Door Module (DDM) and Passenger Door Module
(PDM), which are mounted in their respective front
door, the rear door power window switches mounted
on the rear doors, and the power window motors
mounted to the window regulator in each door. The
DDM houses four master power window switches, the
power window lockout switch and the control logic for
the driver side front and rear door power windows.
The PDM houses the passenger side front door power
window switch and the control logic for the passenger
side front and rear door power windows.
When a master power window switch on the DDM
is used to operate a passenger side power window,
the DDM sends the window switch actuation mes-
sage to the PDM over the Programmable Communi-
cations Interface (PCI) data bus. The PDM responds
to these messages by sending control outputs to move
the passenger side power window motors. In addi-
tion, when the power window lockout switch in the
DDM is actuated to disable power window operation,
a lockout message is sent to the PDM over the PCI
data bus.
The Body Control Module (BCM) also supports and
controls certain features of the power window sys-
tem. The BCM receives a hard wired input from the
ignition switch. The programming in the BCM allows
it to process the information from this input and
send ignition switch status messages to the DDM
and the PDM over the PCI data bus. The DDM and
PDM use this information and hard wired inputs
from the front door ajar switches to control the light-
ing of the power window switch lamps, and to control
the operation of the power window after ignition-off
feature.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of the power window system.
DIAGNOSIS AND TESTING - POWER
WINDOWS
Following are tests that will help to diagnose the
hard wired components and circuits of the power
window system. However, these tests may not prove
conclusive in the diagnosis of this system. In order to
obtain conclusive testing of the power window sys-
tem, the Programmable Communications Interface
(PCI) data bus network and all of the electronic mod-
ules that provide inputs to, or receive outputs from
the power window system components must be
checked.The most reliable, efficient, and accurate means to
diagnose the power window system requires the use
of a DRB scan tool and the proper Diagnostic Proce-
dures manual. The DRB scan tool can provide confir-
mation that the PCI data bus is functional, that all
of the electronic modules are sending and receiving
the proper messages on the PCI data bus, and that
the power window motors are being sent the proper
hard wired outputs by the door modules for them to
perform their power window system functions.
For complete circuit diagrams, refer to the appro-
priate wiring information. The wiring information
includes wiring diagrams, proper wire and connector
repair procedures, details of wire harness routing
and retention, connector pin-out information and
location views for the various wire harness connec-
tors, splices and grounds.
ALL WINDOWS INOPERATIVE
(1) Check the operation of the power lock switch
on the driver side front door. If all of the doors lock
and unlock, but none of the power windows operate,
use a DRB scan tool and the proper Diagnostic Pro-
cedures manual to check the Body Control Module
(BCM), the Driver Door Module (DDM) and the PCI
data bus for proper operation. If not OK, go to Step
2.
(2) Check the operation of the power lock switch
on the passenger side front door. If the passenger
doors lock and unlock, but the driver side front door
does not, go to Step 5. If all of the power locks and
power windows are inoperative from both front doors,
go to Step 3.
(3) Check the fused B(+) fuse in the Power Distri-
bution Center (PDC). If OK, go to Step 4. If not OK,
repair the shorted circuit or component as required
and replace the faulty fuse.
(4) Check for battery voltage at the fused B(+) fuse
in the PDC. If OK, go to Step 5. If not OK, repair the
open fused B(+) circuit to the battery as required.
(5) Disconnect and isolate the battery negative
cable. Remove the trim panel from the driver side
front door. Disconnect the 15-way door wire harness
connector from the DDM connector receptacle. Check
for continuity between the ground circuit cavity of
the 15-way door wire harness connector for the DDM
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) Reconnect the battery negative cable. Check for
battery voltage at the fused B(+) circuit cavity of the
15-way door wire harness connector for the DDM. If
OK, replace the faulty DDM. If not OK, repair the
open fused B(+) circuit to the fuse in the PDC as
required.
