alignment JEEP LIBERTY 2002 KJ / 1.G Service Manual

(3) Pinch the two hooked ends of the wire head-
lamp bulb retainer clip together and engage them
into the slots in the flange of the reflector (Fig. 26).
(4) Position the center opening of the boot seal
over the base of the headlamp bulb and pull it down-
ward until the seal is fully engaged over the bulb
base (Fig. 25).
(5) Position the outer circumference of the boot
seal over the flange on the back of the headlamp unit
housing and pull it downward until the seal is fully
engaged over the flange.
(6) Reinstall the headlamp unit onto the grille
opening reinforcement. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT
- INSTALLATION).
(7) Reconnect the battery negative cable.
(8) Confirm proper headlamp unit alignment.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP UNIT - ADJUSTMENTS).
HEADLAMP HIGH BEAM
RELAY
DESCRIPTION
The headlamp high beam relay is located in the
Junction Block (JB) on the driver side outboard end
of the instrument panel in the passenger compart-
ment of the vehicle. The headlamp high beam relay
is omitted from vehicles manufactured for sale in
Canada, which have a Daytime Running Lamp (DRL)
solid state relay installed in the JB that also per-forms the function of the headlamp high beam relay.
The headlamp high beam relay is a conventional
International Standards Organization (ISO) micro
relay (Fig. 28). Relays conforming to the ISO specifi-
cations have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
The relay is contained within a small, rectangular,
molded plastic housing and is connected to all of the
required inputs and outputs by five integral male
spade-type terminals that extend from the bottom of
the relay base.
The headlamp high beam relay cannot be adjusted
or repaired and, if faulty or damaged, the unit must
be replaced.
OPERATION
The headlamp high beam relay is an electrome-
chanical switch that uses a low current input from
the Body Control Module (BCM) to control a high
current output to the headlamp high beam filaments.
The movable common feed contact point is held
against the fixed normally closed contact point by
spring pressure. When the relay coil is energized, an
electromagnetic field is produced by the coil wind-
ings. This electromagnetic field draws the movable
relay contact point away from the fixed normally
closed contact point, and holds it against the fixed
normally open contact point. When the relay coil is
de-energized, spring pressure returns the movable
contact point back against the fixed normally closed
contact point. A resistor is connected in parallel with
the relay coil in the relay, and helps to dissipate volt-
age spikes and electromagnetic interference that can
be generated as the electromagnetic field of the relay
coil collapses.
The headlamp high beam relay terminals are con-
nected to the vehicle electrical system through a con-
nector receptacle in the Junction Block (JB). The
inputs and outputs of the headlamp high beam relay
include:
²Common Feed Terminal- The common feed
terminal (30) receives battery current at all times
from a fuse in the Power Distribution Center (PDC)
through a fused B(+) circuit.
²Coil Ground Terminal- The coil ground termi-
nal (85) receives battery current at all times from a
fuse in the PDC through a fused B(+) circuit.
²Coil Battery Terminal- The coil battery ter-
minal (86) is connected to a control output of the
Body Control Module (BCM) and to the momentary
optical horn (flash-to-pass) output of the multi-func-
tion switch through a high beam relay control circuit.
The BCM and/or the multi-function switch controls
headlamp high beam operation by controlling a
ground path through this circuit.
Fig. 28 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
KJLAMPS/LIGHTING - EXTERIOR 8L - 33
HEADLAMP BULB (Continued)

enough to disengage the locator tab on the outboard
side of the unit (Fig. 41) or (Fig. 42) from the engage-
ment slot in the outboard edge of the reinforcement.
(5) Pull the headlamp unit away from the grille
opening reinforcement far enough to disconnect the
wire harness connectors from the headlamp bulbsocket (North America), the headlamp bulb base
(Rest-Of-World), the front position lamp socket (if
equipped), and the headlamp leveling motor (if
equipped).
(6) Remove the headlamp unit from the grille
opening reinforcement.
INSTALLATION
(1) Position the headlamp unit to the grille open-
ing reinforcement.
(2) Reconnect the wire harness connectors to the
headlamp bulb socket (North America), the headlamp
bulb base (Rest-Of-World), the front position lamp
socket (if equipped), and the headlamp leveling motor
(if equipped) (Fig. 41) or (Fig. 42).
