POWER DISTRIBUTION
Contents
1. _ DR 80d101d1 Fig 6 IOD FUSE LOCATION 1 IOD FUSE CIRCUITS INCLUDED WITH IOD FUSE e Cluster CCN Diagnostic Connector Map Lamps Glove Box Lamp Courtesy Lamps Radio Underhood Lamp 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 The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical sys tem during new vehicle transportation and predeliv ery storage to reduce battery depletion while still allowing vehicle operation so that the vehicle can be loaded unloaded and moved as needed by both vehi cle transportation company and dealer personnel The IOD fuse is disconnected from Integrated Power Module fuse cavity 51 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 pre pared for delivery the IOD function of this fuse DR IOD FUSE Continued becomes transparent and the fuse that has been assigned the IOD designation becomes only another Fused B circuit fuse The2. power module assembly are broken down into the following 8W 97 3 components the Power Distribution Center PDC the integrated power module cover the Front Control Module FCM and the Integrated Power Module Assembly which includes the power distribution cen ter the cover and FCM Refer to the Front Con trol Module in the Electronic Control Module section of this service manual for information on the front control module OPERATION All of the current from the battery and the gener ator output enters the integrated power module via a stud on the top of the module The integrated power module cover is removed to access the fuses or relays Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board Refer to the Wiring section of the service manual for complete integrated power module circuit schematics REMOVAL 1 Disconnect the negative and positive battery cables 80d101b4 Fig 2 DR INTEGRATED POWER MODULE COVER RETAINING BOLT INTEGRATED POWER MODULE RETAINING BOLT RETAINING SCREW INTEGRATED POWER MODULE COVER RON 2 Unsnap cover and remove the B terminal nut from the integrated power module B terminal Remove the B cable from the integrated power mod ule 3 Disconnect the gray connector from the inte grated power module 8W 97 4 4 Remove the integrated
3. required and replace the faulty fuse 2 Check for battery voltage at the fused B fuse in the integrated power module If OK go to Step 3 If not OK repair the open fused B circuit to the battery as required 3 Remove the plastic protective cap from the power outlet receptacle Check for continuity between the inside circumference of the power outlet recepta cle and a good ground There should be continuity If OK go to Step 4 If not OK go to Step 5 4 Check for battery voltage at the insulated con tact located at the back of the power outlet recepta cle If not OK go to Step 5 5 Disconnect and isolate the battery negative cable Remove the power outlet receptacle from the instrument panel Disconnect the wire harness con nector from the power outlet receptacle Check for continuity between the ground circuit cavity of the power outlet wire harness connector 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 Connect the battery negative cable Check for battery voltage at the fused B circuit cavity of the power outlet wire harness connector If OK replace the faulty power outlet receptacle If not OK repair the open fused B circuit to the integrated power module fuse as required 8W 97 8 POWER OUTLET Continued REMOVAL 1 Disconnect and isolate the battery negative cable 2 Pull the cigar lighter knob and ele
4. DESCRIPTION 80d10207 Fig 1 DR INTEGRATED POWER MODULE 1 POWER DISTRIBUTION CENTER HOUSING 2 FRONT CONTROL MODULE ELECTRICAL CONNECTOR The Integrated Power Module IPM Fig 1 is a combination of the Power Distribution Center PDC and the Front Control Module FCM The IPM is located in the engine compartment next to the bat tery on this model The power distribution center mates directly with the Front Control Module FCM to form the Integrated Power Module Fuse and Relay Center The power distribution center PDC is a printed circuit board based module that contains fuses and relays while the front control module con tains the electronics controlling the integrated power module and other functions This integrated power module connects directly to the battery positive via a stud located on top of the unit The ground connec tion is via electrical connectors The integrated power module provides the primary means of voltage distri bution and protection for the entire vehicle The molded plastic integrated power module hous ing includes a base and cover The integrated power module cover is easily opened or removed for service access by unscrewing the cover retaining nut and has a fuse and relay layout map integral to the inside surface of the cover This integrated power module housing base and cover are secured in place via bolts to the left front fender support assembly Replaceable components of the integrated
