light CHRYSLER VOYAGER 2004 Repair Manual

ULES/POWERTRAIN CONTROL MODULE -
DESCRIPTION) section for more DTC information.The Charging system ªBatteryº light indicates
problems with the charging system (voltage too high/
low, generator failure, etc.). If an extreme condition is
indicated, the lamp will be illuminated. The signal to
activate the lamp is sent via the PCI bus circuits.
The lamp is located on the instrument panel. Refer
to the Instrument Cluster section for additional infor-
mation. The PCM uses the ambient air temperature sensor
to control the charge system voltage. This tempera-
ture, along with data from monitored line voltage, is
used by the PCM to vary the battery charging rate.
The system voltage is higher at cold temperatures
and is gradually reduced as the calculated battery
temperature increases. The ambient temperature sensor is used to control
the battery voltage based upon ambient temperature
(approximation of battery temperature). The PCM
maintains the optimal output of the generator by
monitoring battery voltage and controlling it to a
range of 13.5 - 14.7 volts based on battery tempera-
ture.
DIAGNOSIS AND TESTING - ON-BOARD
DIAGNOSTIC SYSTEM
The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the OBD system. Some
circuits are checked continuously and some are
checked only under certain conditions. If the OBD system senses that a monitored circuit
is bad, it will put a DTC into electronic memory. The
DTC will stay in electronic memory as long as the
circuit continues to be bad. The PCM is programmed
to clear the memory after 40 good trip if the problem
does not occur again.
DIAGNOSTIC TROUBLE CODES
A DTC description can be read using the DRBIII t
scan tool. Refer to the appropriate Powertrain Diag-
nostic Procedures manual for information. A DTC does not identify which component in a cir-
cuit is bad. Thus, a DTC should be treated as a
symptom, not as the cause for the problem. In some
cases, because of the design of the diagnostic test
procedure, a DTC can be the reason for another DTC
to be set. Therefore, it is important that the test pro-
cedures be followed in sequence, to understand what
caused a DTC to be set. ERASING DIAGNOSTIC TROUBLE CODES
The DRBIII tScan Tool must be used to erase a
DTC. The following procedures may be used to diagnose
the charging system if: ² the check gauges lamp or battery lamp is illumi-
nated with the engine running ² the voltmeter (if equipped) does not register
properly ² an undercharged or overcharged battery condi-
tion occurs. Remember that an undercharged battery is often
caused by: ² accessories being left on with the engine not
running ² a faulty or improperly adjusted switch that
allows a lamp to stay on. Refer to Ignition-Off Draw
Test (Refer t o 8 - ELECTRICAL/BATTERY SYSTEM/
BATTERY - STANDARD PROCEDURE) ² loose generator belt.
INSPECTION The Powertrain Control Module (PCM) monitors
critical input and output circuits of the charging sys-
tem, making sure they are operational. A Diagnostic
Trouble Code (DTC) is assigned to each input and
output circuit monitored by the On-Board Diagnostic
(OBD) system. Some charging system circuits are
checked continuously, and some are checked only
under certain conditions. Refer to Diagnostic Trouble Codes in; Powertrain
Control Module; Electronic Control Modules for more
DTC information. This will include a complete list of
DTC's including DTC's for the charging system. To perform a complete test of the charging system,
refer to the appropriate Powertrain Diagnostic Proce-
dures service manual and the DRBIII tscan tool.
Perform the following inspections before attaching
the scan tool. (1) Inspect the battery condition. Refer to the Bat-
tery section (Refer t o 8 - ELECTRICAL/BATTERY
SYSTEM - DIAGNOSIS AND TESTING) for proce-
dures. (2) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required. (3) Inspect all fuses in both the fuseblock and
Power Distribution Center (PDC) or IPM (if
equipped) for tightness in receptacles. They should be
properly installed and tight. Repair or replace as
required. (4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
RS CHARGING8Fs-21
CHARGING (Continued)

battery cable to solenoid connection. If reading is
still above 0.2 volt after correcting poor contacts,
replace battery positive cable.(b) If resistance tests do not detect feed circuit
failures, replace the starter motor.
DIAGNOSIS AND TESTING - FEED CIRCUIT
TEST
NOTE: The following results are based upon the
vehicle being at room temperature.
