headlamp CHRYSLER VOYAGER 1996 User Guide

HEADLAMP SWITCH
REMOVAL
(1) Remove instrument cluster bezel (Fig. 14).
(2) Remove screws holding the headlamp switch
bezel to cluster bezel.
(3) Disconnect the wire connectors from the head-
lamp switch and wire connector from the power mir-
ror switch.
(4) Remove headlamp switch bezel from cluster
bezel.
INSTALLATION
For installation, reverse the above procedures.
HEADLAMP SWITCH LAMP(S)
REMOVAL
(1) Remove instrument cluster bezel.
(2) Disconnect wire connectors.
(3) Remove headlamp switch bezel from instru-
ment cluster bezel.
(4) Rotate bulb socket counterclockwise one quar-
ter turn (Fig. 15).
(5) Pull bulb socket from headlamp switch.
INSTALLATION
For installation, reverse the above procedures.
HVAC CONTROL LAMP
REMOVAL
(1) Remove radio bezel and HVAC Control (Fig.
16).
(2) Remove rear cover from HVAC control.
(3) Rotate bulb socket counterclockwise one quar-
ter turn.
(4) Pull bulb socket from HVAC.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER BACK PANEL
REMOVAL
(1) Remove instrument cluster.
(2) Remove screws holding back panel to instru-
ment cluster (Fig. 17).
(3) Remove back panel.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER BEZEL
REMOVAL
(1) Remove steering column cover.
(2) Remove over steering column bezel (Fig. 18).
(3) Remove left end cover.
(4) Remove screw at left end of cluster bezel and
headlamp switch.
Fig. 14 Headlamp Switch
Fig. 15 Headlamp Switch Lamp
Fig. 16 HVAC Control Lamps
8E - 18 INSTRUMENT PANEL AND SYSTEMSNS/GS
REMOVAL AND INSTALLATION (Continued)

(5) Remove screws holding cluster bezel to instru-
ment panel from each side of steering column.
(6) Disconnect clip holding cluster bezel to instru-
ment panel from above right vent louver.
(7) Separate cluster bezel from instrument panel.
(8) Disconnect wire connectors from back of the
bezel.
INSTALLATION
(1) Connect wire connectors into back of the bezel.
(2) Place cluster bezel in position on instrument
panel. Use care not to place hands on louvers.
(3) Connect clips to hold cluster bezel to instru-
ment panel. Use care not to add pressure on the A/C
louvers to seat the cluster bezel clips.
(4) Install screws to hold cluster bezel to instru-
ment panel on each side of steering column.
(5) Install screw at left end of cluster bezel and
headlamp switch.
(6) Install left end cover.
(7) Install over steering column bezel.
(8) Install lower steering column cover.
INSTRUMENT CLUSTER LENS
REMOVAL
(1) Remove instrument cluster.
(2) Remove screws holding lens to instrument clus-
ter (Fig. 19).
(3) Remove lens from cluster.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER PRINTED CIRCUIT BOARD
REMOVAL
(1) Remove the instrument cluster.
(2) Remove the instrument cluster back panel.
(3) Disconnect the electronic cluster wire connector
from the printed circuit board (Fig. 20).
(4) Remove the screws holding wire connector
insulator to the instrument cluster shell and the
printed circuit board.
Fig. 17 Instrument Cluster Back Panel
Fig. 18 Instrument Cluster Bezel
Fig. 19 Instrument Cluster Lens
Fig. 20 Instrument Cluster Printed Circuit Board
NS/GSINSTRUMENT PANEL AND SYSTEMS 8E - 19
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
(1) Place message center in position on top cover.
(2) Install screws to hold message center to instru-
ment panel top cover.
(3) Connect wire connector into back of message
center.
(4) Install instrument panel top cover.
(5) Install A-pillar trim.
OVER STEERING COLUMN BEZEL
REMOVAL
(1) Remove the lower steering column cover.
(2) Remove the screws holding over steering col-
umn bezel to the cluster bezel (Fig. 45).
