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TABLE OF CONTENTS
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DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
SPLICE INFORMATION
PROCEDURE REQUIRES IT TO BE ON.
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ- WARNING: SET THE PARKING BRAKE WHEN
ical example might be the Supplemental Restraint WORKING ON ANY VEHICLE. AN AUTOMATIC
System connectors. Always check parts availability TRANSMISSION SHOULD BE IN PARK. A MANUAL
before attempting a repair. TRANSMISSION SHOULD BE IN NEUTRAL.
STANDARD PROCEDURE
STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
All ESD sensitive components are solid state and a
symbol (Fig. 6) is used to indicate this. When han-
dling any component with this symbol, comply with
the following procedures to reduce the possibility of
Fig. 5 PROBING TOOL electrostatic charge build up on the body and inad-
vertent discharge into the component. If it is not
1 - SPECIAL TOOL 6801
2 - PROBING END known whether the part is ESD sensitive, assume
that it is.
INTERMITTENT AND POOR CONNECTIONS (1) Always touch a known good ground before han-
Most intermittent electrical problems are caused dling the part. This should be repeated while han-
by faulty electrical connections or wiring. It is also dling the part and more frequently after sliding
possible for a sticking component or relay to cause a across a seat, sitting down from a standing position,
problem. Before condemning a component or wiring or walking a distance.
assembly, check the following items. (2) Avoid touching electrical terminals of the part,
Connectors are fully seated unless instructed to do so by a written procedure.
Spread terminals, or terminal push out (3) When using a voltmeter, be sure to connect the
Terminals in the wiring assembly are fully ground lead first.
seated into the connector/component and locked into (4) Do not remove the part form its protective
position packing until it is time to install the part.
Dirt or corrosion on the terminals. Any amount of (5) Before removing the part from its pakage,
corrosion or dirt could cause an intermittent problem ground the pakage to a known good ground on the
Damaged connector/component casing exposing vehicle.
the item to dirt or moisture
Wire insulation that has rubbed through causing
a short to ground
Some or all of the wiring strands broken inside
of the insulation
Wiring broken inside of the insulation
Fig. 9 TESTING FOR VOLTAGE DROP TERMINAL REMOVING TOOLS 6932 AND 8638
CONNECTOR INSTALLATION
(1) Insert the removed terminal in the same cavity
REMOVAL on the repair connector.
(1) Disconnect battery. (2) Repeat steps for each terminal in the connec-
(2) Release Connector Lock (Fig. 10). tor, being sure that all wires are inserted into the
(3) Disconnect the connector being repaired from proper cavities. For additional connector pin-out
its mating half/component. identification, refer to the wiring diagrams.
(4) Remove the dress cover (if applicable) (Fig. 10). (3) When the connector is re-assembled, the sec-
ondary terminal lock must be placed in the locked
position to prevent terminal push out.
(4) Replace dress cover (if applicable).
(5) Connect connector to its mating half/compo-
nent.
(6) Connect battery and test all affected systems.
DIODE TERMINAL
REMOVAL REMOVAL
(1) Disconnect the battery. (1) Follow steps for removing terminals described
(2) Locate the diode in the harness, and remove in the connector removal section.
the protective covering. (2) Cut the wire 6 inches from the back of the con-
(3) Remove the diode from the harness, pay atten- nector.
tion to the current flow direction (Fig. 13).
INSTALLATION
(1) Select a wire from the terminal repair kit that
best matches the color and gage of the wire being
repaired.
(2) Cut the repair wire to the proper length and
remove onehalf (1/2) inch of insulation.
(3) Splice the repair wire to the wire harness (see
wire splicing procedure).
(4) Insert the repaired wire into the connector.
(5) Install the connector locking wedge, if required,
and reconnect the connector to its mating half/compo-
nent.
(6) Re-tape the wire harness starting at 11/2
inches behind the connector and 2 inches past the
repair.
Fig. 13 DIODE IDENTIFICATION (7) Connect battery and test all affected systems.
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
INSTALLATION
(1) Remove the insulation from the wires in the
harness. Only remove enough insulation to solder in
the new diode.
(2) Install the new diode in the harness, making
sure current flow is correct. If necessary, refer to the
appropriate wiring diagram for current flow (Fig. 13).
(3) Solder the connection together using rosin core
type solder only. Do not use acid core solder.
(4) Tape the diode to the harness using electrical
tape. Make sure the diode is completely sealed from
the elements.
(5) Re-connect the battery and test affected sys-
tems.