The following procedure will require a suitable
volt-ampere tester (Fig. 1).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) Check battery before performing this test. Bat-
tery must be fully charged. (2) Connect a volt-ampere tester to the battery ter-
minals. Refer to the operating instructions provided
with the tester being used. (3) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location. (4) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
and SET parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(5) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
1). ² If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter. ² If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections. ² Voltage below 9.6 volts and amperage draw
above 300 amps, the problem is the starter. Replace
the starter refer to starter removal. (6) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testing
equipment and connect ASD relay. Start the vehicle
several times to assure the problem has been cor-
rected.
SPECIFICATIONS
Torques
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Starter Mounting Bolts 47.4 35
Starter Solenoid Battery Nut 11.3 8.3 100
Fig. 1 Volt Ampere Tester
RS
STARTING8Fs-35
STARTING (Continued)

Refer to the description of the heated seat switch
later in this section for additional information.
Hard wired circuitry connects the heated seat sys-
tem components to each other through the electrical
system of the vehicle. These hard wired circuits are
integral to several wire harnesses, which are routed
throughout the vehicle and retained by many differ-
ent methods. These circuits may be connected to each
other, to the vehicle electrical system and to the
heated seat system components through the use of a
combination of soldered splices and splice block con-
nectors. Refer to Wiring for complete system wiring
schematics. The wiring information also includes the
proper wire and connector repair procedures, further
details on wire harness routing and retention, as well
as pin-out and location views for the various wire
harness connectors, splices and grounds.
OPERATION
The heated seat system components operate on
battery current received through a fuse in the Inte-
grated Power Module (IPM) on a fused ignition
switch output (run) circuit from the Body Control
Module. The system will only operate when the igni-
tion switch is in the On position. The heated seat
system will be turned Off automatically whenever
the ignition switch is turned to any position except
On. Also, the heated seat system will not operate
when the surface temperature of the seat cushion
cover at either heated seat sensor is above the
designed temperature set points of the system. See
the owner's manual in the vehicle glove box for more
information on the features, use and operation of the
heated seat system.
DIAGNOSIS AND TESTING - HEATED SEAT
SYSTEM
The most reliable, efficient, and accurate means to
diagnose the heated seat system requires the use of a
DRBIIItscan tool and the proper Diagnostic Proce-
dures manual. The DRBIIItscan tool can provide
confirmation that the PCI data bus is functional, that
all of the electronic modules are sending and receiv-
ing the proper messages on the PCI data bus, and
that the heated seat modules are receiving the
proper hard wired inputs from and relaying the
proper hard wired outputs to the Body Control Mod-
ule in order to perform its functions. Refer toWiring
Diagramsfor complete wiring schematics. The wir-
ing information also includes the proper wire and
connector repair procedures, further details on wire
harness routing and retention, as well as pin-out and
location views for the various wire harness connec-
tors, splices and grounds.
DRIVER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 2). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switch
assembly that also includes the hazard, rear window
wiper and washer switches. The heated seat switches
each provide a resistor multiplexed signal to its
respective Heated Seat Module (HSM) through sepa-
rate hard wired circuits. Each switch has an Off,
Low, and High position so that both the driver and
the front seat passenger can select a preferred seat
heating mode. Each switch has two Light-Emitting
Diodes (LED) which light to indicate that the heater
for the seat is turned on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
OPERATION
There are three positions that can be selected with
each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
depressed, the Low position is selected and the low
position LED indicator illuminates. When the right
side of the switch rocker is fully depressed, the High
position is selected and the high position LED indi-
Fig. 2 HEATED SEAT SWITCH LOCATION
1 - HEATED SEAT SWITCHES
8G - 8 HEATED SEAT SYSTEMRS
HEATED SEAT SYSTEM (Continued)

(3) Connect the negative battery cable.
(4) Verify heated seat system operation.
(5) Install the appropriate seat cushion or seat
back trim cover. Make certain the seat wire harness
is correctly routed through the seat and seat back.
The excess wire between the cushion and back ele-
ments should be securely tucked between the rear of
the cushion foam and the rear carpet flap of the trim
cover.
HEATED SEAT SENSOR
DESCRIPTION
Two heated seat sensors are used per vehicle, one
in each front seat cushion heating element. The
heated seat temperature sensor is a Negative Tem-
perature Coefficient (NTC) thermistor.
