TJ ELECTRICALLY HEATED SYSTEMS 8N - 1

ELECTRICALLY HEATED SYSTEMS

CONTENTS

page page

GENERAL INFORMATION DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . . . 3

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1 DEFOGGER SYSTEM . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . 4
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . 2 REAR GLASS HEATING GRID . . . . . . . . . . . . . . 3
DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . . . 1 SERVICE PROCEDURES
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . 2 REAR GLASS HEATING GRID REPAIR . . . . . . . . 5
REAR GLASS HEATING GRID . . . . . . . . . . . . . . 1 REMOVAL AND INSTALLATION
DIAGNOSIS AND TESTING DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . . 6
DEFOGGER RELAY . . . . . . . . . . . . . . . . . . . . . . 4 DEFOGGER SWITCH . . . . . . . . . . . . . . . . . . . . . . 6

GENERAL INFORMATION DESCRIPTION AND OPERATION

INTRODUCTION REAR GLASS HEATING GRID

An electrically heated rear window defogger is The heated rear window glass has two electrically
available as factory-installed equipment on models conductive vertical bus bars and a series of horizon-
equipped with the hardtop option. The defogger will tal grid lines made of a silver-ceramic material,
only operate when the ignition switch is in the On which is baked on and bonded to the inside surface of
position. When the defogger switch is in the On posi- the glass. The grid lines and bus bars comprise a
tion, an electric heater grid on the rear window glass parallel electrical circuit.
is energized. This grid produces heat to help clear When the rear window defogger switch is placed in
the rear window glass of ice, snow, or fog. the On position, electrical current is directed to the
The defogger system is controlled by a switch rear window grid lines through the bus bars. The
located in the accessory switch bezel, which is near grid lines heat the rear window to clear the surface
the bottom of the instrument panel center bezel and of fog or snow. Protection for the heated grid circuit
next to the ash receiver. An amber indicator lamp in is provided by a fuse in the Power Distribution Cen-
the switch button will light to indicate when the ter (PDC).
defogger system is turned on. The instrument cluster The grid lines and bus bars are highly resistant to
circuitry, which contains the defogger system timer abrasion. However, it is possible for an open circuit
logic, monitors the state of the defogger switch to occur in an individual grid line, resulting in no
through a hard-wired input. The instrument cluster current flow through the line.
circuitry controls the defogger system through a The grid lines can be damaged or scraped off with
hard-wired control output to the defogger relay. sharp instruments. Care should be taken when clean-
The defogger system will be automatically turned ing the glass or removing foreign materials, decals,
off after a programmed time interval of about ten or stickers from the glass. Normal glass cleaning sol-
minutes. After the initial time interval has expired, if vents or hot water used with rags or toweling is rec-
the defogger switch is turned on again during the ommended.
same ignition cycle, the defogger system will auto- A repair kit is available to repair the grid lines and
matically turn off after about five minutes. bus bars, or to reinstall the heated glass pigtail
The defogger system will automatically shut off if the wires.
ignition switch is turned to the Off position, or it can be
turned off manually by depressing the instrument panel DEFOGGER SWITCH
switch. Refer to the owner’s manual for more informa- The rear window defogger switch is mounted in the
tion on the defogger system controls and operation. accessory switch bezel, which is located in the lower
Following are general descriptions of the major instrument panel center bezel, next to the ash
components in the defogger system. Refer to 8W-48 - receiver. The momentary-type switch provides a
Rear Window Defogger in Group 8W - Wiring Dia- hard-wired ground signal to the instrument cluster
grams for complete circuit descriptions and diagrams. each time it is depressed. The instrument cluster
8N - 2 ELECTRICALLY HEATED SYSTEMS TJ
DESCRIPTION AND OPERATION (Continued)
rear window defogger timer and logic circuitry The rear window defogger relay is located in the
responds by energizing or de-energizing the rear win- Power Distribution Center (PDC) in the engine com-
dow defogger relay. partment. Refer to the PDC label for relay identifica-
Energizing the rear window defogger relay pro- tion and location.
vides electrical current to the rear window defogger The rear window defogger relay cannot be repaired
grid and the amber indicator lamp in the switch, and, if faulty or damaged, it must be replaced.
which lights to indicate when the defogger system is
turned On. The defogger illumination lamp and indi-
cator lamp bulbs are serviceable. The defogger switch DIAGNOSIS AND TESTING
cannot be repaired and, if faulty or damaged, it must
be replaced. DEFOGGER SYSTEM
For circuit descriptions and diagrams, refer to
INSTRUMENT CLUSTER 8W-48 - Rear Window Defogger in Group 8W - Wir-
The instrument cluster is an electromechanical ing Diagrams. The operation of the electrically
unit that contains integrated circuitry and internal heated rear window defogger system can be con-
programming to perform a variety of functions. The firmed in one of the following manners:
instrument cluster circuitry monitors hard-wired 1. Turn the ignition switch to the On position.
switch inputs, as well as message inputs received While monitoring the instrument panel voltmeter, set
from other vehicle electronic control modules on the the defogger switch in the On position. When the
Chrysler Collision Detection (CCD) data bus network. defogger switch is turned On, a distinct voltmeter
The instrument cluster uses these many inputs needle deflection should be noted.
along with its internal programming and integral 2. Turn the ignition switch to the On position. Set
timer and logic circuitry to perform the functions of the defogger switch in the On position. The rear win-
the rear window defogger timer on this model. The dow defogger operation can be checked by feeling the
instrument cluster circuitry also has a self-diagnostic rear window glass. A distinct difference in tempera-
capability. Refer to Group 8E - Instrument Panel ture between the grid lines and the adjacent clear
Systems for more information on this feature. glass can be detected within three to four minutes of
However, there are no diagnostics available for the operation.
rear window defogger timer and logic circuitry. 3. Using a 12-volt DC voltmeter, contact the rear
Therefore, the diagnosis for this system consists of glass heating grid terminal A (right side) with the
confirming the presence of a rear window defogger negative lead, and terminal B (left side) with the pos-
switch input signal at the instrument cluster connec- itive lead (Fig. 1). The voltmeter should read battery
tor, and the resulting rear window defogger relay voltage.
control output signal at the defogger relay. For diag-
nosis of the CCD data bus and the data bus message
inputs, a DRB scan tool and the proper Diagnostic
Procedures manual are recommended.
Refer to Group 8E - Instrument Panel Systems for
the service procedures for the instrument cluster.
The rear window defogger timer and logic circuitry
cannot be adjusted or repaired and, if faulty or dam-
aged, the instrument cluster assembly must be
replaced.

