bulb CHRYSLER VOYAGER 1996 User Guide

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)

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)

(3) Tighten screws to hold magnifying window to
headlamp module. Do not over tighten.FOG LAMP ALIGNMENT
Prepare an alignment screen. Refer to the Align-
ment Screen Preparation paragraph in this section. A
properly aligned fog lamp will project a pattern on
the alignment screen 100 mm (4 in.) below the fog
lamp center line and straight ahead (Fig. 6). To
improve visual interpretation of the fog lamp pattern
on the alignment screen, disable the headlamps by
disengaging the wire connectors from the headlamp
bulbs.
The Town and Country fog lamp adjustment screw
is located through the lens (Fig. 7).
Fig. 6 Fog Lamp Alignment
Fig. 5 Magnifying Window and Bubble Level
Calibration
Fig. 7 Fog Lamp Adjustment Screw
8L - 8 LAMPSNS
ADJUSTMENTS (Continued)

EXTERIOR LAMP BULB SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB........................ 13
FOG LAMP BULB ± TOWN and COUNTRY..... 11
FOG LAMP BULB........................ 10
FRONT PARKING AND TURN SIGNAL LAMP
BULB ± TOWN and COUNTRY............ 12
FRONT SIDE MARKER LAMP BULB TOWN and
COUNTRY............................ 11HEADLAMP BULB ± TOWN & COUNTRY....... 9
HEADLAMP BULB........................ 9
LICENSE PLATE LAMP BULB.............. 13
PARKING AND TURN SIGNAL BULB......... 11
TAIL, STOP, TURN SIGNAL AND BACK-UP
LAMP BULB.......................... 12
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) From behind radiator closure panel, disconnect
wire connector from back of headlamp bulb base.
(3) Rotate headlamp bulb retaining ring counter-
clockwise.
(4) Remove retaining ring from headlamp (Fig. 1).
(5) Pull headlamp bulb from back of headlamp.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) From behind radiator closure panel, insert
headlamp bulb into back of headlamp.
(2) Engage retaining ring onto headlamp (Fig. 1).(3) Rotate headlamp bulb retaining ring clockwise.
(4) Connect wire connector into headlamp bulb
base.
(5) Verify headlamp alignment.
HEADLAMP BULB ± TOWN & COUNTRY
HEADLAMP HIGH BEAM
REMOVAL
(1) Release hood latch and open hood.
(2) From behind radiator closure panel, disconnect
wire connector from back of high headlamp bulb
base.
(3) Rotate headlamp bulb counterclockwise and
pull bulb from back of headlamp module (Fig. 2).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) Insert bulb into the back of the headlamp mod-
ule.
(2) Rotate headlamp bulb clockwise to engage
bulb.
(3) Connect wire connector to the low beam head-
lamp. Verify headlamp bulb operation
(4) Verify headlamp alignment.
HEADLAMP LOW BEAM
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the three headlamp mounting nuts.
(3) Remove one attaching screw on top of the
crossmember.
(4) Disconnect wire connector from the back of the
low beam headlamp bulb base (Fig. 4).
Fig. 1 Headlamp Bulb
NSLAMPS 8L - 9

(5) Rotate headlamp bulb retainer counterclock-
wise and disengage retainer from headlamp (Fig. 3).
(6) Pull headlamp bulb from back of the headlamp
module.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) Place headlamp bulb into headlamp module.
(2) Rotate headlamp bulb retainer clockwise to
engage retainer.
(3) Connect wire connector to the low beam head-
lamp. Verify headlamp bulb operation
(4) Install the headlamp module.
(5) Verify headlamp alignment.
FOG LAMP BULB
REMOVAL
(1) Remove fog lamp from vehicle.
(2) Remove rear cover from fog lamp.
(3) Disengage wire clip holding bulb in fog lamp
(Fig. 5).
(4) Hinge wire retainer clip out of bulb removal
path.
(5) Pull bulb from lamp.
(6) Disconnect wire connector from fog lamp wire
harness.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other oily surfaces, reduced bulb life
will result.
Fig. 2 Headlamp High Beam Bulb ± T&C
Fig. 3 Low Beam Headlamp Retainer
Fig. 4 Headlamp Low Beam Bulb ± T&C
Fig. 5 Fog Lamp Bulb
8L - 10 LAMPSNS
REMOVAL AND INSTALLATION (Continued)