The heated seat sensors cannot be repaired or
adjusted and if found to be faulty, the complete
heated seat cushion element must be replaced.
OPERATION
The temperature sensor is a NTC thermistor.
When the temperature of the seat cushion cover
rises, the resistance of the sensor decreases. The
heated seat module supplies a five-volt current to one
side of each sensor, and monitors the voltage drop
through the sensor on a return circuit. The heated
seat module uses this temperature sensor input to
monitor the temperature of the seat, and regulates
the current flow to the seat heating elements accord-
ingly.
DIAGNOSIS AND TESTING - HEATED SEAT
SENSOR
For complete circuit diagrams, refer toWiring
Diagrams.
(1) Disconnect and isolate the battery negative
cable. Disconnect the green 4-way heated seat mod-
ule wire harness connector.
(2) Using an ohmmeter, check the resistance
between cavities 2 and 3. The sensor resistance
should be between 50 kilohms at 15É C (60É F) and 2
kilohms at 30É C (85É F). If not OK, replace the
faulty seat element and sensor assembly.
PASSENGER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 6). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switchassembly that also includes the hazard, rear window
wiper and washer switches. The heated seat switches
each provide a resistor multiplexed signal to its
respective Heated Seat Module (HSM) through sepa-
rate hard wired circuits. Each switch has an Off,
Low, and High position so that both the driver and
the front seat passenger can select a preferred seat
heating mode. Each switch has two Light-Emitting
Diodes (LED) which light to indicate that the heater
for the seat is turned on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
OPERATION
There are three positions that can be selected with
each of the heated seat switches: Off, Low, or High.
When the left side of the switch rocker is fully
depressed, the Low position is selected and the low
position LED indicator illuminates. When the right
side of the switch rocker is fully depressed, the High
position is selected and the high position LED indi-
cator illuminates. When the switch rocker is moved
to its neutral position (middle), Off is selected and
both LED indicators are extinguished.
Each switch provides separate resistor multiplexed
hard wire inputs to its respective Heated Seat Mod-
ule (HSM) to indicate the selected switch position.
The heated seat module responds to the heated seat
switch status messages by controlling the output to
the seat heater elements of the selected seat. The
Fig. 6 HEATED SEAT SWITCH LOCATION
1 - HEATED SEAT SWITCHES
8G - 12 HEATED SEAT SYSTEMRS
HEATED SEAT ELEMENTS (Continued)

REMOVAL
REMOVAL - 2.4L
The camshaft position sensor is mounted to the
rear of the cylinder head.
(1) Remove the negative battery cable.
(2) Disconnect electrical connectors from the cam-
shaft position sensor (Fig. 3).
(3) Remove camshaft position sensor mounting
screws. Remove sensor.
(4) Loosen screw attaching target magnet to rear
of camshaft and remove magnet (Fig. 4).
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2)
Remove the air box cover and inlet tube (Fig. 5).
(3) Disconnect camshaft position sensor electrical
connector from the wiring harness connector (Fig. 6).
(4) Remove bolt holding sensor.
(5) Rotate sensor away from block.
(6) Pull sensor up out of the chain case cover.Do
not pull on the sensor wiring.There is an O-ring
on the body of the sensor. The O-ring may make
removal difficult. A light tap to top of sensor prior to
removal may reduce force needed for removal.
Fig. 3 EGR/CAM SENSOR 2.4L
Fig. 4 Target Magnet Removal/Installation
1 - TARGET MAGNET
2 - MOUNTING BOLT
3 - REAR OF CYLINDER HEAD
Fig. 5 AIR BOX COVER
Fig. 6 CAMSHAFT POSITION SENSOR
RSIGNITION CONTROL8I-5
CAMSHAFT POSITION SENSOR (Continued)

INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS.........................2
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS...........................2REMOVAL.............................10
INSTALLATION.........................10
CLUSTER LENS
REMOVAL.............................10
INSTALLATION.........................10
INSTRUMENT CLUSTER
DESCRIPTION
The instrumentation gauges are contained in a
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.
The Mechanical Instrument Cluster (MIC) with a
tachometer is equipped with a electronic vacuum flu-
orescent transmission range indicator (PRND3L),
odometer, and trip odometer display.