DEFOGGER RELAY
The rear window defogger relay is a International
Standards Organization (ISO)-type relay. The rear
window defogger relay is a electromechanical device
that switches fused battery current to the rear glass Fig. 1 Rear Window Glass Grid Test
heating grid and the indicator lamp of the defogger The above checks will confirm system operation.
switch, when the instrument cluster rear window Illumination of the defogger switch indicator lamp
defogger timer and logic circuitry grounds the relay means that there is electrical current available at the
coil. See the Diagnosis and Testing section of this output of the defogger relay, but does not confirm
group for more information on the operation of the that the electrical current is reaching the rear glass
rear window defogger relay. heating grid lines.
TJ ELECTRICALLY HEATED SYSTEMS 8N - 3
DIAGNOSIS AND TESTING (Continued)
If the defogger system does not operate, the prob- DEFOGGER SWITCH
lem should be isolated in the following manner: For circuit descriptions and diagrams, refer to
(1) Confirm that the ignition switch is in the On 8W-48 - Rear Window Defogger in Group 8W - Wir-
position. ing Diagrams.
(2) Ensure that the rear glass heating grid feed
and ground wires are connected to the glass. Confirm WARNING: ON VEHICLES EQUIPPED WITH AIR-
that the ground wire has continuity to ground. BAGS, REFER TO GROUP 8M - PASSIVE
(3) Check the fuses in the Power Distribution Cen- RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
ter (PDC) and in the fuseblock module. The fuses STEERING WHEEL, STEERING COLUMN, OR
must be tight in their receptacles and all electrical INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
connections must be secure. SERVICE. FAILURE TO TAKE THE PROPER PRE-
When the above steps have been completed and the CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
rear glass heating grid is still inoperative, one or BAG DEPLOYMENT AND POSSIBLE PERSONAL
more of the following is faulty: INJURY.
• Defogger switch
• Defogger relay (1) Disconnect and isolate the battery negative
• Instrument cluster circuitry cable. Remove the accessory switch bezel and unplug
• Rear window grid lines (all grid lines would the defogger switch wire harness connector.
have to be broken or one of the feed wires discon- (2) Check for continuity between the ground cir-
nected for the entire system to be inoperative). cuit cavity of the defogger switch wire harness con-
If setting the defogger switch to the On position nector and a good ground. There should be
produces a severe voltmeter deflection, check for a continuity. If OK, go to Step 3. If not OK, repair the
short circuit between the defogger relay output and open circuit as required.
the rear glass heating grid. (3) Check for continuity between the ground cir-
cuit and rear window defogger switch sense circuit
REAR GLASS HEATING GRID terminals on the back of the switch housing (Fig. 2).
For circuit descriptions and diagrams, refer to There should be momentary continuity as the defog-
8W-48 - Rear Window Defogger in Group 8W - Wir- ger switch button is depressed, and then no continu-
ing Diagrams. To detect breaks in the grid lines, the ity. If OK, see the diagnosis for the Instrument
following procedure is required: Cluster in this group. If not OK, replace the faulty
(1) Turn the ignition switch to the On position. Set switch.
the defogger switch in the On position. The indicator
lamp should light. If OK, go to Step 2. If not OK, see
the Defogger Relay diagnosis in this group.
(2) Using a 12-volt DC voltmeter, contact the ver-
tical bus bar on the right side of the vehicle with the
negative lead. With the positive lead, contact the ver-
tical bus bar on the left side of the vehicle. The volt-