5. DR _ 8W 97 POWER DISTRIBUTION 8W 97 POWER DISTRIBUTION TABLE OF CONTENTS page POWER DISTRIBUTION DESGRIPTION sce sides a eae 1 OPERATION seresa aiaa a ele de as 1 SPECIAL TOOLS POWER DISTRIBUTION SYSTEMS 2 CIGAR LIGHTER OUTLET DESCRIPTION ess ensaereed wah ederd a ed ae 2 OPERATION sesde eed gad Pane eee en aes 2 DIAGNOSIS AND TESTING CIGAR LIGHTER OUTLET serei cooks ages Mee cette akon aa aout 2 INTEGRATED POWER MODULE DESCRIPTION ee ee 3 OPERATION 4 22 41 o eth et Gets oth Bee oe 3 REMOVAL ee eee 3 INSTALLATION 2 1 2 0 ce ee eee 4 FRONT CONTROL MODULE DESCRIPTION chased aaeeda0 e oaeled ace be aes 5 POWER DISTRIBUTION DESCRIPTION This group covers the various standard and optional power distribution components used on this model The power distribution system for this vehicle consists of the following components e Integrated Power Module IPM e Front Control Module FCM e Power Distribution Center PDC e Power Outlets e Cigar Lighter Outlets e Relays Refer to Wiring Diagrams for complete circuit sche matics The power distribution system also incorporates various types of circuit control and protection fea tures including e Automatic resetting circuit breakers e Blade type fuses e Cartridge fuses e Relays Following are general descriptions of the major components in the power distribution system See the owner s man
6. IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days However it must be remembered that disconnecting the IOD fuse will not eliminate IOD but only reduce this normal condition If a vehicle will be stored for more than about thirty days the battery negative cable should be discon nected to eliminate normal IOD and the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the bat tery from becoming discharged or damaged REMOVAL The Ignition Off Draw IOD fuse is disconnected from Integrated Power Module fuse cavity 51 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 1 Turn the ignition switch to the Off position 2 Remove the Integrated Power Module cover 3 Grasp the outer tabs of the IOD fuse holder unit in fuse cavity 51 between the thumb and fore finger and pull the unit firmly upward 4 Install the Integrated Power Module cover INSTALLATION 1 Turn the ignition switch to the Off position 2 Remove the Integrated Power Module cover 3 To install the IOD fuse use a thumb to press the IOD fuse holder unit in fuse cavity 51 firmly into the Integrated Power Module 4 Install the Integrated Powe
7. TAINING LATCH GRAY CONNECTOR GREEN CONNECTOR GREEN CONNECTOR BLUE CONNECTOR WHITE CONNECTOR BLACK CONNECTOR BLACK CONNECTOR ONOaARWN DR _ 8W 97 POWER DISTRIBUTION INTEGRATED POWER MODULE Continued 3 Connect the electrical connectors by pushing straight on and rotating the connector arm inboard until the connector is firmly locked in place on the module assembly 4 Grasp the integrated power module with two hands and install the assembly on the battery tray Fig 5 ID 80d101f8 Fig 5 INTEGRATED POWER MODULE MOUNTING TABS 1 INTEGRATED POWER MODULE MOUNTING HOLES 2 BATTERY TRAY ASSEMBLY 3 FRONT CONTROL MODULE 5 Install the integrated power module retaining bolt and screw 6 Connect the gray connector on the integrated power module housing 7 Install the B terminal cable and nut on the integrated power module B terminal Snap the cover in place 8 Connect the negative and positive battery cables FRONT CONTROL MODULE DESCRIPTION The Front Control Module FCM is a micro con troller based module located in the left front corner of the engine compartment On this model the inte grated power module must be positioned aside in order to access the front control module The front control module mates to the power distribution cen ter to form the Integrated Power Module IPM The 8W 97 5 integrated p
8. ceptacle base until the retaining bosses of the mount are fully engaged in their receptacles 8W 97 POWER DISTRIBUTION _ DR A Ay bi N DS PULL BASE OUT THROUGH MOUNT 80a95367 Fig 7 Cigar Lighter and Power Outlet Remove Install KNOB AND ELEMENT RETAINING BOSSES ENGAGE PLIERS HERE BASE PARTIALLY REMOVED EXTERNAL SNAP RING PLIERS MOUNT BASE NOoORWD 5 Install the cigar lighter knob and element into the cigar lighter receptacle base or the protective cap into the power outlet receptacle base 6 Reconnect the battery negative cable