The MIC without a tachometer is equipped with a
Light Emitting Diode (LED) transmission range indi-
cator (PRND3L) and a vacuum fluorescent odometer
display.
The MIC is equipped with the following warning
lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
²Coolant Temperature
²Anti-Lock Brake
²Brake
²Oil Pressure
²MIL (Malfunction Indicator Lamp)
²VTSS/SKIS Indicator
²Airbag
²Traction Control
²Autostick
The MIC without a tachometer also has the follow-
ing warning lamps:
²Turns Signals
²High Beam
WATER IN FUEL LAMP - EXPORT
The Water In Fuel Lamp is located in the message
center. When moisture is found within the fuel sys-
tem, the sensor sends a message via the PCI data
bus to the instrument cluster. The MIC illuminates
the bulb in the message center, The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
Refer to the vehicle Owner's Manual for operation
instructions and conditions for the Instrument Clus-
ter Gauges.
WATER IN FUEL LAMP - EXPORT
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RSINSTRUMENT CLUSTER8J-1

LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR............... 1LAMPS/LIGHTING - INTERIOR............... 20
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION..........................2
OPERATION............................2
WARNING.............................3
SPECIFICATIONS
EXTERIOR LAMPS.....................3
BRAKE LAMP SWITCH
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH.............................4
REMOVAL.............................5
INSTALLATION..........................5
CENTER HIGH MOUNTED STOP LAMP
REMOVAL.............................6
INSTALLATION..........................6
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL.............................6
INSTALLATION..........................6
FRONT FOG LAMP
DIAGNOSIS AND TESTING - FRONT FOG
LAMP...............................7
REMOVAL.............................8
INSTALLATION..........................8
FRONT FOG LAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - FRONT FOG
LAMP UNIT ALIGNMENT.................9
STANDARD PROCEDURE - FRONT FOG
LAMP UNIT ALIGNMENT - EXPORT........9
REMOVAL.............................9
INSTALLATION.........................10
HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP.....10
REMOVAL.............................12
INSTALLATION.........................12HEADLAMP SWITCH
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH............................12
REMOVAL.............................13
INSTALLATION.........................13
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP
UNIT ALIGNMENT.....................13
STANDARD PROCEDURE - HEADLAMP
UNIT ALIGNMENT - EXPORT.............14
REMOVAL.............................15
INSTALLATION.........................17
HEADLAMP UNIT - EXPORT
REMOVAL.............................17
INSTALLATION.........................17
LICENSE LAMP
REMOVAL.............................17
INSTALLATION.........................17
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM.....17
OPERATION - TURN SIGNAL SYSTEM.......18
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH...................18
REMOVAL.............................18
INSTALLATION.........................18
PARK/TURN SIGNAL LAMP
REMOVAL.............................18
INSTALLATION.........................18
TAIL LAMP
REMOVAL.............................18
INSTALLATION.........................19
TAIL LAMP UNIT
REMOVAL.............................19
INSTALLATION.........................19
RSLAMPS8L-1

LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power and high
side drivers source, ON/OFF device, lamps and body
grounds to operate properly. Plastic lamps require a
wire in the harness to supply body ground to the
lamp socket. Replace sockets and bulbs that are cor-
roded.
Some of the interior and exterior lighting functions
are governed by the Body Control Module (BCM).
The headlamp, dome, and the door ajar switches pro-
vide signals to the BCM. The BCM in turn sends a
Programmable Communication Interface (PCI) bus
message to the Front Control Module (FCM) to
enable the necessary drivers to set the required illu-
mination configuration.
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 intelligent power
module. Verify that bulbs are in good condition and
test continuity of the circuit ground. Refer to the
appropriate wiring information.
AUTOMATIC HEADLAMP SYSTEM
The Automatic Headlamp system turns the instru-
mentation and exterior illumination lamps ON when
the ambient light levels are Night and the engine
RPM is 450 or above, and OFF when light levels are
Day.
DAYTIME RUNNING LAMPS
Operating the high-beam headlamps at reduced
power provides daytime running lamps, which are
required on all new Canadian vehicles. Daytime run-
ning lamps are functional when 450 rpm's are
reached.