8N - 34 POWER WINDOWSWJ
POWER WINDOWS (Continued)

and no voltage in the neutral position. If OK,(Refer
to 8 - ELECTRICAL/POWER WINDOWS/WINDOW
MOTOR - DIAGNOSIS AND TESTING). If not OK,
replace the faulty door module.
(9) Check the rear door power window switch con-
tinuity. (Refer to 8 - ELECTRICAL/POWER WIN-
DOWS/POWER WINDOW SWITCH - DIAGNOSIS
AND TESTING). If OK, go to Step 10. If not OK,
replace the faulty rear door power window switch.
(10) Disconnect and isolate the battery negative
cable. Reconnect the door wire harness connector to
the rear door power window switch. Disconnect the
door wire harness connector from the inoperative
power window motor wire harness connector. Check
for continuity between the rear window driver up cir-
cuit cavity of the 15-way door wire harness connector
for the door module and a good ground. Repeat the
check for the rear window driver down circuit. In
each case there should be no continuity. If OK, go to
Step 11. If not OK, repair the shorted rear window
driver up or down circuit as required.
(11) Check for continuity between the rear window
driver up circuit cavities of the 15-way door wire har-
ness connector for the door module and the power
window motor wire harness connector. Repeat the
check for the rear window driver down circuit. In
each case there should be continuity. If OK, go to
Step 12. If not OK, repair the open rear window
driver up or down circuit as required.
NOTE: The door module feeds battery current to
both terminals of the rear door power window
motors when the power window lockout switch is in
the Unlock position, until the master window switch
on the driver side front door is actuated. The door
module feeds ground to both terminals of the rear
door power window motor when the power window
lockout switch is in the Lock position, until the
master window switch on the driver side front door
is actuated.
(12) Reconnect the 15-way door wire harness con-
nector for the door module to the door module con-
nector receptacle. Connect the battery negative cable.
Check for battery voltage at each cavity in the door
wire harness connector for the power window motor.
Each cavity should have battery voltage when the
power window switch is in the neutral position. Each
cavity should also have battery voltage in one other
switch position, either up or down, and zero volts
with the switch in the opposite position. If OK, (Refer
to 8 - ELECTRICAL/POWER WINDOWS/WINDOW
MOTOR - DIAGNOSIS AND TESTING). If not OK,
replace the faulty door module.POWER WINDOW SWITCH
DESCRIPTION
The power window motors are controlled by a two-
way momentary switch mounted on the trim panel of
each passenger door, and four two-way momentary
switches on the driver side front door trim panel. The
driver side front door trim panel also has a two-posi-
tion power window lockout switch. Each power win-
dow switch, except the lockout switch, is illuminated
by a Light-Emitting Diode (LED) that is integral to
the switch paddle.
The front door power window switches and the
power window lockout switch are integral to the
Driver Door Module (DDM) and Passenger Door
Module (PDM). The front door power window
switches and their lamps cannot be adjusted or
repaired and, if faulty or damaged, the entire DDM
or PDM unit must be replaced. The rear door power
window switches and their lamps cannot be adjusted
or repaired but, if faulty or damaged, only the
affected rear door power window switch must be
replaced. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/DRIVER DOOR MODULE -
REMOVAL).
OPERATION
The front door power window switches provide an
up or down (or lock and unlock signal in the case of
the lockout switch) to the door module circuitry. The
Driver Door Module (DDM) circuitry controls the out-
put to the driver side front and rear door power win-
dow motors, and supplies electrical current as
required for the stand-alone operation of the driver
side rear door power window switch. The Passenger
Door Module (PDM) circuitry controls the output to
the passenger side front and rear door power window
motors, and supplies electrical current as required
for the stand-alone operation of the passenger side
rear door power window switch.
When a DDM-integrated master power window
switch for a passenger side window is actuated, or
when the power window lockout switch is actuated to
disable the passenger door power windows, the DDM
circuitry sends a message to the PDM over the Pro-
grammable Communications Interface (PCI) data bus
to control the output to that power window motor(s).