(3) Engage the locator tab on the outboard side of
the headlamp unit into the engagement slot in the
outboard edge of the grille opening reinforcement.
(4) Align the two mounting tabs on the inboard
side of the headlamp unit housing to the mounting
holes in the grille opening reinforcement (Fig. 40).
(5) Install and tighten the two screws that secure
the mounting tabs on the inboard side of the head-
lamp unit housing to the grille opening reinforce-
ment. Tighten the screws to 3 N´m (30 in. lbs.).
(6) Reinstall the grille panel onto the grille open-
ing reinforcement. (Refer to 23 - BODY/EXTERIOR/
GRILLE - INSTALLATION).
(7) Reconnect the battery negative cable.
(8) Confirm proper headlamp unit alignment.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP UNIT - ADJUSTMENTS).
ADJUSTMENTS
ADJUSTMENT - HEADLAMP UNIT
VEHICLE PREPARATION FOR HEADLAMP ALIGNMENT
(1) Verify headlamp dimmer (multi-function)
switch and high beam indicator operation.
(2) If the vehicle is equipped with headlamp level-
ing, be certain that the headlamp leveling switch is
in the ª0º position.
(3) Repair or replace any faulty or damaged com-
ponents that could hinder proper lamp alignment.
(4) Verify proper tire inflation.
(5) Clean headlamp lenses.
(6) Verify that cargo area is not heavily loaded.
(7) The fuel tank should be Full. Add 2.94 kilo-
grams (6.5 pounds) of weight over the fuel tank for
each estimated gallon of missing fuel.
HEADLAMP ALIGNMENT SCREEN PREPARATION
Prepare an alignment screen as illustrated.
(1) Position the vehicle on a level surface perpen-
dicular to a flat wall 7.62 meters (25 feet) away from
Fig. 41 Headlamp Unit - North America
1 - MOUNTING TAB (2)
2 - ADJUSTING SCREW
3 - LOCK RING
4 - HOUSING
5 - LOCATOR TAB
6 - SOCKET & BULB
Fig. 42 Headlamp Unit - Rest-Of-World
1 - LEVELING MOTOR (IF EQUIPPED)
2 - BOOT SEAL
3 - ADJUSTING SCREW
4 - LOCATOR TAB
5 - HOUSING
6 - FRONT POSITION LAMP SOCKET & BULB
7 - HEADLAMP BULB
8 - MOUNTING TAB (2)
8L - 42 LAMPS/LIGHTING - EXTERIORKJ
HEADLAMP UNIT (Continued)

the front of the headlamp lens for North American
vehicles, or 10.0 meters (32.81 feet) away from the
front of the headlamp lens for Rest-Of-World vehicles
(Fig. 43). If necessary, tape a line on the floor at the
appropriate distance away from and parallel to the
wall.
(2) Measure up on the wall 1.27 meters (5 feet)
from the floor and tape a vertical line on the align-
ment screen at the centerline of the vehicle. Sight
along the centerline of the vehicle (from the rear of
the vehicle forward) to verify the accuracy of the cen-
terline placement.
(3) Rock the vehicle from side-to-side three times
to allow the suspension to stabilize, then jounce the
front suspension three times by pushing downward
on the front bumper and releasing. Measure the dis-
tance from the center of the headlamp lens to the
floor. Transfer this measurement to the alignment
screen and tape a horizontal line on the wall at this
mark. This line will be used for up-and-down adjust-
ment reference.(4) Measure the distance from the centerline of the
vehicle to the center of each headlamp being aligned.
Transfer these measurements to the alignment
screen and tape a vertical line this distance to each
side of the vehicle centerline. These lines will be used
for left/right reference.
HEADLAMP ADJUSTMENT
A properly aligned headlamp will project a pattern
on the alignment screen from just below horizontal to
75 millimeters (3 inches) below the headlamp center-
line for vehicles in North America, or from just below
horizontal to 125 millimeters (5 inches) below the
headlamp horizontal centerline for vehicles in Rest-
Of-World.