meter should read battery voltage. If OK, go to Step
3. If not OK, repair the open circuit to the defogger
relay as required.
(3) With the negative lead of the voltmeter, contact
a good body ground point. The voltage reading should
not change. If OK, go to Step 4. If not OK, repair the
circuit to ground as required.
(4) Connect the negative lead of the voltmeter to
the right side bus bar and touch each grid line at
midpoint C with the positive lead. A reading of
approximately six volts indicates a line is good. A
reading of zero volts indicates a break in the grid
line between midpoint C and the left side bus bar. A
reading of ten to fourteen volts indicates a break
between midpoint C and the right side bus bar. Move
the positive lead on the grid line towards the break Fig. 2 Defogger Switch Continuity
and the voltage reading will change as soon as the
break is crossed.
8N - 4 ELECTRICALLY HEATED SYSTEMS TJ
DIAGNOSIS AND TESTING (Continued)
DEFOGGER RELAY (3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
WARNING: ON VEHICLES EQUIPPED WITH AIR- gized position. This terminal supplies battery voltage
BAGS, REFER TO GROUP 8M - PASSIVE to the rear glass heating grid and the defogger
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY switch indicator lamp. There should be continuity
STEERING WHEEL, STEERING COLUMN, OR between the cavity for relay terminal 87 and the rear
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR window defogger relay output circuit cavities of the
SERVICE. FAILURE TO TAKE THE PROPER PRE- rear glass heating grid and defogger switch connec-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- tors at all times. If OK, go to Step 4. If not OK,
BAG DEPLOYMENT AND POSSIBLE PERSONAL repair the open circuit(s) as required.
INJURY. (4) The coil battery terminal (86) is connected to
the electromagnet in the relay. This terminal is pro-
vided with ground by the instrument cluster rear
RELAY TEST window defogger timer and logic circuitry to energize
The defogger relay (Fig. 3) is located in the Power the defogger relay. There should be continuity to
Distribution Center (PDC), in the engine compart- ground at the cavity for relay terminal 86 when the
ment. Remove the defogger relay from the PDC as defogger switch is turned On. However, with the
described in this group to perform the following tests: defogger relay removed, the defogger switch indicator
(1) A relay in the de-energized position should lamp will not light to show that the defogger system
have continuity between terminals 87A and 30, and is turned On. Be certain that you depress the defog-
no continuity between terminals 87 and 30. If OK, go ger switch at least twice to confirm that the system
to Step 2. If not OK, replace the faulty relay. is turned on during this test. If OK, go to Step 5. If
(2) Resistance between terminals 85 and 86 (elec- not OK, repair the open circuit to the instrument
tromagnet) should be 75 6 10 ohms. If OK, go to cluster as required.
Step 3. If not OK, replace the faulty relay. (5) The coil ground terminal (85) is connected to
(3) Connect a battery to terminals 85 and 86. the electromagnet in the relay. It is connected to
There should now be continuity between terminals fused ignition switch output voltage and should be
30 and 87, and no continuity between terminals 87A hot when the ignition switch is in the On position.
and 30. If OK, see the Relay Circuit Test in this Check for battery voltage at the cavity for relay ter-
group. If not OK, replace the faulty relay. minal 85 with the ignition switch in the On position.
If OK, see the diagnosis for Instrument Cluster in
this group. If not OK, repair the open circuit to the
fuse in the fuseblock module as required.