AN 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15
8W-53 WIPERS
Component Page Component Page
Central Timer Module . . . . . . . . . . . . . . 8W-53-2, 3 Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
Data Link Connector . . . . . . . . . . . . . . . . . 8W-53-2 G112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
Front Washer Pump/Motor . . . . . . . . . . . . . 8W-53-2 G113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3
Front Wiper Motor . . . . . . . . . . . . . . . . . 8W-53-2, 3 Junction Block . . . . . . . . . . . . . . . . . . . . 8W-53-2, 3
Front Wiper Relay . . . . . . . . . . . . . . . . . 8W-53-2, 3 Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
AN 8W-54 TRAILER TOW 8W - 54 - 1
DRIVER DOOR POWER LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 G75 22TN DRIVER DOOR AJAR SWITCH SENSE
2 Z2 20BK/LG GROUND
3 P59 18DB DRIVER DOOR UNLOCK RELAY OUTPUT
4 P33 18OR/BK DOOR LOCK RELAY OUTPUT
LEFT REAR DOOR POWER LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 G74 18TN/RD PASSENGER DOOR AJAR SWITCH SENSE
2 Z2 20BK/LG GROUND
3 P34 16PK/BK DOOR UNLOCK RELAY OUTPUT
4 P33 16OR/BK DOOR LOCK RELAY OUTPUT
PASSENGER DOOR POWER LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 G74 20TN/RD PASSENGER DOOR AJAR SWITCH SENSE
2 Z2 20BK/LG GROUND
3 P34 18PK/BK DOOR UNLOCK RELAY OUTPUT
4 P33 18OR/BK DOOR LOCK RELAY OUTPUT
AN 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57
RIGHT REAR DOOR POWER LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY
CAV CIRCUIT FUNCTION
1 G74 18TN/RD PASSENGER DOOR AJAR SWITCH SENSE
2 Z2 20BK/LG GROUND
3 P34 16PK/BK DOOR UNLOCK RELAY OUTPUT
4 P33 16OR/BK DOOR LOCK RELAY OUTPUT
AN 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CONNECTORS
GROUNDS
Fig. 21 HVAC
8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION AN
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 32 CAB
8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION AN
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Fig. 34 CHASSIS
8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION AN
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
TABLE OF CONTENTS
page page
POWER DISTRIBUTION plete circuit diagrams for the various power distribu-
tion system components.
DESCRIPTION
This group covers the various standard and
OPERATION
The power distribution system for this vehicle is
optional power distribution components used on this
designed to provide safe, reliable, and centralized dis-
model. The power distribution system for this vehicle
tribution points for the electrical current required to
consists of the following components:
operate all of the many standard and optional facto-
Power Distribution Center (PDC)
ry-installed electrical and electronic powertrain,
Junction Block (JB)
chassis, safety, security, comfort and convenience sys-
The power distribution system also incorporates
tems. At the same time, the power distribution sys-
various types of circuit control and protection fea-
tem was designed to provide ready access to these
tures, including:
electrical distribution points for the vehicle techni-
Automatic resetting circuit breakers
cian to use when conducting diagnosis and repair of
Blade-type fuses
faulty circuits. The power distribution system can
Cartridge fuses
also prove useful for the sourcing of additional elec-
Circuit splice blocks
trical circuits that may be required to provide the
Flashers
electrical current needed to operate many accessories
Relays.
that the vehicle owner may choose to have installed
Following are general descriptions of the major
in the aftermarket.
components in the power distribution system. See the
owners manual in the vehicle glove box for more
information on the features and use of all of the
power distribution system components. Refer to the
index in this service manual for the location of com-
8W - 97 - 2 8W-97 POWER DISTRIBUTION AN
IOD FUSE and as a fuse holder that conveniently stores the fuse
in the same JB cavity after it has been disconnected.
DESCRIPTION
OPERATION
The term ignition-off draw identifies a normal con-
dition where power is being drained from the battery
with the ignition switch in the Off position. The IOD
fuse feeds the memory and sleep mode functions for
some of the electronic modules in the vehicle as well
as various other accessories that require battery cur-
rent when the ignition switch is in the Off position,
including the clock. The only reason the IOD fuse is
disconnected is to reduce the normal IOD of the vehi-
cle electrical system during new vehicle transporta-
tion and pre-delivery storage to reduce battery
depletion, while still allowing vehicle operation so
that the vehicle can be loaded, unloaded and moved
as needed by both vehicle transportation company
and dealer personnel.
