engine CHRYSLER VOYAGER 1996 Service Manual

(6) Disconnect front washer hose at front wiper
unit in the engine compartment (Fig. 4). The front
hose will be removed with the bottle.
(7) Disconnect hose from rear washer pump nipple
(Fig. 5).
(8) Allow washer bottle to drain.
(9) Remove screws holding washer bottle to front
fender support and remove bottle.INSTALLATION
For installation, reverse the above procedure.
WINDSHIELD WIPER BLADE
REMOVAL
(1) Lift the wiper arm away from windshield.
(2) Disengage the release tab holding the wiper
blade to the wiper arm and remove the wiper blade
from the wiper arm (Fig. 6).
(3) Remove the wiper blade from the wiper arm.
INSTALLATION
For installation, reverse the above procedure.
Fig. 5 Rear Washer Hose Routing
Fig. 4 Front Washer Hose
Fig. 6 Windshield Wiper Blade
NSWINDSHIELD WIPERS AND WASHERS 8K - 5
REMOVAL AND INSTALLATION (Continued)

WINDSHIELD WIPER BLADE ELEMENT
REMOVAL
(1) Disengage the release tab holding the wiper
blade to the wiper arm and remove the wiper blade
from the wiper arm (Fig. 6).
(2) Disengage clip holding the wiper element to
wiper blade (Fig. 7).
(3) Pull the element from the claws on the wiper
blade.
INSTALLATION
(1) Insert the element vertebra (Fig. 8) into claw
at the open end of the wiper blade and through each
claw location along the blade.
(2) Engage clip to hold wiper element to wiper
blade.
(3) Test wiper effectiveness using washer mode
and align if necessary.
WINDSHIELD WIPER MOTOR
REMOVAL
(1) Remove wiper unit from vehicle.
(2) Remove wiper linkage and motor mount plate
from wiper unit.
(3) Disconnect wire connectors from back of wiper
motor (Fig. 16).
(4) Remove wiper linkage from motor crank. Do
NOT remove crank from motor.(5) Remove bolts holding wiper motor to mount
plate and remove motor (Fig. 9) and (Fig. 10).
INSTALLATION
(1) Place wiper unit on a suitable work surface.
(2) Place wiper motor in position on mount plate.
(3) Install bolts to hold wiper motor to mount
plate.
(4) Install wiper linkage and motor mount plate
into wiper unit.
(5) Connect wire connectors to wiper motor (Fig.
16).
(6) Place the wiper unit into engine compartment
and connect wiper unit wire connector to engine wire
harness (Fig. 13).
(7) Operate wiper motor and verify that the wiper
motor parks when wiper switch is turned OFF.
Fig. 7 Windshield Wiper Blade Element
Fig. 8 Wiper Blade and Element
Fig. 9 Wiper Motor Crank
Fig. 10 Wiper Motor
8K - 6 WINDSHIELD WIPERS AND WASHERSNS
REMOVAL AND INSTALLATION (Continued)

WIPER ARM
CAUTION: The Driver side wiper arm must be parked
above the passenger side. Failure to do so will result
in damage to the arms, blades, or system.
REMOVAL
(1) Disengage the clip holding outside end of the
wiper arm pivot cover to the wiper arm.
(2) Lift the arm cap upward.
(3) Remove the nut holding wiper arm to the wiper
pivot.
(4) Using a suitable two jaw puller, separate the
wiper arm from the wiper pivot (Fig. 11).
INSTALLATION
(1) Verify that the wiper motor and linkage are in
the park position.
(2) Place the wiper arm in position over the wiper
pivot (Fig. 12). Refer to Alignment.
(3) Install the nut to hold the wiper arm to the
wiper pivot. Tighten nut to 35 N´m (26 ft. lbs.).
(4) Push the arm cap cover down.
(5) Engage clip to the hold outside end of wiper
arm pivot cover to the wiper arm.
WIPER UNIT
REMOVAL
(1) Remove the wiper arms.
(2) Remove the cowl cover. Refer to Group 23 Body
for proper procedure.
(3) Release the hood latch and open hood.
(4) Disconnect the positive lock on the wiper unit
wire connector (Fig. 13).
(5) Disconnect the wiper unit wire connector from
the engine compartment wire harness.
(6) Disconnect the windshield washer hose from
coupling inside unit.(7) Disconnect the drain tubes from nipples on bot-
tom of the wiper unit.
(8) Remove nuts holding wiper unit to lower wind-
shield fence.
(9) Remove bolts holding the wiper unit to the
dash panel (Fig. 14).
(10) Lift wiper unit from weld-studs on lower
windshield fence.
CAUTION: Do not allow wiper unit to rest on brake
master cylinder reservoir, damage to brake system
can result.
(11) Remove wiper unit.
INSTALLATION
For installation, reverse the above procedure.
WIPER LINKAGE
REMOVAL
(1) Remove the windshield wiper unit from vehicle.
Fig. 11 Wiper Arm Removal
Fig. 12 Wiper Arm Adjustment
Fig. 13 Wiper Unit Wire Connector
NSWINDSHIELD WIPERS AND WASHERS 8K - 7
REMOVAL AND INSTALLATION (Continued)

HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn generator drive belt. 2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
7. Low beam headlamp / foglamp fuse
blown.7. Locate cause of blown fuse and repair.
HEADLAMP BULBS BURN
OUT FREQUENTLY1. Charging system output too high. 1. Test and repair charging system. Refer to
Group 8A.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and
splices. Refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system. Refer to
Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. High resistance in headlamp circuit. 3. Test amperage draw of headlamp circuit.
4. Low beam headlamp / fog lamp
fuse blown.4. Locate cause of blown fuse and repair.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
2. High resistance in headlamp circuit. 2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or
splices in circuit.3. Inspect and repair all connectors and
splices. Refer to Group 8W.
HEADLAMPS DO NOT
ILLUMINATE1. No voltage to headlamps. 1. Repair open headlamp circuit. Refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground. Refer to Group 8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer (multi-
function) switch.4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.5. Repair connector terminal or wire splice.
6. Defective or burned out bulb. 6. Replace bulb.
7. Body controller malfunction. 7. Refer to appropriate body controller
diagnostics.
NSLAMPS 8L - 3
DIAGNOSIS AND TESTING (Continued)

FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM WITH
ENGINE IDLING OR IGNITION
TURNED OFF.1. Loose or corroded battery
cables.1. Clean and secure battery cable
clamps and posts.
2. Loose or worn generator drive
belt.2. Adjust or replace generator drive
belt.
3. Charging system output too low. 3. Test and repair charging system.
Refer to Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge.
Refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group
8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
FOG LAMP BULBS BURN OUT
FREQUENTLY1. Charging system output too high. 1. Test and repair charging system.
Refer to Group 8A.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS ARE DIM WITH
ENGINE RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system.
Refer to Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
3. High resistance in fog lamp
circuit.3. Test amperage draw of fog lamp
circuit.
FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
2. High resistance in fog lamp
circuit.2. Test amperage draw of fog lamp
circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS DO NOT ILLUMINATE 1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group
8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to
Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or
wire splice in fog lamp circuit.4. Repair connector terminal or wire
splice.
5. Defective or burned out bulb. 5. Replace bulb.
8L - 4 LAMPSNS
DIAGNOSIS AND TESTING (Continued)

EXTERIOR LAMP SERVICE
INDEX
page page
GENERAL INFORMATION
HEADLAMP DIMMER SWITCH.............. 14
HEADLAMP MODULE.................... 14
HEADLAMP SWITCH..................... 14
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)............................. 17
FOG LAMP ± TOWN and COUNTRY......... 15
FOG LAMP............................. 14FRONT PARKING AND TURN SIGNAL LAMP ±
TOWN and COUNTRY.................. 15
FRONT SIDE MARKER LAMP TOWN and
COUNTRY............................ 15
HEADLAMP MODULE.................... 14
LICENSE PLATE LAMP................... 16
TAIL, STOP, TURN SIGNAL AND BACK-UP
LAMP............................... 16
GENERAL INFORMATION
HEADLAMP MODULE
Minor amounts of fogging may occur around the
edges of the headlamp lens when exposed to humid
conditions. This is considered normal. The fogging
will dissipate with increased ambient temperature or
headlamp usage.
HEADLAMP SWITCH
Service procedures for the headlamp switch can be
found in Group 8E, Instrument Panel and Gauges.
More information can be found in Group 8W, Wiring
Diagrams.
HEADLAMP DIMMER SWITCH
The headlamp dimmer switch is incorporated into
the multi-function (turn signal) switch. Proper proce-
dures can be found in Group 8J, Turn Signal and
Flashers. More information can be found in Group
8W, Wiring Diagrams.
REMOVAL AND INSTALLATION
HEADLAMP MODULE
REMOVAL
(1) Release hood latch and open hood.
(2) From inside engine compartment, remove nuts
holding headlamp module to radiator closure panel.
(3) Remove screw holding top of module to closure
panel.
(4) Remove headlamp module from radiator clo-
sure panel (Fig. 1).
(5) Disconnect wire connectors from back of head-
lamp module.
(6) Separate headlamp module from vehicle.
INSTALLATION
(1) Place headlamp module in position on vehicle.
(2) Connect wire connectors into back of headlamp
module.
(3) Place headlamp module in position on radiator
closure panel.
(4) Install nuts to hold headlamp module to radia-
tor closure panel.
(5) Install screw to hold top of module to closure
panel.
(6) Verify headlamp operation and alignment.
FOG LAMP
REMOVAL
(1) Remove screws holding fog lamp to front
bumper fascia (Fig. 2).
(2) Remove fog lamp from fascia.
(3) Disconnect wire connector from body wire har-
ness.
(4) Remove fog lamp from vehicle.
Fig. 1 Headlamp Module ± Typical
8L - 14 LAMPSNS

BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 25SPECIFICATIONS
EXTERIOR LAMP BULBS.................. 25
INTERIOR LAMP BULBS.................. 25
GENERAL INFORMATION
INTRODUCTION
The following Bulb Application Tables list the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
If a halogen bulb is contaminated with oil, clean
bulb with denatured alcohol or ammonia based sol-
vent.
SPECIFICATIONS
EXTERIOR LAMP BULBS
LAMP BULB
Back-up...............................3057
CHMSL................................921
Fog Lamp...............................H3
FogLamp±T&C ........................9040
Headlamp..............................9007
Headlamp high beam ± T&C...............9005
Headlamp low beam ± T&C............9005 SLL
License Plate............................168
Parking/Turn Signal/Front Side Marker. . . .3157NA
Parking/Turn Signal ± T&C............4157NAK
Tail, Stop, Turn Signal and Side Marker......3057
Front Side Marker......................194NA
INTERIOR LAMP BULBS
LAMP BULB
ABS.................................PC194
AirBag ..............................PC194
Alarm Set (Security)....................PC194
Brake Warning.........................PC194
Center/Rear Reading Lamps.................578
Center/Rear Dome Lamps...................579
Check Engine Ind.......................PC194
Front Door Courtesy.......................567
Door Ajar Ind..........................PC194
Front Header Reading Lamp................567
Glove Box Lamp..........................194
High Beam Ind.........................PC194
Instrument Cluster.....................PC194
IP Bin/Ash Tray..........................161
Liftgate Flood Lamps......................567
Liftgate Ajar Ind.........................PC74
Low Fuel Ind..........................PC194
Oil Pressure Ind........................PC194
O/H Console Reading Lamps................579
Seat Belt Ind...........................PC74
Engine Temp Ind.......................PC194
Turn Signal...........................PC194
Engine Compartment Lamps................579
Visor Vanity Lamp....................6501966
Low Washer Fluid.......................PC74
Low Volts Warning.......................PC74
Cruise Indicator........................PC194
NSLAMPS 8L - 25

HEADLAMP LEVELING MOTOR
This vehicle is equipped with a remote headlamp
leveling system. This system allows the driver to
adjust the vertical headlamp aim from the interior of
the vehicle to compensate for passenger or cargo
load. A headlamp leveling switch is located in the
instrument panel and controls the headlamp leveling
motor found on the back of the headlamp module.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the head-
lamp system, verify the condition of the battery connec-
tions, charging system, headlamp bulbs, wire
connectors, relay, high beam dimmer switch and head-
lamp switch. Refer to Group 8W, Wiring Diagrams, for
component locations and circuit information.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn alternator drive
belt.2. Adjust or replace alternator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer
to Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
HEADLAMP BULBS BURN
OUT FREQUENTLY1. Charging system output too high. 1. Test and repair charging system. Refer
to Group 8A.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and
splices. Refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system. Refer
to Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
2. High resistance in headlamp
circuit.2. Test amperage draw of headlamp circuit.
3. Loose or corroded terminals or
splices in circuit.3. Inspect and repair all connectors and
splices. Refer to Group 8W.
HEADLAMPS DO NOT
ILLUMINATE1. No voltage to headlamps. 1. Repair open headlamp circuit. Refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground. Refer to Group
8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer
(multi-function) switch.4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.5. Repair connector terminal or wire splice.
6. Defective or burned out bulb. 6. Replace bulb.
7. Body controller malfunction. 7. Refer to appropriate body controller
diagnostics.
8L - 2 LAMPSNS/GS
GENERAL INFORMATION (Continued)