The power window switch for the driver side front
door power window has two detent positions in the
Down direction. The first detent provides normal
power window down operation. If this switch is
depressed to the second detent, the Auto Down cir-
cuitry of the DDM is activated. The Auto-Down cir-
cuitry will automatically move the driver side front
door window to its fully lowered position, even if the
power window switch is released. The Auto-Down
8N - 36 POWER WINDOWSWJ
POWER WINDOWS (Continued)

INSTALLATION
(1) Position the power window switch to the rear
door trim panel switch receptacle.
(2) Press firmly and evenly on the back of the
power window switch until it snaps into rear door
trim panel switch receptacle.
(3) Install the trim panel onto the rear door. (Refer
to 23 - BODY/DOORS - REAR/TRIM PANEL -
INSTALLATION) for the procedures.
(4) Reconnect the battery negative cable.
WINDOW MOTOR
DESCRIPTION
Power operated front and rear door windows are
standard equipment on this model. Each door has a
permanent magnet reversible electric motor with an
integral right angle gearbox mechanism that oper-
ates the window regulator. In addition, each power
window motor is equipped with an integral self-reset-
ting circuit breaker to protect the motor from over-
loads.
The power window motor gearbox housing is
secured to the window regulator drum housing with
screws. The window regulators used in all four doors
are single vertical post cable-and-drum type. A
molded plastic slider guided by the post is driven by
the regulator cables. The slider raises and lowers the
window glass through a steel lift plate attachment.
Front and rear glass channels within each door guide
and stabilize each end of the glass.
The power window motor and gearbox assembly
cannot be repaired and, if faulty or damaged, the
entire power window motor and gearbox unit must be
replaced. The window regulators are available for
service. (Refer to 23 - BODY/DOOR - FRONT/WIN-
DOW REGULATOR - REMOVAL) or (Refer to 23 -
BODY/DOORS - REAR/WINDOW REGULATOR -
REMOVAL) for the regulator service procedures.
OPERATION
A positive and negative battery connection to the
two motor terminals will cause the power window
motor to rotate in one direction. Reversing the cur-
rent through these same two connections will cause
the motor to rotate in the opposite direction.
When the power window motor operates, it rotates
the regulator cable drum through its gearbox. The
window regulator cable drum is connected through
two cables to the plastic slider on the vertical post.
As the cable drum rotates, it lets cable out on one
side of the drum, and takes cable in on the other side
of the drum. The changes in cable length move the
slider up or down the vertical post, raising or lower-
ing the window glass.If the window regulator or window glass bind,
encounter obstructions, or reach their travel limits it
overloads the power window motor. The overloading
condition causes the power window motor self-reset-
ting circuit breaker to open, which stops the motor
from running.
DIAGNOSIS AND TESTING - WINDOW MOTOR
Before you proceed with this diagnosis, confirm
proper switch operation. (Refer to 8 - ELECTRICAL/
ELECTRONIC CONTROL MODULES/DRIVER
DOOR MODULE - OPERATION) or (Refer to 8 -
ELECTRICAL/POWER WINDOWS/POWER WIN-
DOW SWITCH - OPERATION). For complete circuit
diagrams, refer to the appropriate wiring informa-
tion. The wiring information includes wiring dia-
grams, proper wire and connector repair procedures,
details of wire harness routing and retention, connec-
tor pin-out information and location views for the
various wire harness connectors, splices and grounds.
(1) Remove the trim panel from the door with the
inoperative power window. (Refer to 23 - BODY/
DOOR - FRONT/TRIM PANEL - REMOVAL) or
(Refer to 23 - BODY/DOORS - REAR/TRIM PANEL -
REMOVAL) for the procedures.
(2) Disconnect the door wire harness connector
from the power window motor wire harness connec-
tor. Apply battery current to one cavity of the power
window motor wire harness connector, and apply
ground to the other cavity of the connector. The
power window motor should operate in one direction.
Remember, if the window is in the full up or full
down position, the motor will not operate in that
direction by design. If OK, go to Step 3. If not OK,
replace the faulty power window motor.