The IOD fuse is disconnected from JB fuse cavity
12 when the vehicle is shipped from the assembly
plant. Dealer personnel must reconnect the IOD fuse
when the vehicle is being prepared for delivery in
order to restore full electrical system operation. Once
the vehicle is prepared for delivery, the IOD function
of this fuse becomes transparent and the fuse that
Fig. 4 Ignition-Off Draw Fuse - Typical
has been assigned the IOD designation becomes only
1 - JUNCTION BLOCK
2 - IGNITION-OFF DRAW FUSE AND HOLDER
another Fused B(+) circuit fuse. The IOD fuse serves
3 - LEFT INSTRUMENT PANEL END BRACKET no useful purpose to the dealer technician in the ser-
vice or diagnosis of any vehicle system or condition,
All vehicles are equipped with an Ignition-Off other than the same purpose as that of any other
Draw (IOD) fuse (Fig. 4) that is disconnected within standard circuit protection device.
the Junction Block (JB) when the vehicle is shipped The IOD fuse can be used by the vehicle owner as
from the factory. Dealer personnel are to reconnect a convenient means of reducing battery depletion
the IOD fuse in the JB as part of the preparation when a vehicle is to be stored for periods not to
procedures performed just prior to new vehicle deliv- exceed about thirty days. However, it must be
ery. remembered that disconnecting the IOD fuse will not
The left end of the instrument panel cover has a eliminate IOD, but only reduce this normal condition.
snap-fit fuse access panel that can be removed to pro- If a vehicle will be stored for more than about thirty
vide service access to the fuses in the JB. A finger days, the battery negative cable should be discon-
recess is molded into the access panel for easy nected to eliminate normal IOD; and, the battery
removal. An adhesive-backed fuse layout map is should be tested and recharged at regular intervals
secured to the instrument panel side of the access during the vehicle storage period to prevent the bat-
panel to ensure proper fuse identification. The IOD tery from becoming discharged or damaged. Refer to
fuse is a 15 ampere mini blade-type fuse. The fuse is Battery in the index of this service manual for the
secured within a black molded plastic fuse holder location of additional service information covering
and puller unit that serves both as a tool for discon- the battery.
necting and reconnecting the fuse in its JB cavity,
8W - 97 - 6 8W-97 POWER DISTRIBUTION AN
IOD FUSE (Continued)
REMOVAL INSTALLATION
The Ignition-Off Draw (IOD) fuse is disconnected The Ignition-Off Draw (IOD) fuse is disconnected
from Junction Block (JB) fuse cavity 12 (Fig. 5) when from Junction Block (JB) fuse cavity 12 when the
the vehicle is shipped from the assembly plant. vehicle is shipped from the assembly plant. Dealer
Dealer personnel must reconnect the IOD fuse when personnel must reconnect the IOD fuse when the
the vehicle is being prepared for delivery in order to vehicle is being prepared for delivery in order to
restore full electrical system operation. restore full electrical system operation.
(1) Turn the ignition switch to the Off position.
(2) Remove the fuse access panel by unsnapping it
from the left outboard end of the instrument panel.
(3) To install the IOD fuse, use a thumb to press
the IOD fuse holder unit in fuse cavity 12 firmly into
the JB.
(4) Install the fuse access panel by snapping it
onto the left outboard end of the instrument panel.
JUNCTION BLOCK
DESCRIPTION
OPERATION
All of the circuits entering and leaving the JB do Fig. 7 Fuse Access Panel Remove/Install
so through up to nine wire harness connectors, which 1 - INSTRUMENT PANEL
are connected to the JB through integral connector 2 - FUSE ACCESS PANEL
receptacles molded into the JB housing. Internal con- 3 - SCREW
nection of all of the JB circuits is accomplished by an
(5) Reach through the outboard side of the instru-
intricate combination of hard wiring and bus bars.
ment panel steering column opening to access and
Refer to Wiring for the location of complete JB cir-
disconnect all of the wire harness connectors from
cuit diagrams.
the JB connector receptacles (Fig. 8).
REMOVAL
WARNING: DISABLE THE AIRBAG SYSTEM
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
Fig. 8 Junction Block Remove/Install
(1) Disconnect and isolate the battery negative
cable. 1 - JUNCTION BLOCK
2 - INSTRUMENT PANEL
(2) Remove the fuse access panel by unsnapping it 3 - SCREW
from the left outboard end of the instrument panel 4 - CONNECTORS
(Fig. 7).