(3) Remove over steering column bezel from vehi-
cle.
(4) Disconnect the clips holding over column bezel
to the cluster bezel.
(5) If equipped with traction control switch, discon-
nect the wire pigtail connector from the traction con-
trol switch.
(6) Remove the over steering column bezel.
INSTALLATION
(1) Place the over steering column bezel in position
and engage clips to the cluster bezel. If equipped
with traction control switch connect the wire pigtail
before engaging clips.
(2) Install the screws to hold the over steering col-
umn bezel to the cluster bezel.
(3) Install the lower column cover.
POWER MIRROR SWITCH
REMOVAL
(1) Remove instrument cluster bezel (Fig. 46).
(2) Disconnect wire connector from back of power
mirror switch.
(3) Disengage lock tabs above and below the mir-
ror switch.
(4) Pull power mirror switch from headlamp
switch bezel.
(5) Remove power mirror switch.
INSTALLATION
For installation, reverse the above procedures.
POWER MIRROR SWITCH LAMP
REMOVAL
(1) Remove instrument cluster bezel (Fig. 47).
(2) Rotate bulb socket counterclockwise one quar-
ter turn.
(3) Pull bulb socket from back of power mirror
switch.
Fig. 45 Over Steering Column Bezel
Fig. 46 Power Mirror Switch
Fig. 47 Power Mirror Switch Lamp
8E - 28 INSTRUMENT PANEL AND SYSTEMSNS/GS
REMOVAL AND INSTALLATION (Continued)

take advantage of low current switching require-
ments in the vehicle. It is plugged into the Junction
Block at positions 4 (Fig. 1) where all wiring associ-
ated with its operation is terminated. The Junction
Block is adjacent to and left of the steering column of
the vehicle.
To gain access to the device, remove the lower
steering column cover and knee blocker, refer to
Group 8E, Instrument Panel and Systems.
The combination flasher may be operated in its
hazard warning mode either with or without the igni-
tion circuit being active. However, in order to operate
in the turn signal mode, the ignition circuit must be
completed to the module.
While the combination flasher is idle, there is no
current drawn through the module. The device does
not become active until a signal ground circuit is
supplied to either of the turn signal inputs or the
hazard warning input.
Typical flash rate for the flasher is 90 flashes per
minute.
When a lamp is burnt out for a given side of the
vehicle or a wire is open to a lamp, the flash rate will
increase to 180 flashes per minute when in the turn
signal mode. When in the hazard warning signal
mode the flash rate remains at 90 flashes per
minute.
Turn signal inputs that actuate the flasher are low
current grounds, each drawing a maximum of 300
mA., and are provided to the flasher through the
Junction Block from the multi-function switch that is
mounted to the steering column. The hazard warning
signal input is a low current ground drawing a max-
imum of 600 mA. through the multi-function switch.
COMBINATION FLASHER / DAYTIME RUNNING
LAMPS (DRL) MODULE
The Combination Flasher/DRL is a module provid-
ing turn signal, hazard warning, and daytime run-
ning light functions, and has been designed with
internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged
into the junction block at positions 3 AND 4 (Fig. 2)
where all wiring associated with its operation is ter-
minated. The Junction Block is adjacent to and left of
the steering column of the vehicle.
To gain access to the device, remove the lower
steering column cover and knee blocker, refer to
Group 8E, Instrument Panel and Gauges.
The combination flasher/DRL may be operated in
its hazard warning mode either with or without the
ignition circuit being active. However, in order to
operate in the turn signal mode or the DRL mode,
the ignition circuit must be completed to the module.
While the combination flasher portion is idle, there
is no current drawn through the module. The devicedoes not become active in the turn signal or hazard
warning modes until a signal ground circuit is sup-
plied to either of the turn signal inputs or the hazard
warning input. With the ignition OFF, there is no
current drawn through the module.
While the ignition is ON, the front turn signal fil-
aments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by
applying a signal ground input from either the park
brake circuit or the headlamp relay activation circuit.
Typical flash rate for the flasher is 90 flashes per
minute.