9. electrical current needed to operate many accessories that the vehicle owner may choose to have installed in the aftermarket 8W 97 2 POWER DISTRIBUTION Continued SPECIAL TOOLS POWER DISTRIBUTION SYSTEMS Se Terminal Pick Kit 6680 CIGAR LIGHTER OUTLET DESCRIPTION On models equipped a cigar lighter outlet is installed to the left of the center stack area in the lower instrument panel The cigar lighter outlet is secured by a snap fit within the bezel The cigar lighter outlet plastic cap and the knob and heating element unit are available for service replacement These components cannot be repaired and if faulty or damaged they must be replaced OPERATION The cigar lighter consists of two major components a knob and heating element unit and the cigar lighter base or outlet shell The receptacle shell is connected to ground and an insulated contact in the bottom of the shell is connected to battery current The cigar lighter receives battery voltage from a fuse in the junction block when the ignition switch is in the Accessory or Run positions The cigar lighter knob and heating element are encased within a spring loaded housing which also features a sliding protective heat shield When the knob and heating element are inserted in the outlet shell the heating element resistor coil is grounded through its housing to the outlet shell If the cigar lighter knob is pushed inward the heat shield slides up toward the kn
10. ment out of the cigar lighter receptacle base or unsnap the pro tective cap from the power outlet receptacle base 3 Look inside the cigar lighter or power outlet receptacle base and note the position of the rectangu lar retaining bosses of the mount that secures the receptacle base to the panel Fig 7 4 Insert a pair of external snap ring pliers into the cigar lighter or power outlet receptacle base and engage the tips of the pliers with the retaining bosses of the mount 5 Squeeze the pliers to disengage the mount retaining bosses from the receptacle base and using a gentle rocking motion pull the pliers and the receptacle base out of the mount 6 Pull the receptacle base away from the instru ment panel far enough to access the instrument panel wire harness connector 7 Disconnect the instrument panel wire harness connector from the cigar lighter or power outlet receptacle base connector receptacle 8 Remove the cigar lighter or power outlet mount from the instrument panel INSTALLATION 1 Reconnect the instrument panel wire harness connector to the cigar lighter or power outlet recep tacle base connector receptacle 2 Install the cigar lighter or power outlet mount into the instrument panel 3 Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount 4 Press firmly on the cigar lighter or power out let re
11. ob exposing the heating element and the heating element extends from the housing toward the insulated contact in the bottom of the outlet shell Two small spring clip retainers are located on either side of the insulated contact inside the bottom of the outlet shell These clips engage and hold the heating element against the insulated contact long 8W 97 POWER DISTRIBUTION DR enough for the resistor coil to heat up When the heating element is engaged with the contact battery current can flow through the resistor coil to ground causing the resistor coil to heat When the resistor coil becomes sufficiently heated excess heat radiates from the heating element caus ing the spring clips to expand Once the spring clips expand far enough to release the heating element the spring loaded housing forces the knob and heat ing element to pop back outward to their relaxed position When the cigar lighter knob and element are pulled out of the outlet shell the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety DIAGNOSIS AND TESTING CIGAR LIGHTER OUTLET For complete circuit diagrams refer to Wiring Diagrams 1 Check the fused B fuse in the integrated power module If OK go to Step 2 If not OK repair the shorted circuit or component as required and replace the faulty fuse 2 Turn the igni