(3) Reach through the instrument panel fuse (6) Reach through the outboard side of the instru-
access panel opening to access and remove the one ment panel steering column opening to access and
screw that secures the Junction Block (JB) to the left remove the relay and fuse block from the JB. Push
instrument panel end bracket. the relay and fuse block towards the left end of the
(4) Remove the steering column opening cover instrument panel to disengage its mounting slots
from the instrument panel. Refer to Steering Col- from the tabs on the JB.
umn Opening Cover in the Body section of this (7) Reach through the outboard side of the instru-
manual for the location of the steering column open- ment panel steering column opening to access and
ing cover procedures. remove the one screw that secures the JB to the left
instrument panel end bracket.
8W - 97 - 8 8W-97 POWER DISTRIBUTION AN
JUNCTION BLOCK (Continued)
(8) Reach through the outboard side of the instru- (7) Install the fuse access panel by snapping it
ment panel steering column opening to remove the onto the left outboard end of the instrument panel.
JB from the left instrument panel end bracket. (8) Reconnect the battery negative cable.
INSTALLATION
POWER DISTRIBUTION
WARNING: DISABLE THE AIRBAG SYSTEM CENTER
BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
DESCRIPTION
COMPONENT DIAGNOSIS OR SERVICE. DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE, THEN WAIT TWO MINUTES FOR
THE AIRBAG SYSTEM CAPACITOR TO DISCHARGE
BEFORE PERFORMING FURTHER DIAGNOSIS OR
SERVICE. THIS IS THE ONLY SURE WAY TO DIS-
ABLE THE AIRBAG SYSTEM. FAILURE TO TAKE
THE PROPER PRECAUTIONS COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
(4) Look inside the cigar lighter or power outlet (4) Install the cigar lighter knob and element into
receptacle base and note the position of the rectangu- the cigar lighter receptacle base, or the protective cap
lar retaining bosses of the mount that secures the into the power outlet receptacle base.
receptacle base to the instrument panel lower bezel (5) Install the lower bezel onto the instrument
(Fig. 11). panel.
(5) Insert a pair of external snap ring pliers into (6) Reconnect the battery negative cable.
the cigar lighter or power outlet receptacle base and
engage the tips of the pliers with the retaining
bosses of the mount. REAR POWER OUTLET
(6) Squeeze the pliers to disengage the mount
retaining bosses from the receptacle base and, using REMOVAL
a gentle rocking motion, pull the pliers and the (1) Disconnect and isolate the battery negative
receptacle base out of the mount. cable.
(7) Remove the cigar lighter or power outlet mount (2) Remove the lower bezel from the instrument
from the instrument panel lower bezel. panel. Refer to Instrument Panel Lower Bezel in
the Body section of this manual for the procedure.
INSTALLATION (3) Pull the cigar lighter knob and element out of
(1) Install the cigar lighter or power outlet mount the cigar lighter receptacle base, or unsnap the pro-
into the instrument panel lower bezel. tective cap from the power outlet receptacle base.
(2) Align the splines on the outside of the cigar (4) Look inside the cigar lighter or power outlet
lighter or power outlet receptacle base connector receptacle base and note the position of the rectangu-
receptacle with the grooves on the inside of the lar retaining bosses of the mount that secures the
mount. receptacle base to the instrument panel lower bezel.
(3) Press firmly on the cigar lighter or power out- (5) Insert a pair of external snap ring pliers into
let receptacle base until the retaining bosses of the the cigar lighter or power outlet receptacle base and
mount are fully engaged in their receptacles.
8W - 97 - 12 8W-97 POWER DISTRIBUTION AN
REAR POWER OUTLET (Continued)
engage the tips of the pliers with the retaining receptacle with the grooves on the inside of the
bosses of the mount. mount.
(6) Squeeze the pliers to disengage the mount (3) Press firmly on the cigar lighter or power out-
retaining bosses from the receptacle base and, using let receptacle base until the retaining bosses of the
a gentle rocking motion, pull the pliers and the mount are fully engaged in their receptacles.
receptacle base out of the mount. (4) Install the cigar lighter knob and element into
(7) Remove the cigar lighter or power outlet mount the cigar lighter receptacle base, or the protective cap
from the instrument panel lower bezel. into the power outlet receptacle base.
(5) Install the lower bezel onto the instrument
INSTALLATION panel.
(1) Install the cigar lighter or power outlet mount (6) Reconnect the battery negative cable.
into the instrument panel lower bezel.
(2) Align the splines on the outside of the cigar
lighter or power outlet receptacle base connector