(1) Vehicles for all markets except Japan should
have the headlamp low beams selected with the dim-
mer (multi-function) switch during the adjustment
procedure. Vehicles for the Japanese market should
have the headlamp high beams selected.
(2) Cover the lens of the headlamp that is not
being adjusted.
Fig. 43 Headlamp Alignment Screen - Typical
1 - CENTER OF VEHICLE TO CENTER OF HEADLAMP LENS
2 - FLOOR TO CENTER OF HEADLAMP LENS
3 - 7.62 METERS (25 FEET) NORTH AMERICA/10.0 METERS
(32.81 FEET) REST-OF-WORLD4 - FRONT OF HEADLAMP
5 - VEHICLE CENTERLINE
KJLAMPS/LIGHTING - EXTERIOR 8L - 43
HEADLAMP UNIT (Continued)

(4) If the multi-function switch fails any of the
continuity or resistance tests, replace the faulty
switch unit as required.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,
FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) If the vehicle is equipped with the optional tilt
steering column, move the tilt steering column to the
fully lowered position and leave the tilt release lever
in the released (down) position.
(3) From below the steering column, remove the
two screws that secure the lower shroud to the upper
shroud (Fig. 52).
(4) Using hand pressure, push gently inward on
both sides of the upper shroud near the parting line
between the upper and lower shrouds to release the
snap features that secure the two halves to each
other.
(5) Remove both the upper and lower shrouds from
the steering column.
(6) Disconnect the two instrument panel wire har-
ness connectors for the multi-function switch from
the two connector receptacles on the back of the
switch housing.
(7) Remove the multi-function switch from the
steering column lock housing by carefully rocking the
switch and pulling the switch housing upward far
enough to disengage its alignment posts and locator
tabs from the lock housing.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,
PASSENGER AIRBAG, SEAT BELT TENSIONER,FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
CAUTION: Before attempting to install the multi-
function switch, be certain that the left control stalk
is in the neutral turn signal position and the turn
signal cancel actuator is in the retracted (neutral)
position.
(1) Position the multi-function switch to the steer-
ing column.
(2) Reconnect the two instrument panel wire har-
ness connectors for the multi-function switch to the
two connector receptacles on the back of the switch
housing (Fig. 52).
Fig. 52 Multi-Function Switch Remove/Install
1 - UPPER SHROUD
2 - MULTI-FUNCTION SWITCH
3 - CLOCKSPRING
4 - LOWER SHROUD
5 - SCREW (2)
6 - STEERING COLUMN
7 - WIRE HARNESS CONNECTOR (2)
KJLAMPS/LIGHTING - EXTERIOR 8L - 53
MULTI-FUNCTION SWITCH (Continued)

(3) Position the multi-function switch onto the
steering column lock housing. Be certain that the
switch alignment posts and locator tabs are fully
seated on the lock housing.
(4) Position the upper and lower shrouds onto the
steering column.
(5) Align the snap features on the lower shroud
with the receptacles on the upper shroud and apply
hand pressure to snap them together.
(6) From below the steering column, install and
tighten the two screws that secure the lower shroud
to the upper shroud. Tighten the screws to 2 N´m (20
in. lbs.).
(7) If the vehicle is equipped with the optional tilt
steering column, move the tilt steering column back
to the fully raised position and move the tilt release
lever into the locked (up) position.
(8) Reconnect the battery negative cable.
PARK LAMP RELAY
DESCRIPTION
The park lamp relay is located in the Junction
Block (JB) below the driver side outboard end of the
instrument panel in the passenger compartment of
the vehicle. The park lamp relay is a conventional
International Standards Organization (ISO) micro
relay (Fig. 53). Relays conforming to the ISO specifi-
cations have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
The relay is contained within a small, rectangular,
molded plastic housing and is connected to all of therequired inputs and outputs by five integral male
spade-type terminals that extend from the bottom of
the relay base.
The park lamp relay cannot be adjusted or
repaired and, if faulty or damaged, the unit must be
replaced.