When a lamp is burnt out for a given side of the
vehicle or a wire is open to a lamp, the flash rate will
increase to 180 flashes per minute when in the turn
signal mode. When in the hazard warning signal
mode the flash rate remains at 90 flashes per
minute.
Turn signal inputs that actuate the flasher are low
current grounds, each could draw a maximum of 300
mA., and are provided to the flasher through the
Junction Block from the multi-function switch that is
mounted to the steering column. The hazard warning
signal input is a low current ground that could draw
a maximum of 600 mA. through the multi-function
switch.
DIAGNOSIS AND TESTING
TURN SIGNAL MULTI-FUNCTION SWITCH
To test turn signal, headlamp beam select and opti-
cal horn portion of the multi-function switch:
(1) Remove the multi-function switch, refer to
removal procedures.
(2) Using an ohmmeter check continuity reading
between multi-function switch pins. Refer to (Fig. 3)
for proper pin numbers and Turn Signal Multi-Func-
tion Switch Test chart.
Fig. 2 Junction Block Terminal Pins
8J - 2 TURN SIGNAL AND FLASHERSNS
DESCRIPTION AND OPERATION (Continued)

JUNCTION BLOCK TERMINAL CALL-OUT WITH DRL
CAV. CKT. WIRE
GAUGECOLOR FUNCTION
1 L09 18 BLK/WT BATTERY INTPUT MAIN FEED
2 L61 18 LG LEFT FRONT T/S OUTPUT TO LAMP
3 L60 18 TN RIGHT FRONT T/S OUTPUT TO LAMP
4 L63 18 DG/RD LEFT REAR T/S OUTPUT TO LAMP
5 L62 18 BR/RD RIGHT REAR T/S OUTPUT TO LAMP
6 A22D 20 BK/OR IGNITION INPUT SENSE ONLY
7 L305 22 LB/WT LEFT T/S SWITCH INPUT SENSE ONLY
8 L302 22 LB/YL RIGHT T/S SWITCH INPUT SENSE ONLY
9 L91 22 DB/PK HAZARD SWITCH INPUT SENSE ONLY
10 G09 22 GY/BK PARK BRAKE SWITCH INPUT SENSE ONLY
11 Z01 14 BK GROUND MAIN GRD.
12 L93 22 RD/YL HEADLAMP RELAY SWITCH
INPUTSENSE ONLY
NSTURN SIGNAL AND FLASHERS 8J - 5
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
TURN SIGNAL AND HAZARD
WARNING FLASHERS
FUNCTION PROPERLY BUT
DAYTIME RUNNING LIGHTS
(DRL) DO NOT COME ON WHILE
DRIVING
(The brake lamp in the message
center remains illuminated under
the circumstances noted to the
right in step #3.0 through 3.5
unless the lamp is burned out.)
(Headlamps, either low or high
beam, remain illuminated under
the circumstances noted to the
right in step #4.0 through 4.3 even
though the headlamp switch is
OFF.)1. FAULTY GROUND FEED TO
JUNCTION BLOCK FROM
GROUND STUD CONNECTOR
THROUGH I/P HARNESS.
2. FAULTY GROUND FEED
THROUGH JUNCTION BLOCK TO
CAVITY #11 IN POSITION #3 OF
THE JUNCTION BLOCK.
3.0. FAULTY PARK BRAKE
SWITCH.
3.1. PARK BRAKE INPUT CIRCUIT
FALSELY GROUNDED. COULD BE
THE G09 CIRCUIT WHICH IS A
(20) GA. GY/BK WIRE BETWEEN
THE MESSAGE CENTER AND THE
JUNCTION BLOCK,
3.2. OR BETWEEN THE PARK
BRAKE SWITCH AND THE
JUNCTION BLOCK,
3.3. OR BETWEEN THE BRAKE
PRESSURE SWITCH AND THE
JUNCTION BLOCK,
3.4. OR BETWEEN THE IGNITION
SWITCH AND THE JUNCTION
BLOCK,
3.5. OR A SHORTED IGNITION
SWITCH (CONTACT SHOULD
ONLY BE MADE WHEN IN START
POSITION).