HEADLAMPS ON WITH WINDSHIELD WIPERS
For vehicles equipped with the Automatic Head-
lamp System, the instrumentation and exterior illu-
mination lamps will be turned ON when the
headlamp switch is in the AUTO position, RPM >450 and the windshield wipers have been in the
intermittent, low or high mode of operation for more
than ten seconds. When the windshield wipers are
turned OFF the Body Control Module will determine
if the instrumentation and exterior illumination
lamps should remain ON base upon the current
ambient light level.
HEADLAMP SYSTEM
The configuration of the headlamp system of head-
lamps, park lamps and fog lamps is determined by
the BCM. The BCM determines the lighting configu-
ration as a result of the inputs from the ignition
switch, headlamp switch and multi-function switch. A
PCI bus is transmitted from the BCM to the FCM to
enable the necessary drivers to set the illumination
configuration. Four wires are connected between the
headlamp switch and the BCM. The first wire con-
tains information regarding the position of the head-
lamp switch (Off, Automatic Headlamps, Automatic
Headlamp switch fog, Park with Fog, Head, or Head
with Fog Lamps). The second wire contains informa-
tion regarding the position of the dimmer switch
(Dome Lamp, Daytime Brightness, Dimming Level or
Off). The third wire is a dedicated signal return
(ground) wire. The fourth wire provides power to the
front fog lamp indicator.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is controlled by
the Body Control Module (BCM) via a PCI bus mes-
sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body
Control Module (BCM). With the headlamp switch in
the AUTO position, the BCM will control the head-
lamp, parking, side marker, tail and instrumentation
lamps based on ambient light levels. Ambient light
levels are monitored by the BCM using the Day/
Night signal and Electrochromatic Mirror (ECM)
present from the Compass Mini Trip (CMTC) located
on the front windshield in front of the rear view mir-
ror ECM. Ambient light readings are averaged to
limit cycling the lamps ON and OFF when passing
through areas with varying light levels. The auto-
matic headlamps will only function when the engine
is running with RPM > 450. When the headlamp
switch is in the AUTO position (Automatic mode), the
Headlamp Time Delay system will function when the
ignition switch is placed in any position other than
run/start.
8L - 2 LAMPS/LIGHTING - EXTERIORRS

DAYTIME RUNNING LAMPS
Power is reduced using pulse-width modulation to
the high beams, where by the power is switched on
and off rapidly instead of remaining on continuously.
The duration and interval of the power pulses is pro-
grammed into the FCM. Daytime running lamps are
functional when 450 rpm's are reached.
HEADLAMP SYSTEM
The headlamp system will default to headlamps
ON position when ignition switch is ON and when an
open or short circuit failure occurs on the headlamp
switch input or PCI data bus communication between
the BCM and the FCM fails. The system will return
to normal operation when the open or short is
repaired. A fault will be reported by the BCM when a
failure occurs on the dimmer or headlamp switch
input.
If the exterior lamps are ON and the headlamp
switch is in any position other than OFF or AUTO
and with the ignition switch OFF (LOCK) after 3
minutes the BCM sends a message via PCI bus to
the FCM informing the FCM to turn off the head-
lamps, park lamps and fog lamps. This feature pre-
vents the vehicle battery from being discharged when
the vehicle lights have been left ON.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is activated by
turning the headlamps ON (high or low beam) while
the engine is running, turning the ignition switch
OFF, and then turning the headlamp switch OFF
within 45 seconds. The system will not activate if
more than 45 seconds elapse between ignition switch
OFF and headlamp switch OFF. The BCM will allow
the headlamps to remain ON for 90 seconds (config-
urable) before they automatically turn off (If the key
is in the ignition during the headlamp time delay
mode, then both the headlamps and park lamps
(including panel dimming) will be ON). Refer to the
Owner's Manual for more information.
If the headlamp switch is in the Auto Headlamp
Position, the headlamps are ON due to the night sig-
nal from the CMTC and the ignition switch is in any
position other than run/start, the BCM shall enter a
90 second (configurable) Auto Headlamps time delay
mode. If the key is in the ignition during the head-
lamp time delay mode, then both the headlamps and
park lamps (including panel dimming) will be ON. If
the key is not in the ignition, then only the head-
lamps will be ON. The BCM will allow the head-
lamps to remain ON for 90 seconds before they
automatically turn OFF. Refer to the Owner's Man-
ual for more information.