12. ower module connects directly to the bat tery and provides the primary means of circuit pro tection and power distribution for all vehicle electrical systems The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the PCI bus circuit J 1850 For information on the Integrated Power Mod ule Refer to the Power Distribution Section of the service manual OPERATION As messages are sent over the PCI bus circuit the front control module reads these messages and con trols power to some of the vehicles electrical systems by completing the circuit to ground low side driver or completing the circuit to 12 volt power high side driver The following functions are Controlled by the Front Control Module e Headlamp Power with Voltage Regulation e Windshield Wiper ON OFF Relay Actuation Windshield Wiper HI LO Relay Actuation Windshield Washer Pump Motor Fog Lamp Relay Actuation e Park Lamp Relay Actuation e Horn Relay Actuation The following inputs are Received Monitored by the Front Control Module e B Connection Detection e Power Ground Ambient Temperature Sensing Ignition Switch Run Washer Fluid Level Switch Windshield Wiper Park Switch PCI Bus Circuit DIAGNOSIS AND TESTING FRONT CONTROL MODULE The front control module is a printed circuit board based module with a on board micro
13. power module retaining bolt and screw Fig 2 5 Grasp the integrated power module with two hands and slide the assembly in the direction shown Fig 3 to free the module from its mounting bracket Position the assembly upside down to access the elec trical connectors located on the bottom of the unit 80d101eb Fig 3 REMOVING INTEGRATED POWER MODULE 6 Disconnect the electrical connectors by depress ing the locking tab and rotating the connector arm outboard until the connector is free from the module assembly Be certain to pull the connectors straight off 7 Position the integrated power module on a bench and remove the four front control module retaining screws 8 Disconnect the front control module by pulling it straight off the integrated power module 8W 97 POWER DISTRIBUTION INTEGRATED POWER MODULE Continued DR LLATION INSTALLATION 1 Connect the front control module by pushing it straight on the integrated power module electrical receptacle 2 Install the four front control module retaining screws Torque to 30 in Ibs H 5 NOTE Integrated power module electrical connec tors are color coded to ease location reference Fig 4 OQ G4 gt lo LETZ KN j SS ANG 2 GEF KNIE KJ A Le n a NZ yal VA cai WA f V7 GOK Athy 80d101fc Fig 4 INTEGRATED POWER MODULE ELECTRICAL CONNECTIONS RE
14. processor The front control module interfaces with other electronic modules in the vehicle via the Programmable Com munications Interface PCI data bus J 1850 In order to obtain conclusive testing the Programmable Communications Interface PCI data bus network and all of the electronic modules that provide inputs to or receive outputs from the front control module must be checked All PCI J 1850 communication faults must be resolved prior to further diagnosing any front control module related issues The front control module was designed to be diag nosed with an appropriate diagnostic scan tool such as the DRB III The most reliable efficient and accurate means to diagnose the front control module 8W 97 6 FRONT CONTROL MODULE Continued requires the use of a DRB III scan tool and the proper Body Diagnostic Procedures manual Before any testing of the front control module is attempted the battery should be fully charged and all wire harness and ground connections inspected around the affected areas on the vehicle REMOVAL 1 Disconnect the positive and negative battery cables from the battery 2 Partially remove the integrated power module from the engine compartment Refer to 8 ELECTRI CAL POWER DISTRIBUTIONANTEGRATED POWER MODULE REMOVAL 3 Remove the front control screws 4 Using both hands pull the front control module straight from the integrated power module assembly to disconnect the 49 wa
15. r Module cover POWER OUTLET DESCRIPTION Two power outlets are utilized on this model One in the instrument panel center lower bezel and the other in the center console The power outlet bases are secured by a snap fit within the instrument panel or trim panel A plastic protective cap snaps into the power outlet base when the power outlet is not being used and hangs from the power outlet base mount by an integral bail strap while the power out let is in use 8W 97 POWER DISTRIBUTION 8W 97 7 The power outlet receptacle unit and the accessory power outlet protective cap are available for service The power outlet receptacle cannot be repaired and if faulty or damaged it must be replaced OPERATION The power outlet base or receptacle shell is con nected to ground and an insulated contact in the bottom of the shell is connected to battery current The power outlet receives battery voltage from a fuse in the integrated power module at all times While the power outlet is very similar to a cigar lighter base unit it does not include the two small spring clip retainers inside the bottom of the recepta cle shell that are used to secure the cigar lighter heating element to the insulated contact DIAGNOSIS AND TESTING POWER OUTLET For complete circuit diagrams refer to Wiring Diagrams 1 Check the fused B fuse in the integrated power module If OK go to Step 2 If not OK repair the shorted circuit or component as