OPERATION
The park lamp relay is an electromechanical
switch that uses a low current input from the Body
Control Module (BCM) to control a high current out-
put to the park lamps. The movable common feed
contact point is held against the fixed normally
closed contact point by spring pressure. When the
relay coil is energized, an electromagnetic field is
produced by the coil windings. This electromagnetic
field draws the movable relay contact point away
from the fixed normally closed contact point, and
holds it against the fixed normally open contact
point. When the relay coil is de-energized, spring
pressure returns the movable contact point back
against the fixed normally closed contact point. A
resistor is connected in parallel with the relay coil in
the relay, and helps to dissipate voltage spikes and
electromagnetic interference that can be generated as
the electromagnetic field of the relay coil collapses.
The park lamp relay terminals are connected to
the vehicle electrical system through a connector
receptacle in the Junction Block (JB). The inputs and
outputs of the headlamp low beam relay include:
²Common Feed Terminal- The common feed
terminal (30) is connected to the park lamps through
the park lamp relay output circuit and provides
ground to the park lamps when the relay is de-ener-
gized, and battery current to the park lamps when-
ever the relay is energized.
²Coil Ground Terminal- The coil ground termi-
nal (85) is connected to a control output of the Body
Control Module (BCM) through a park lamp relay
control circuit. The BCM controls park lamp opera-
tion by controlling a ground path through this cir-
cuit.
²Coil Battery Terminal- The coil battery ter-
minal (86) receives battery current at all times from
a fuse in the PDC through a fused B(+) circuit.
²Normally Open Terminal- The normally open
terminal (87) receives battery current at all times
from a fuse in the Power Distribution Center (PDC)
through a fused B(+) circuit.
²Normally Closed Terminal- The normally
closed terminal (87A) is connected to ground at all
times through a ground circuit that receives ground
through a splice block located in the instrument
panel wire harness with an eyelet terminal connector
that is secured by a nut to a ground stud on the
Fig. 53 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
8L - 54 LAMPS/LIGHTING - EXTERIORKJ
MULTI-FUNCTION SWITCH (Continued)

(5) From the front of the vehicle, pull the front fog
lamp unit out of the front bumper fascia far enough
to access and disconnect the wire harness connector
for the front fog lamp unit from the lamp socket con-
nector receptacle (Fig. 15).
(6) Remove the front fog lamp unit from the front
bumper fascia.
INSTALLATION
(1) Position the front fog lamp unit to the front
bumper fascia.
(2) Reconnect the wire harness connector for the
front fog lamp to the lamp socket connector recepta-
cle (Fig. 15).
(3) Position the front fog lamp unit into the front
bumper fascia.
(4) Reach into the front wheel opening and
through the access hole to install and tighten the
three screws that secure the front fog lamp unit
housing to the front bumper fascia (Fig. 14). Tighten
the screws to 3 N´m (25 in. lbs.).
(5) Lower and snap shut the cover over the access
hole at the front of the front wheelhouse splash
shield.
(6) Reconnect the battery negative cable.
(7) Confirm proper front fog lamp unit alignment.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/FRONT FOG LAMP UNIT - ADJUST-
MENTS).
ADJUSTMENTS
ADJUSTMENT - FRONT FOG LAMP UNIT
VEHICLE PREPARATION FOR FOG LAMP ALIGNMENT
(1) Repair or replace any faulty or damaged com-
ponents that could hinder proper lamp alignment.
(2) Verify proper tire inflation.
(3) Clean the front fog lamp lenses.
(4) Verify that the cargo area is not heavily loaded.
(5) The fuel tank should be Full. Add 2.94 kilo-
grams (6.5 pounds) of weight over the fuel tank for
each estimated gallon of missing fuel.
FOG LAMP ALIGNMENT
Prepare an alignment screen as illustrated. A prop-
erly aligned front fog lamp will project a pattern on
the alignment screen 100 millimeters (4 inches)
below the fog lamp centerline and straight ahead of
the lamp.
(1) Position the vehicle on a level surface perpen-
dicular to a flat wall 7.62 meters (25 feet) away from
the front of the front fog lamp lens (Fig. 16). If nec-
essary, tape a line on the floor 7.62 meters (25 feet)
away from and parallel to the wall.
(2) Measure up on the wall 1.27 meters (5 feet)
from the floor and tape a vertical line on the align-
ment screen at the centerline of the vehicle. Sight
along the centerline of the vehicle (from the rear of
the vehicle forward) to verify the accuracy of the cen-
terline placement.