INSTRUMENT CLUSTER
Before performing this test, complete the Defogger
Switch and the Defogger Relay tests as described in
this group. For circuit descriptions and diagrams,
refer to 8W-48 - Rear Window Defogger in Group 8W
- Wiring Diagrams.

WARNING: ON VEHICLES EQUIPPED WITH AIR-

BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
Fig. 3 Defogger Relay SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
RELAY CIRCUIT TEST BAG DEPLOYMENT AND POSSIBLE PERSONAL
(1) The relay common feed terminal cavity (30) is INJURY.
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open (1) Disconnect and isolate the battery negative
circuit to the PDC fuse as required. cable. Remove the defogger relay from the Power Dis-
(2) The relay normally closed terminal (87A) is tribution Center (PDC) and unplug the defogger
connected to terminal 30 in the de-energized position, switch wire harness connector.
but is not used for this application. Go to Step 3.
TJ ELECTRICALLY HEATED SYSTEMS 8N - 5
DIAGNOSIS AND TESTING (Continued)
(2) Remove the instrument cluster from the instru-
ment panel. Refer to Instrument Cluster in Group 8E
- Instrument Panel Systems for the procedures.
(3) Check for continuity between the rear window
defogger switch sense circuit cavity of the right
instrument cluster wire harness connector (connector
B) and a good ground. There should be no continuity.
If OK, go to Step 4. If not OK, repair the short circuit
as required.
(4) Check for continuity between the rear window
defogger switch sense circuit cavities of the right
instrument cluster wire harness connector (connector
B) and the defogger switch wire harness connector.
There should be continuity. If OK, go to Step 5. If not Fig. 4 Grid Line Repair - Typical
OK, repair the open circuit as required.
(5) Check for continuity between the rear window (2) Follow the instructions in the repair kit for
defogger relay control circuit cavity of the right preparing the damaged area.
instrument cluster wire harness connector (connector (3) Remove the package separator clamp and mix
B) and a good ground. There should be no continuity. the two conductive epoxy components thoroughly
If OK, go to Step 6. If not OK, repair the short circuit within the packaging. Fold the package in half and
as required. cut the center corner to dispense the epoxy.
(6) Check for continuity between the rear window (4) For grid line repairs, mask the area to be
defogger relay control circuit cavities of the right repaired with masking tape or a template.
instrument cluster wire harness connector (connector (5) Apply the epoxy through the slit in the mask-
B) and the defogger relay receptacle (the cavity for ing tape or template. Overlap both ends of the break
ISO relay terminal 86) in the PDC. There should be by at least 19 mm (0.75 in.).
continuity. If OK, replace the faulty instrument clus- (6) For a terminal or pigtail wire replacement,
ter. If not OK, repair the open circuit as required. mask the adjacent areas so the epoxy can be
extended onto the adjacent grid line as well as the
bus bar. Apply a thin layer of epoxy to the area
SERVICE PROCEDURES where the terminal or pigtail wire was fastened and
onto the adjacent grid line.
REAR GLASS HEATING GRID REPAIR (7) Apply a thin layer of conductive epoxy to the
Repair of the rear glass heating grid lines, bus terminal or bare wire end of the pigtail and place it
bars, or pigtail wires can be accomplished using a in the proper location on the bus bar. To prevent the
Mopar Rear Window Defogger Repair Kit (P/N terminal or pigtail wire from moving while the epoxy
4267922) or equivalent. is curing, it must be wedged or clamped.
(8) Carefully remove the masking tape or tem-
WARNING: MATERIALS CONTAINED IN THE plate.
REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION.
THE KIT CONTAINS EPOXY RESIN AND AMINE CAUTION: Do not allow the glass surface to exceed
TYPE HARDENER, WHICH ARE HARMFUL IF SWAL- 204° C (400° F) or the glass may fracture.
LOWED. AVOID CONTACT WITH THE SKIN AND
EYES. FOR SKIN CONTACT, WASH THE AFFECTED (9) Allow the epoxy to cure 24 hours at room tem-
AREAS WITH SOAP AND WATER. FOR CONTACT perature, or use a heat gun with a 260° to 371° C
WITH THE EYES, FLUSH WITH PLENTY OF WATER. (500° to 700° F) range for fifteen minutes. Hold the
DO NOT TAKE INTERNALLY. IF TAKEN INTER- heat gun approximately 25.4 cm (10 in.) from the
NALLY, INDUCE VOMITING AND CALL A PHYSICIAN repair.
IMMEDIATELY. USE WITH ADEQUATE VENTILA- (10) After the conductive epoxy is properly cured,
TION. DO NOT USE NEAR FIRE OR FLAME. CON- remove the wedge or clamp from the terminal or pig-
TAINS FLAMMABLE SOLVENTS. KEEP OUT OF THE tail wire. Do not attach the wire harness connectors
REACH OF CHILDREN. until the curing process is complete.
(11) Check the operation of the rear window defog-
(1) Mask the repair area so that the conductive ger glass heating grid.
epoxy can be applied neatly. Extend the epoxy appli-
cation onto the grid line or the bus bar on each side
of the break (Fig. 4).
8N - 6 ELECTRICALLY HEATED SYSTEMS TJ