(3) Reverse the battery and ground connections to
the two cavities of the power window motor wire har-
ness connector. The power window motor should now
operate in the other direction. Remember, if the win-
dow is in the full up or full down position, the motor
will not operate in that direction by design. If OK, go
to Step 4. If not OK, replace the faulty power window
motor.
(4) If the power window motor operates in both
directions, check the operation of the window glass
and regulator mechanism through its complete up
and down travel. There should be no binding or stick-
ing of the window glass or regulator mechanism
through the entire travel range. If not OK, (Refer to
23 - BODY/DOOR - FRONT/WINDOW REGULATOR
- REMOVAL) or (Refer to 23 - BODY/DOORS -
REAR/WINDOW REGULATOR - REMOVAL) to
check for proper installation or damage of the win-
dow glass mounting and operating hardware.
8N - 38 POWER WINDOWSWJ
POWER WINDOW SWITCH (Continued)

WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
JUNCTION BLOCK.................... 8W-12-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
POWER SUNROOF................... 8W-64-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUT................ 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION............... 8W-97-1 WJWIRING 8W - 1

Component Page
Power Outlet......................... 8W-41
Power Seats.......................... 8W-63
Power Windows....................... 8W-60
Powertrain Control Module.............. 8W-30
Radio............................... 8W-47
Rain Sensor.......................... 8W-49
Recirculation Door Motor/Actuator........ 8W-42
Red Brake Warning Indicator Switch....... 8W-35
Remote Keyless Module................. 8W-39
Remote Radio Switches................. 8W-47
Splices.............................. 8W-10
Seat Belt Switch...................... 8W-43
Seat Module.......................... 8W-63
Sentry Key Immobilizer Module.......... 8W-39
Shifter Assembly...................... 8W-31
Side Impact Sensors................... 8W-43
Side Marker Lamps.................... 8W-50
Side Repeater Lamps................... 8W-52
Siren............................... 8W-49
Speakers............................ 8W-47Component Page
Speed Control Switches................. 8W-33
Sunroof............................. 8W-64
Temperature Valve Actuator............. 8W-42
Throttle Position Sensor................ 8W-30
Trailer Tow.......................... 8W-54
Transfer Case Position Sensor............ 8W-31
Transmission......................... 8W-31
Turn Signal Lamps.................... 8W-52
Underhood Lamp...................... 8W-44
Vehicle Information Center.............. 8W-49
Viscous/Cabin Heater................... 8W-30
Visor/Vanity Lamps.................... 8W-44
Washer Fluid Level Switch.............. 8W-53
Wastegate Solenoid.................... 8W-30
Water In Fuel Sensor................... 8W-30
Wheel Speed Sensors................... 8W-35
Window Defogger...................... 8W-48
Wiper High/Low Relay.................. 8W-53
Wiper Motor.......................... 8W-53
Washer Pump......................... 8W-5
8W - 02 - 2 8W-02 COMPONENT INDEXWJ

8W-60 POWER WINDOWS
Component Page
Body Control Module............... 8W-60-2, 3
Diagnostic Junction Port............. 8W-60-2, 3
Driver Door Module............ 8W-60-2, 3, 4, 5
Driver Front Power Window Motor..... 8W-60-2, 3
Driver Rear Power Window Motor....... 8W-60-5
Driver Rear Power Window Switch....... 8W-60-5
Fuse 12.......................... 8W-60-2, 3
G300........................ 8W-60-2, 4, 5, 6Component Page
G301........................ 8W-60-3, 4, 5, 6
Junction Block.................. 8W-60-2, 3, 4
Passenger Door Module.......... 8W-60-2, 3, 4, 6
Passenger Front Power
Window Motor................... 8W-60-2, 3
Passenger Rear Power Window Motor.... 8W-60-6
Passenger Rear Power Window Switch.... 8W-60-6
Power Distribution Center........... 8W-60-2, 3
WJ8W-60 POWER WINDOWS 8W - 60 - 1

leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will notalways seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create a
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessive
wear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
23 - 2 BODYWJ
BODY (Continued)

However, evaporator capacity used to reduce the
amount of moisture in the air is not wasted. Wring-
ing some of the moisture out of the air entering the
vehicle adds to the comfort of the passengers.