Fig. 14 Front Fog Lamp Unit Remove/Install
1 - FRONT FOG LAMP UNIT
2 - SCREW (3)
3 - FRONT WHEELHOUSE SPLASH SHIELD
4 - FRONT BUMPER FASCIA
5 - ACCESS HOLE
Fig. 15 Front Fog Lamp Unit
1 - ADJUSTING SCREW
2 - MOUNTING BRACKET
3 - HOUSING
4 - SOCKET & BULB
5 - LENS
KJLAMPS8Ls-25
FRONT FOG LAMP UNIT (Continued)

(3) Rock the vehicle from side-to-side three times
to allow the suspension to stabilize, then jounce the
front suspension three times by pushing downward
on the front bumper and releasing. Measure the dis-
tance from the center of the front fog lamp lens to
the floor. Transfer this measurement to the align-
ment screen and tape a horizontal line on the wall at
this mark. This line will be used for up-and-down
adjustment reference.
(4) Measure the distance from the centerline of the
vehicle to the center of each front fog lamp being
aligned. Transfer these measurements to the align-
ment screen and tape a vertical line this distance to
each side of the vehicle centerline. These lines will be
used for left/right reference.
(5) Rotate the front fog lamp adjusting screws to
adjust the beam height as required (Fig. 17).
Fig. 16 Front Fog Lamp Alignment - Typical
1 - VEHICLE CENTERLINE
2 - CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS
3 - HIGH-INTENSITY AREA
4 - FLOOR TO CENTER OF FOG LAMP LENS5 - 100 MILLIMETERS (4 INCHES)
6 - 7.62 METERS (25 FEET)
7 - FRONT OF FOG LAMP
Fig. 17 Front Fog Lamp Adjusting Screw
1 - FRONT BUMPER FASCIA
2 - ADJUSTING SCREW
3 - FRONT FOG LAMP UNIT
8Ls - 26 LAMPSKJ
FRONT FOG LAMP UNIT (Continued)

INSTALLATION
(1) Position the front lamp unit to the front
bumper fascia.
(2) Reconnect the wire harness connector(s) for the
front lamp unit to the lamp socket pigtail wire(s).
(3) Engage the tab on the inboard end of the front
lamp unit housing into the receptacle in the front
bumper fascia.
(4) Position the outboard end of the front lamp
unit housing to the front bumper fascia.
(5) Install and tighten the screw that secures the
outboard end of the front lamp unit housing to the
front bumper fascia (Fig. 19). Tighten the screw to 2
N´m (20 in. lbs.).
(6) Reconnect the battery negative cable.
FRONT POSITION LAMP BULB
REMOVAL
The front position lamps are integral to the head-
lamp units on vehicles manufactured for certain mar-
kets where these lamps are required.
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the headlamp unit from the front grille
opening reinforcement. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT
- REMOVAL).
(3) Rotate the front position lamp socket near the
bottom of the headlamp unit housing counterclock-
wise about 30 degrees (Fig. 20).
(4) Pull the socket and bulb straight out of the
headlamp unit housing.(5) Pull the bulb straight out of the front position
lamp socket.
INSTALLATION
The front position lamps are integral to the head-
lamp units on vehicles manufactured for certain mar-
kets where these lamps are required.
CAUTION: Always use the correct bulb size and
type for replacement. An incorrect bulb size or type
may overheat and cause damage to the lamp, the
socket and/or the lamp wiring.
(1) Align the base of the bulb with the receptacle
in the front position lamp socket.
(2) Push the bulb straight into the front position
lamp socket until it is firmly seated.
(3) Align the socket and bulb with the socket open-
ing near the bottom of the headlamp unit housing
(Fig. 20).
(4) Push the socket and bulb straight into the
headlamp unit housing until it is firmly seated
(5) Rotate the front position lamp socket near the
bottom of the headlamp unit housing clockwise about
30 degrees.
(6) Reinstall the headlamp unit onto the grille
opening reinforcement. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT
- INSTALLATION).
(7) Reconnect the battery negative cable.
(8) Confirm proper headlamp unit alignment.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP UNIT - ADJUSTMENTS).