4.0. L93 CIRCUIT FALSELY
GROUNDED BETWEEN JUNCTION
BLOCK AND MULTI-FUNCTION
SWITCH.
4.1. L307 CIRCUIT FALSELY
GROUNDED BETWEEN
HEADLAMP SWITCH AND BODY
CONTROL MODULE.
4.2. HEADLAMP SWITCH
SHORTED.
4.3. HEADLAMP CONTROL
OUTPUT FALSELY GROUNDED BY
BODY CONTROL MODULE.1. REPLACE GROUND CIRCUIT TO
JUNCTION BLOCK.
2. REPLACE JUNCTION BLOCK.
3.0. REPLACE THE PARK BRAKE
SWITCH.
3.1-3.4. REPAIR THE G09 CIRCUIT
TO ELIMINATE THE FALSE
GROUND SOURCE.
3.5. REPLACE IGNITION SWITCH.
4.0. REPAIR OR REPLACE FAULTY
WIRING CONNECTION BETWEEN
JUNCTION BLOCK AND MULTI-
FUNCTION SWITCH.
4.1. REPAIR OR REPLACE FAULTY
WIRING CONNECTION BETWEEN
HEADLAMP SWITCH AND BODY
CONTROL MODULE.
4.2. REPLACE SHORTED
HEADLAMP SWITCH.
4.3. REPLACE BODY CONTROL
MODULE.
8J - 10 TURN SIGNAL AND FLASHERSNS
DIAGNOSIS AND TESTING (Continued)

WIPER AND WASHER SYSTEMS
CONTENTS
page page
HEADLAMP WASHERS................... 1
HEADLAMP WASHERS
INDEX
page page
GENERAL INFORMATION
INTRODUCTION........................ 1
REMOVAL AND INSTALLATION
HEADLAMP WASHER NOZZLE............. 1HEADLAMP WASHER PUMP............... 2
WINDSHIELD/HEADLAMP WASHER
RESERVOIR.......................... 1
GENERAL INFORMATION
INTRODUCTION
Headlamp washers are available as a factory-in-
stalled option on this model. The headlamp washers
on this vehicle work in conjunction with the wind-
shield washers. The headlamp washers are enabled
with the headlamps ªONº and the windshield wash-
ers activated. With the windshield washers activated
the headlamp washers will spray for a preset amount
of time controlled by a relay.
The headlamp washer system utilizes a separate pump
that is attached to the windshield washer reservoir. The
headlamp washer pump feeds two nozzles that are
mounted in the front fascia of the vehicle. These nozzles
spray the headlamps when the system is activated.
REMOVAL AND INSTALLATION
WINDSHIELD/HEADLAMP WASHER RESERVOIR
Removal
(1) Remove the right headlamp assembly. Refer to
Group 8L, Lamps.
(2) Partially remove the inner fender well as
needed to gain access to the reservoir.
(3)
Disconnect the windshield washer pump, rear
washer pump and headlamp washer pump electrical con-
nectors.
(4) Disconnect the headlamp washer pump hose.(5) Partially remove the front fascia to aid in the
removal of the reservoir.
(6) Remove the reservoir mounting bolts. (Fig. 1)
(7) Slide the reservoir rearward and remove from
the vehicle.
Installation
(1) For installation, reverse the above procedures
HEADLAMP WASHER NOZZLE
Removal
(1) Remove the headlamp assembly. Refer to
Group 8L, Lamps.
(2)
Disconnect the hose at the headlamp washer nozzle.
(3) Remove the headlamp washer nozzle retaining
nuts and remove the nozzle from the front fascia.
NS/GSWIPER AND WASHER SYSTEMS 8K - 1

Installation
(1) For installation, reverse the above procedures.
HEADLAMP WASHER PUMP
Removal
(1) Remove the right headlamp assembly. Refer to
Group 8L, Lamps.
(2) Disconnect the headlamp washer pump electri-
cal connector.