OPTICAL HORN/HIGH BEAMS
When the multi-function switch is pulled to the
first detent (optical horn) signal, the headlamps are
ON, key-in the ignition the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers to illuminate all four filaments (Low
and High beams). When the multi-function switch is
pulled to the second detent (high beam) signal and
the headlamps are ON, the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers. The High Beams are illuminated and
the Low Beams and Fog Lamps (if ON) are extin-
guished. If the headlamps were in the high beam
configuration when power was removed from the
headlamps, the headlamps will be configured as low
beam the next time they are activated.
NOTE: For RG - Export vehicles, the low beams and
front fog lamps will remain ON when high beams
are activated.
WARNING
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY OR DEATH 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 other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
CAUTION: Do not use bulbs other than those listed
in the Bulb Application Table. Damage to lamp can
result. Do not touch halogen bulbs with fingers or
other oily surfaces. Bulb life will be reduced.
SPECIFICATIONS
EXTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3057
CHMSL 921
FRONT SIDE MARKER/PARK/
TURN3157A
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)

LAMP BULB
FRONT FOG 9040
HEADLAMP 9007
LICENSE 168
TAIL, STOP 3057
TURN SIGNAL 3057
BULB APPLICATION TABLE - EXPORT
LAMP BULB
HEADLAMP LOW/HIGH BEAM H7
FRONT FOG H3
FRONT POSITION W5W
FRONT TURN SIGNAL PY21W
SIDE REPEATER T4W
LICENSE PLATE W5W/168
REAR TAIL AND STOP P21/5W
REAR TURN SIGNAL PY21W
BACK-UP P21W
REAR FOG P21W
CHMSL W16W/921
BRAKE LAMP SWITCH
DESCRIPTION
The brake lamp switch is located under the instru-
ment panel, at the brake pedal arm (Fig. 3). It has
three internal switches controlling various functions
of the vehicle. It's main function is to control opera-
tion of the vehicle's brake lamps via a brake switch
input to the BCM. The BCM will then activate the
stop lamps. Other functions include speed control
deactivation, brake sense for the antilock brake sys-
tem and brake sense for the brake transmission shift
interlock.
CAUTION: The switch can only be adjusted once.
That is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
OPERATION
When the brake pedal is pressed, the plunger on
the outside of the brake lamp switch extends out-
ward. This action opens or closes the contacts of the
three switches inside the brake lamp switch.
With the brake pedal pressed down (plunger
extended), the switch for terminals 1 and 2 is closedcompleting the circuit. The switch for terminals 3
and 4 is open and so is the switch for terminals 5
and 6.
When the brake pedal is released (plunger pushed
in), the three switches assume the opposite positions.
The switch for terminals 1 and 2 is now open while
the other two switches are now closed, completing
their circuits.
A lever on the back of the switch is used to set the
switch into the ªadjustedº position. A non-adjusted
switch will have the lever set to the diagonal position
in relation to the switch housing. The plunger can be
moved in and out, but the states of the internal
switches will not change.
CAUTION: Never move the adjustment lever of the
new brake lamp switch without it being properly
installed in the vehicle first. Such action will render
the switch unusable and the switch must be dis-
carded.
Once installed in the vehicle as described in the
brake lamp switch installation procedure (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION), the new
switch's adjustment lever is rotated to the adjusted
position as indicated (Fig. 4). This action locks the
plunger to the internal switches.Once in this posi-
tion the switch is permanently adjusted (or
locked) and cannot be readjusted or released
even if the lever is moved back.
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
NOTE: Before proceeding with this diagnostic test,
verify the adjustment lever on the back of the
switch is in the adjusted position. If the lever is in
the non-adjusted (diagonal) position it may have
never been adjusted (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - OPERATION). For adjustment, (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION)
If the electrical circuit has been tested and the
brake lamp switch is suspected of being faulty, it can
be tested using the following method.
(1) Remove the switch from the vehicle. (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL)
(2) With the switch in the released position
(plunger extended), use an ohmmeter to test each of
the three internal switches as shown (Fig. 1). You
should achieve the results as listed in the figure.
(3) Gently push the plunger on the brake lamp
switch in until it stops.
8L - 4 LAMPS/LIGHTING - EXTERIORRS
LAMPS/LIGHTING - EXTERIOR (Continued)