Although, an owner may expect too much from their
air conditioning system on humid days. A perfor-
mance test is the best way to determine whether the
system is performing up to standard. This test also
provides valuable clues as to the possible cause of
trouble with the air conditioning system.
If the vehicle has the optional Automatic Zone Control
(AZC) system, and has intermittent operational prob-
lems or fault codes, be certain that the wire harness
connectors on the HVAC housing are properly seated
(Fig. 2). To check this condition, unplug the two wire
harness connector halves, then plug them in again.
Before performing the following procedure, (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - CAUTION) (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - WARNING). The air
temperature in the test room and in the vehicle must
be a minimum of 21É C (70É F) for this test.
(1)
Connect a tachometer and a manifold gauge set.
(2) If the vehicle has the standard manual temper-
ature control, set the A/C Heater mode control switch
knob in the Panel position, the temperature control
knob in the full cool (Fresh Air Mode) position, the
A/C button in the On position, and the blower motor
switch knob in the highest speed position. If the vehi-
cle has the optional AZC, set the A/C Heater mode
control switch knob in the Panel position, the tem-
perature control knob in the full cool position, the
A/C button in the On position, and the blower motor
switch knob in the highest (manual) speed position.
(3) Start the engine and hold the idle at 1,300 rpm
with the compressor clutch engaged.
(4) The engine should be at operating temperature.
The doors and windows must be open.
(5)
Insert a thermometer in the driver side center
A/C (panel) outlet. Operate the engine for five minutes.
(6) The compressor clutch may cycle, depending
upon the ambient temperature and humidity.(7) With the compressor clutch engaged, record the
discharge air temperature and the compressor dis-
charge pressure.
(8) Compare the discharge air temperature to the
Performance Temperature and Pressure chart. If the
discharge air temperature is high, (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
DIAGNOSIS AND TESTING - REFRIGERANT SYS-
TEM LEAKS) and (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING - STANDARD PRO-
CEDURE - REFRIGERANT SYSTEM CHARGE).
Performance Temperature and Pressure
Ambient Air Temperature
and Humidity21É C
(70É F @ 80%
humidity)27É C
(80É F @ 80%
humidity)32É C
(90É F @ 80%
humidity)38É C
(100ÉF@50%
humidity)43É C
110É F @ 20%
humidity)
Air Temperature at Center
Panel Outlet10 to 13É C
(50 to 55É F)14 to 17É C
(58 to 63É F)15 to 18É C
(60 to 65É F)17 to 20É C
(63 to 68É F)14 to 17É C
(58 to 63É F)
Evaporator Inlet Pressure
at Charge Port241 to 276 kPa
(35 to 40 psi)262 to 290 kPa
(38 to 42 psi)269 to 296 kPa
(39 to 43 psi)275 to 303 kPa
(40 to 44 psi)262 to 290 kPa
(38 to 42 psi)
Compressor Discharge
Pressure1241 to 1792
kPa
(180 to 260 psi)1380 to 1930
kPa
(200 to 280 psi)1380 to 1930
kPa
(200 to 280 psi)1655 to 2206
kPa
(240 to 320 psi)1567 to 2068
kPa
(220 to 300 psi)
Note: The discharge air temperatures will be lower if the humidity is less than the percentages shown.