FOG LAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM WITH
ENGINE IDLING OR IGNITION
TURNED OFF.1. Loose or corroded battery cables. 1. Clean and secure battery cable
clamps and posts.
2. Loose or worn alternator drive
belt.2. Adjust or replace alternator drive
belt.
3. Charging system output too low. 3. Test and repair charging system.
Refer to Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge.
Refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group
8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
FOG LAMP BULBS BURN OUT
FREQUENTLY1. Charging system output too high. 1. Test and repair charging system.
Refer to Group 8A.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS ARE DIM WITH
ENGINE RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system.
Refer to Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
3. High resistance in fog lamp
circuit.3. Test amperage draw of fog lamp
circuit.
FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
2. High resistance in fog lamp
circuit.2. Test amperage draw of fog lamp
circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS DO NOT
ILLUMINATE1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group 8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to
Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.4. Repair connector terminal or wire
splice.
5. Defective or burned out bulb. 5. Replace bulb.
NS/GSLAMPS 8L - 3
DIAGNOSIS AND TESTING (Continued)

BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION....................... 17
CLEANING AND INSPECTION
HEADLAMP CLEANING.................. 17SPECIFICATIONS
EXTERIOR LAMP BULBS................. 17
INTERIOR LAMP BULBS................. 17
GENERAL INFORMATION
INTRODUCTION
The following Bulb Application Tables list the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
If a halogen bulb is contaminated with oil, clean
bulb with denatured alcohol or ammonia based sol-
vent.
CLEANING AND INSPECTION
HEADLAMP CLEANING
This vehicle is equipped with plastic headlights
that are lighter and less susceptible to stone break-
age than glass headlights.
This plastic is not as scratch resistant as glass and
therefore a different lens cleaning procedures must
be followed.
To minimize the possibility of scratching the lenses
and reducing light output, avoid wiping with a dry
cloth. To remove road dirt, wash with a mild soap
solution followed by rinsing with water.
Do not use abrasive cleaning components, solvents,
steel wool or other aggressive material to clean the
lenses.
SPECIFICATIONS
EXTERIOR LAMP BULBS
LAMP BULB
Back-up.............................P21W
CHMSL (Non-Solar Tint)................P21W
CHMSL (Solar Tint)....................R10WLAMP BULB
Fog Lamp..............................H3
Headlamp..............................H4
License Plate..........................C5W
Front Turn Signal....................PY21W
Citylight..............................T4W
Front Side Repeater.....................T4W
Tail, Stop...........................P21/5W
Rear Turn Signal......................P21W
Rear Fog Lamp........................P21W
INTERIOR LAMP BULBS
LAMP BULB
ABS ................................PC194
AirBag .............................PC194
Alarm Set (Security/Immobilzer)..........PC194
Brake Warning.......................PC194
Center/Rear Reading Lamps...............578
Center/Rear Dome Lamps.................579
Cruise Indicator.......................PC194
Door Ajar Indicator....................PC194
Engine Compartment Lamps...............579
Engine Temp Indicator.................PC194
Front Door Courtesy......................567
Glove Box Lamp.........................194
Glow Plug Indicator (Diesel Engine Only) . . . PC194
High Beam Indicator...................PC194
Instrument Cluster....................PC194
IP/Ash Tray (Left Hand Drive Only).........161
Liftgate Flood Lamps.....................567
Liftgate Ajar Indicator...................PC74
Low Coolant Level (Diesel Engine Only).....PC74
Low Fuel Indicator....................PC194
Low Volts Warning.....................PC74
Low Washer Fluid......................PC74
Oil Pressure Indicator..................PC194
O/H Console Reading Lamps...............579
Seat Belt Indicator (Except Diesel).........PC74
Service Engine Soon...................PC194
Turn Signal..........................PC194
Visor Vanity Lamp...................6501966
NS/GSLAMPS 8L - 17