16. tion switch to the Run position Check for battery voltage at the fused B fuse in the integrated power module If OK go to Step 3 If not OK repair the open or short as required 3 Remove the cigar lighter knob and element from the cigar lighter outlet shell Check for continu ity between the inside circumference of the cigar lighter outlet shell and a good ground there should be continuity If OK go to Step 4 If not OK go to Step 5 4 Turn the ignition switch to the Run position Check for battery voltage at the insulated contact located at the back of the cigar lighter outlet shell If OK replace the faulty cigar lighter knob and de ment If not OK go to Step 5 5 Turn the ignition switch to the Off position Disconnect and isolate the battery negative cable Check for continuity between the ground circuit cav ity of the cigar lighter wire harness connector 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 Connect the battery negative cable Turn the ignition switch to the Accessory or Run positions Check for battery voltage at the fused B circuit cavity of the cigar lighter wire harness connector If OK replace the faulty cigar lighter outlet If not OK repair the open fused B circuit to the integrated power module fuse as required DR _ 8W 97 POWER DISTRIBUTION INTEGRATED POWER MODULE
17. ual in the vehicle glove box for more information on the features and use of all of the power distribution system components 8W 97 1 page OPERATION a conetanwatmn adn deee eae e Maes 5 DIAGNOSIS AND TESTING FRONT CONTROL MODULE eeeicu dear saeia 5 REMOVAL atipe wheter Seb bebo e eS eb oes 6 INSTALLATION s2sca everneegaaes seaweeds 6 IOD FUSE DESCRIPTION satcinaieteg Rea Gaewe edna dane 6 OPERATION sosis ossa a iiare ea eee oe 6 REMOVAL seeceecde teen eee eee ede ee 7 INSTALLATION 1 0 2 eee 7 POWER OUTLET DESCRIPTION isise siacedi e idend aa 7 OPERATION vaereirerciceseiestisirenavtsus 7 DIAGNOSIS AND TESTING POWER OUTLET wetwcave rere eedwent oa 7 REMOVAL uroni oada deh ea be RY ee eee ba 8 INSTALLATION 02 s De deede kay Dairia 8 OPERATION The power distribution system for this vehide is designed to provide safe reliable and centralized dis tribution points for the electrical current required to operate all of the many standard and optional facto ry installed electrical and electronic powertrain chassis safety security comfort and convenience sys tems At the same time the power distribution sys tem was designed to provide ready access to these electrical distribution points for the vehide techni cian to use when conducting diagnosis and repair of faulty circuits The power distribution system can also prove useful for the sourcing of additional elec trical circuits that may be required to provide the
18. y electrical connector and remove the front control module from the vehicle INSTALLATION 1 Install the front control module on the inte grated power module assembly by pushing the 49 way electrical connector straight in 2 Install the front control module retaining screws Torque the screws to 7 in Ibs 3 Install the integrated power module Refer to 8 ELECTRICAL POWER DISTRIBUTION INTE GRATED POWER MODULE INSTALLATION 4 Connect the positive and negative battery cables module retaining IOD FUSE DESCRIPTION All vehicles are equipped with an Ignition Off Draw IOD fuse that is disconnected within the Inte grated Power Module when the vehicle is shipped from the factory Dealer personnel are to reconnect the IOD fuse in the Integrated Power Module as part of the preparation procedures performed just prior to new vehicle delivery A laser printed fuse layout map is integral to the Integrated Power Module cover to ensure proper fuse identification The IOD fuse is a 20 ampere mini blade type fuse located in fuse cavity 51 Fig 6 The fuse is secured within a black molded plastic fuse holder and puller unit that serves both as a tool for disconnecting and reconnecting the fuse in its Integrated Power Module cavity and as a fuse holder that conveniently stores the fuse in the same Inte grated Power Module cavity after it has been discon nected 8W 97 POWER DISTRIBUTION
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