HAZARD SWITCH
DESCRIPTION
The hazard switch is integral to the hazard switch
module, which is secured near the center of instru-
ment panel just above the radio (Fig. 21). Only the
hazard switch button is visible through a dedicated,
round, beveled opening on the outer surface of the
instrument panel between the two center panel out-
lets of the heater and air conditioning system. A red,
stencil-like International Control and Display Symbol
icon for ªHazard Warningº identifies the hazard
switch button. On the opposite end of the black,
molded plastic hazard switch module housing from
the switch button is an integral connector receptacle
and a stamped steel mounting bracket with two latch
feature tabs that extend downward, while a short
dowel-like alignment pin is integral to each side of
the housing just below the switch button. The switch
module is connected to the vehicle electrical system
through a dedicated take out and connector of the
instrument panel wire harness. Within the hazard
Fig. 20 Front Position Lamp Bulb Remove/Install
1 - HEADLAMP HOUSING
2 - SOCKET
3 - BULB
8Ls - 28 LAMPSKJ
FRONT LAMP UNIT (Continued)

(2) Remove the radio from the instrument panel.
(Refer to 8 - ELECTRICAL/AUDIO/RADIO -
REMOVAL).
(3) Remove the screw at the top of the instrument
panel radio opening that secures the hazard switch
to the instrument panel trim (Fig. 22).
(4) Reach through and above the instrument panel
radio opening to access the two latch tabs of the
stamped metal hazard switch mounting bracket.
(5) Using two fingertips, pull rearward and down-
ward on the latch tabs on the back of the hazard
switch until it is disengaged from the instrument
panel trim.
(6) Push the hazard switch button through the
button opening of the instrument panel far enough to
disengage the alignment pins on each side of the
switch housing from the saddle formations of the two
stanchions on the back of the instrument panel trim,
just below and to either side of the button opening.
(7) Disconnect the instrument panel wire harness
connector for the hazard switch from the switch con-
nector receptacle.
(8) Remove the hazard switch through the instru-
ment panel radio opening.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE SUPPLEMENTAL RESTRAINT
SYSTEM BEFORE ATTEMPTING ANY STEERING
WHEEL, STEERING COLUMN, DRIVER AIRBAG,PASSENGER AIRBAG, SEAT BELT TENSIONER,
FRONT IMPACT SENSORS, SIDE CURTAIN AIRBAG,
OR INSTRUMENT PANEL COMPONENT DIAGNOSIS
OR SERVICE. DISCONNECT AND ISOLATE THE
BATTERY NEGATIVE (GROUND) CABLE, THEN
WAIT TWO MINUTES FOR THE SYSTEM CAPACI-
TOR TO DISCHARGE BEFORE PERFORMING FUR-
THER DIAGNOSIS OR SERVICE. THIS IS THE ONLY
SURE WAY TO DISABLE THE SUPPLEMENTAL
RESTRAINT SYSTEM. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCI-
DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY.
(1) Position the hazard switch through the instru-
ment panel radio opening.
(2) Reconnect the instrument panel wire harness
connector for the hazard switch to the switch connec-
tor receptacle.
(3) Reach through and above the instrument panel
radio opening to position the hazard switch for
installation.
(4) Guide the hazard switch button through the
button opening of the instrument panel, which will
engage the alignment pins on each side of the switch
housing with the saddle formations of the two stan-
chions on the back of the instrument panel trim, just
below and to either side of the button opening.
(5) Using hand pressure, press upward on the
back of the hazard switch until the latch tabs of the
mounting bracket on the back of the switch are both
engaged with the instrument panel trim (Fig. 22).
(6) Install and tighten the screw at the top of the
instrument panel radio opening that secures the haz-
ard switch to the instrument panel trim. Tighten the
screw to 2 N´m (17 in. lbs.).
(7) Reinstall the radio into the instrument panel.
(Refer to 8 - ELECTRICAL/AUDIO/RADIO -
INSTALLATION).
(8) Reconnect the battery negative cable.
HEADLAMP BULB
REMOVAL
NORTH AMERICA
(1) Disconnect and isolate the battery negative
cable.
(2) Reach behind the headlamp unit from the
engine compartment side of the upper radiator cross-
member to access the headlamp bulb lock ring (Fig.