(3) Disconnect the headlamp washer pump hose.
(4) Remove the headlamp washer pump from the
reservoir.
Installation
(1) For installation, reverse the above procedures.
Fig. 1 Reservoir Removal
Fig. 2 HeadLamp Washer Nozzle
Fig. 3 Headlamp Washer Pump
8K - 2 WIPER AND WASHER SYSTEMSNS/GS
REMOVAL AND INSTALLATION (Continued)

LAMPS
CONTENTS
page page
BULB APPLICATION...................... 25
EXTERIOR LAMP BULB SERVICE............ 9
EXTERIOR LAMP SERVICE................. 14HEADLAMP ALIGNMENT................... 5
INTERIOR LAMPS........................ 18
LAMP DIAGNOSIS........................ 1
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
ELECTRONIC DAYTIME RUNNING LIGHT (DRL).1
GENERAL INFORMATION.................. 1SAFETY PRECAUTIONS................... 1
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 2
GENERAL INFORMATION
GENERAL INFORMATION
NS vehicles use lighting on the interior and exte-
rior of the vehicle for illuminating and indicating
purposes. Lighting circuits are protected by fuses.
Lighting circuits require an overload protected power
source, on/off device, lamps and body ground to oper-
ate properly. Plastic lamps require a wire in the har-
ness to supply body ground to the lamp socket.
Replace sockets and bulbs that are corroded.
Some of the interior and exterior lighting functions
are governed by the body controller. The headlamp,
dome, and the door ajar switches provide signals to
the body controller. The body controller in turn acti-
vates relay(s) in order to provide either a ground or
feed line to the appropriate lamp(s).
Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors,
inspect the terminals inside the connector. Male ter-
minals should not be bent or disengaged from the
insulator. Female terminals should not be sprung
open or disengaged from the insulator. Bent and
sprung terminals can be repaired using needle nose
pliers and pick tool. Corroded terminals appear
chalky or green. Corroded terminals should be
replaced to avoid recurrence of the problem symp-
toms.
Begin electrical system failure diagnosis by testing
related fuses in the fuse block and power distribution
center. Verify that bulbs are in good condition andtest continuity of the circuit ground. Refer to Group
8W, Wiring Diagrams, for component location and cir-
cuit information.SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
ELECTRONIC DAYTIME RUNNING LIGHT (DRL)
The Combination Flasher/DRL is a module provid-
ing turn signal, hazard warning, and daytime run-
NSLAMPS 8L - 1

ning light functions (for Canadian vehicles), and has
been designed with internal relays to take advantage
of low current switching requirements in the vehicle.
It is plugged into the junction block at positions
three and four (Fig. 1), where all wiring associated
with its operation is terminated. The junction block
is adjacent to and left of the steering column of the
vehicle. For diagnostic information refer to Group 8J,
Turn Signal and Flashers.
On vehicles built for use in the United States, only
position four is used. Vehicles built for use in Canada
utilize both positions three and four.
To gain access to the device, remove the lower
steering column cover and knee blocker. Refer to
Group 8E, Instrument Panel and Gauges.SYSTEM FUNCTION
The combination-flasher/DRL may be operated in
its hazard warning mode either with or without the
ignition circuit being active. However, in order to
operate in the turn signal mode or the DRL mode,
the ignition circuit must be completed to the module.
While the combination-flasher portion is idle, there
is no current drawn through the module. The device
does not become active in the turn signal or hazard
warning modes until a signal ground circuit is sup-
plied to either of the turn signal inputs or the hazard
warning input. With the ignition OFF, there is no
current drawn through the module.
While the ignition is ON, the front turn signal fil-
aments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by
applying a signal ground input from either the park
brake circuit or the headlamp relay activation circuit.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, charging system, headlamp bulbs, wire
connectors, relay, high beam dimmer switch and
headlamp switch. Refer to Group 8W, Wiring Dia-
grams, for component locations and circuit informa-
tion.
Fig. 1 Junction Block Terminal PINS
8L - 2 LAMPSNS
GENERAL INFORMATION (Continued)