Fig. 2 HVAC Housing - (rear view)
1 - Instrument Panel
2 - Air Intake
3 - Expansion Valve
4 - HVAC Housing
5 - Heater Core Input/Output Ports
6 - Instrument Panel Wiring Harness
7 - Blower Motor
WJHEATING & AIR CONDITIONING 24 - 3
HEATING & AIR CONDITIONING (Continued)

(a) If the refrigerant system fails to reach the
specified vacuum, the system has a leak that must
be corrected. (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - DIAGNOSIS AND
TESTING - REFRIGERANT SYSTEM LEAKS)
(b) If the refrigerant system maintains the spec-
ified vacuum for five minutes, restart the vacuum
pump, open the suction and discharge valves and
evacuate the system for an additional ten minutes.
(3) Close all of the valves, and turn off the charg-
ing station vacuum pump.
(4) The refrigerant system is now ready to be
charged with R-134a refrigerant. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
STANDARD PROCEDURE - REFRIGERANT
SYSTEM CHARGE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
After the refrigerant system has been tested for
leaks and evacuated, a refrigerant charge can be
injected into the system. (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - SPECIFICA-
TIONS - CHARGE CAPACITY)
A R-134a refrigerant recovery/recycling/charging
station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. Refer to the operating instructions sup-
plied by the equipment manufacturer for proper care
and use of this equipment.
PARTIAL CHARGE METHOD
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
The partial charge method is used to add a partial
charge to a refrigerant system that is low on refrig-
erant. To perform this procedure the evaporator inlet
and outlet tube temperatures are measured. The
temperature difference is measured with a tempera-
ture meter with one or two clamp-on thermocouple
probes. The difference between the evaporator inlet
and outlet tube temperatures will determine the
amount of refrigerant needed.Before adding a partial refrigerant charge, check
for refrigerant system leaks. (Refer to 24 - HEATING
& AIR CONDITIONING/PLUMBING - DIAGNOSIS
AND TESTING - REFRIGERANT SYSTEM LEAKS)
If a leak is found, make the necessary repairs before
attempting a full or partial refrigerant charge.
(1) Attach a manifold gauge set to the refrigerant
system service ports.
(2) Attach the two clamp-on thermocouple probes
to the inlet and outlet tubes of the evaporator coil.
²If a single thermocouple probe is used, attach
the probe to the evaporator inlet tube just before the
collar of the refrigerant line connector fitting. The
probe must make contact with the bottom surface of
the evaporator inlet tube.
²If dual thermocouple probes are used, attach
probe 1 to the evaporator inlet tube, and probe 2 to
the evaporator outlet tube. Attach both probes to the
evaporator tubes just before the collar of the refrig-
erant line connector fittings. The probes must make
contact with the bottom surfaces of the evaporator
inlet and outlet tubes.
(3) Open all of the windows or doors of the passen-
ger compartment.
(4) Set the A/C button on the A/C Heater controls
to the on position, the temperature control knob in
the full cool position, select Recirculation Mode, and
place the blower motor switch in the highest speed
position.
(5) Start the engine and hold the engine idle speed
at 1,000 rpm. Allow the engine to warm up to normal
operating temperature.
(6) The compressor clutch may cycle, depending
upon ambient temperature, humidity, and the refrig-
erant system charge level.
(7) Hold the engine idle speed at 1,000 rpm.
(8) Allow three to five minutes for the refrigerant
system to stabilize, then record the temperatures of
the evaporator inlet and outlet tubes.
²If a single probe is used, record the temperature
of the evaporator inlet tube. Then remove the probe
from the inlet tube and attach it to the evaporator
outlet tube just before the collar of the refrigerant
line connector fitting. The probe must make contact
with the bottom surface of the evaporator outlet tube.
Allow the thermocouple and meter time to stabilize,
then record the temperature of the evaporator outlet
tube. Subtract the inlet tube temperature reading
from the outlet tube temperature reading.
²If dual probes are used, record the temperatures
of both the evaporator inlet and outlet tubes. Then
subtract the inlet tube temperature reading from the
outlet tube temperature reading.
(9) If the measured temperature differential is
higher than 22É C to 26É C (40É F to 47É F), add 0.4
kilograms (14 ounces) of refrigerant.
24 - 56 PLUMBINGWJ
PLUMBING (Continued)