Dodge Sprinter. Manual - part 215

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 fuse block at all times.

DIAGNOSIS AND TESTING - POWER OUTLET

(1) Check for battery voltage at the fused B(+) fuse

in the fuse block. If OK, go to Step 2. If not OK,
repair the open fused B(+) circuit to the battery as
required.

(2) Check for continuity between the inside cir-

cumference of the power outlet receptacle and a good
ground. There should be continuity. If OK, go to Step
3. If not OK, go to Step 4.

(3) 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 4.

(4) Disconnect and isolate the battery negative

cable. Check for continuity between the ground cir-
cuit cavity of the power outlet wire harness connector
and a good ground. There should be continuity. If
OK, go to Step 5. If not OK, repair the open ground
circuit to ground as required.

(5) 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 fuse in the fuse
block as required.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Pull the cigar lighter knob and element 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 instrument panel.

(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) Disconnect the instrument panel wire harness

connector from the connector receptacle of the cigar
lighter or the power outlet receptacle base.

(7) Remove the cigar lighter or power outlet mount

from the instrument panel.

INSTALLATION

(1) Install the cigar lighter or power outlet mount

into the instrument panel.

(2) Reconnect the instrument panel wire harness

connector to the connector receptacle of the cigar
lighter or the power outlet receptacle base.

(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 receptacle base until the retaining bosses of the
mount are fully engaged in their receptacles.

(5) Install the cigar lighter knob and element into

the cigar lighter receptacle base.

(6) Reconnect the battery negative cable.

RELAY

DESCRIPTION

A relay (Fig. 1) is an electromechanical device that

switches fused battery current to a electrical compo-
nent when the ignition switch is turned to the Acces-
sory or Run positions, or when controlled by a
electronic module. The relays are located in the fuse
block.

The relay is a International Standards Organiza-

tion (ISO) relay. Relays conforming to the ISO speci-
fications have common physical dimensions, current
capacities, terminal patterns, and terminal functions.

Fig. 1 ISO RELAY

COMMON FEED

COIL GROUND

COIL BATTERY

NORMALLY OPEN

87A

NORMALLY CLOSED

8W - 97 - 4

8W-97 POWER DISTRIBUTION

A relay cannot be repaired or adjusted and, if

faulty or damaged, it must be replaced.

OPERATION

The ISO relay consists of an electromagnetic coil, a

resistor and three (two fixed and one movable) elec-
trical contacts. The movable (common feed) relay con-
tact is held against one of the fixed contacts
(normally closed) by spring pressure. When the elec-
tromagnetic coil is energized, it draws the movable
contact away from the normally closed fixed contact,
and holds it against the other (normally open) fixed
contact.

When the electromagnetic coil is de-energized,

spring pressure returns the movable contact to the
normally closed position. The resistor is connected in
parallel with the electromagnetic coil in the relay,
and helps to dissipate voltage spikes that are pro-
duced when the coil is de-energized.

DIAGNOSIS AND TESTING - RELAY

(1) Remove the relay from its mounting location.
(2) A relay in the de-energized position should

have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 3. If not OK, replace the faulty relay.

(3) Resistance between terminals 85 and 86 (elec-

tromagnet) should be 60.7 - 80.3 ohms. If OK, go to
Step 4. If not OK, replace the faulty relay.

(4) Connect a battery to terminals 85 and 86.

There should now be continuity between terminals
30 and 87, and no continuity between terminals 87A
and 30. If OK, perform the Relay Circuit Test that
follows. If not OK, replace the faulty relay.

DIAGNOSIS AND TESTING - RELAY CIRCUIT TEST

(1) The relay common feed terminal cavity (30) of

the fuse block is connected to battery voltage and
should be hot at all times. Check for battery voltage
at the fused B(+) circuit cavity in the fuse block
receptacle for the relay. If OK, go to Step 2. If not
OK, repair the fused B(+) circuit to the fuse block
fuse as required.

(2) The relay normally closed terminal (87A) is

connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.

(3) The relay normally open terminal (87) is con-

nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the fused B(+) fuse in the fuse block that feeds the
accessory when the relay is energized by the ignition
switch. There should be continuity between the fuse
block cavity for relay terminal 87 and the fused B(+)
fuse in the fuse block at all times. If OK, go to Step
4. If not OK, repair the open fused B(+) circuit to the
fuse block fuse as required.

(4) The coil ground terminal (85) is connected to

the electromagnet in the relay. It receives battery
feed to energize the relay when the ignition switch is
in the Accessory or Run positions. Turn the ignition
switch to the On position. Check for battery voltage
at the fused ignition switch output (acc/run) circuit
cavity for relay terminal 85 in the fuse block recep-
tacle for the relay. If OK, go to Step 5. If not OK,
repair the open fused ignition switch output (acc/run)
circuit to the ignition switch as required.

(5) The coil battery terminal (86) is connected to

the electromagnet in the relay. The fuse block cavity
for this terminal should have continuity to ground at
all times. If not OK, repair the open ground circuit to
ground as required.

REMOVAL

(1) Disconnect and isolate the negative battery

cable.

(2) Remove the relay by grasping it firmly and

pulling it straight out from its receptacle. A slight
back and fourth rocking motion may help the
removal process.

INSTALLATION

(1) Position the relay to the proper receptacle.
(2) Align the relay terminals with the terminal

cavities in the receptacle.

(3) Push firmly and evenly on the top of the relay

until the terminals are fully seated in the terminal
cavities in the receptacle.

(4) Connect the negative battery cable.

8W-97 POWER DISTRIBUTION