REMOVAL AND INSTALLATION (6) Remove the accessory switch bezel from the
instrument panel.
DEFOGGER SWITCH (7) With a small thin-bladed screwdriver, gently
pry the snap clips at the top and bottom of the rear
WARNING: ON VEHICLES EQUIPPED WITH AIR- window defogger switch receptacle on the back of the
BAGS, REFER TO GROUP 8M - PASSIVE accessory switch bezel and pull the switch out of the
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY bezel.
STEERING WHEEL, STEERING COLUMN, OR (8) Reverse the removal procedures to install. Be
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR certain that both of the switch snap clip retainers in
SERVICE. FAILURE TO TAKE THE PROPER PRE- the receptacle on the back of the accessory switch
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- bezel are fully engaged. Tighten the mounting screws
BAG DEPLOYMENT AND POSSIBLE PERSONAL to 2.2 N·m (20 in. lbs.).
INJURY.
DEFOGGER RELAY
(1) Disconnect and isolate the battery negative (1) Disconnect and isolate the battery negative
cable. cable.
(2) Remove the center bezel from the instrument (2) Remove the cover from the Power Distribution
panel. See Instrument Panel Center Bezel in Group Center (PDC) (Fig. 6).
8E - Instrument Panel Systems for the procedures.
(3) Remove the four screws that secure the acces-
sory switch bezel to the instrument panel (Fig. 5).

Fig. 6 Power Distribution Center

(3) Refer to the label on the PDC for defogger
relay identification and location.
Fig. 5 Accessory Switch Bezel Remove/Install
(4) Unplug the defogger relay from the PDC.
(4) Pull the accessory switch bezel out from the (5) Install the defogger relay by aligning the relay
instrument panel far enough to access the wire har- terminals with the cavities in the PDC and pushing
ness connectors. the relay firmly into place.
(5) Unplug the wire harness connectors from the (6) Install the PDC cover.
rear of the accessory switches and the cigar lighter/ (7) Connect the battery negative cable.
power outlet. (8) Test the relay operation.