23).
(3) Firmly grasp the lock ring on the back of the
headlamp unit housing.
Fig. 22 Hazard Switch Remove/Install
1 - WIRE HARNESS CONNECTOR
2 - HAZARD SWITCH
3 - ALIGNMENT PIN (2)
4 - STANCHION (2)
5 - INSTRUMENT PANEL
6 - SCREW (1)
7 - MOUNTING BRACKET LATCH TAB (2)
8Ls - 30 LAMPSKJ
HAZARD SWITCH (Continued)

(5) Position the outer circumference of the boot
seal over the flange on the back of the headlamp unit
housing and pull it downward until the seal is fully
engaged over the flange.
(6) Reinstall the headlamp unit onto the grille
opening reinforcement. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/HEADLAMP UNIT
- INSTALLATION).
(7) Reconnect the battery negative cable.
(8) Confirm proper headlamp unit alignment.
(Refer to 8 - ELECTRICAL/LAMPS/LIGHTING -
EXTERIOR/HEADLAMP UNIT - ADJUSTMENTS).
HEADLAMP HIGH BEAM
RELAY
DESCRIPTION
The headlamp high beam relay is located in the
Junction Block (JB) on the driver side outboard end
of the instrument panel in the passenger compart-
ment of the vehicle. The headlamp high beam relay
is omitted from vehicles manufactured for sale in
Canada, which have a Daytime Running Lamp (DRL)
solid state relay installed in the JB that also per-
forms the function of the headlamp high beam relay.
The headlamp high beam relay is a conventional
International Standards Organization (ISO) micro
relay (Fig. 28). Relays conforming to the ISO specifi-
cations have common physical dimensions, current
capacities, terminal patterns, and terminal functions.
The relay is contained within a small, rectangular,molded plastic housing and is connected to all of the
required inputs and outputs by five integral male
spade-type terminals that extend from the bottom of
the relay base.
The headlamp high beam relay cannot be adjusted
or repaired and, if faulty or damaged, the unit must
be replaced.
OPERATION
The headlamp high beam relay is an electrome-
chanical switch that uses a low current input from
the Body Control Module (BCM) to control a high
current output to the headlamp high beam filaments.
The movable common feed contact point is held
against the fixed normally closed contact point by
spring pressure. When the relay coil is energized, an
electromagnetic field is produced by the coil wind-
ings. This electromagnetic field draws the movable
relay contact point away from the fixed normally
closed contact point, and holds it against the fixed
normally open contact point. When the relay coil is
de-energized, spring pressure returns the movable
contact point back against the fixed normally closed
contact point. A resistor is connected in parallel with
the relay coil in the relay, and helps to dissipate volt-
age spikes and electromagnetic interference that can
be generated as the electromagnetic field of the relay
coil collapses.
The headlamp high beam relay terminals are con-
nected to the vehicle electrical system through a con-
nector receptacle in the Junction Block (JB). The
inputs and outputs of the headlamp high beam relay
include:
²Common Feed Terminal- The common feed
terminal (30) receives battery current at all times
from a fuse in the Power Distribution Center (PDC)
through a fused B(+) circuit.
²Coil Ground Terminal- The coil ground termi-
nal (85) is connected to a control output of the Body
Control Module (BCM) through a head lamp relay
control circuit. The BCM controls head lamp opera-
tion by controlling a ground path through this circuit
²Coil Battery Terminal- The coil battery ter-
minal (86) is connected to a control output of the
Body Control Module (BCM) and to the momentary
optical horn (flash-to-pass) output of the multi-func-
tion switch through a high beam relay control circuit.
The BCM and/or the multi-function switch controls
headlamp high beam operation by controlling a
ground path through this circuit.
²Normally Open Terminal- The normally open
terminal (87) is connected to the headlamp high
beam filaments through the high beam relay output
circuit and provides battery current to the headlamp
high beams whenever the relay is energized.
Fig. 28 ISO Micro Relay
30 - COMMON FEED
85 - COIL GROUND
86 - COIL BATTERY
87 - NORMALLY OPEN
87A - NORMALLY CLOSED
KJLAMPS8Ls-33
HEADLAMP BULB (Continued)