(1) Connect wire connector into fog lamp wire har-
ness.
(2) Insert bulb into lamp so index notches on bulb
engage with bosses in lamp (Fig. 5).
(3) Hinge wire retainer clip over bulb base.
(4) Engage wire clip to hold bulb into lamp.
(5) Install rear cover on fog lamp.
(6) Install fog lamp on vehicle.
FOG LAMP BULB ± TOWN and COUNTRY
REMOVAL
(1) Reach behind fascia and remove bulb by rotat-
ing counterclockwise (Fig. 6).
(2) Rotate lamp bulb counterclockwise to disengage
bulb.
(3) Disconnect the wire connector from fog lamp
bulb base.
(4) Replace bulb.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other oily surfaces, reduced bulb life
will result.
(1) Connect wire connector into fog lamp bulb
base.
(2) Insert bulb into fog lamp housing.
(3) Rotate lamp bulb clockwise to engage bulb.
(4) Verify bulb operation.
(5) Verify fog lamp alignment.
FRONT SIDE MARKER LAMP BULB TOWN and
COUNTRY
REMOVAL
(1) Remove screw attaching side marker lamp to
fascia.(2) Remove housing by pulling rearward and away
from fascia (Fig. 7).
(3) Rotate lamp socket counterclockwise one quar-
ter turn.
(4) Pull bulb socket from the rear of lamp (Fig. 8).
(5) Pull bulb from socket.
INSTALLATION
(1) Insert bulb into socket.
(2) Insert bulb socket into rear of housing.
(3) Rotate park and turn signal socket clockwise
one quarter turn.
(4) Verify bulb operation.
(5) Install screw attaching side marker lamp.
PARKING AND TURN SIGNAL BULB
REMOVAL
(1) From under front wheelhouse, remove access
cover behind parking and turn signal lamp.
(2) Through access hole in wheelhouse, rotate
parking and turn signal socket counterclockwise one
quarter turn.
(3) Pull socket from back of lamp (Fig. 9).
(4) Pull bulb from socket.
INSTALLATION
(1) Align key on bulb base to groove in socket and
insert bulb into socket.
Fig. 6 Fog Lamp Bulb ± T&C
Fig. 7 Front Side Marker Lamp Bulb ± T&C
Fig. 8 Front Side Marker Lamp Sockets
NSLAMPS 8L - 11
REMOVAL AND INSTALLATION (Continued)

(2) Through access hole in wheelhouse, insert
socket into back of lamp.
(3) Rotate parking and turn signal socket clock-
wise one quarter turn.
(4) Install access cover and verify lamp operation.
FRONT PARKING AND TURN SIGNAL LAMP BULB
± TOWN and COUNTRY
REMOVAL
(1) Remove screw attaching side marker lamp to
fascia.
(2) Remove housing by pulling outward and away
from the fascia (Fig. 10).
(3) Remove screw attaching parking and turn sig-
nal lamp housing.
(4) Rotate lamp socket(s) counterclockwise one
quarter turn (Fig. 11).
(5) Pull bulb socket(s).
(6) Pull bulb from socket(s).
INSTALLATION
(1) Insert bulb into socket.
(2) Insert bulb socket into housing.(3) Rotate parking and turn signal socket clock-
wise one quarter turn.
(4) Verify bulb(s) operation.
(5) Install screw attaching parking and turn signal
lamp housing.
(6) Install screw attaching side marker lamp.
TAIL, STOP, TURN SIGNAL AND BACK-UP LAMP
BULB
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws holding tail, stop, turn signal
and back-up lamp to rear door opening trough.
(3) Remove inner end of lamp from quarter panel.
(4) Disengage hook holding outer end of lamp to
quarter panel opening.
(5) Remove lamp from quarter panel.
(6) Rotate lamp socket counterclockwise one quar-
ter turn (Fig. 12).
(7) Pull socket from back of lamp.
(8) Pull bulb from socket (Fig. 13).
INSTALLATION
(1) Align key on bulb base to groove in socket and
insert bulb into socket (Fig. 13).
(2) Insert socket into back of lamp.
(3) Rotate lamp socket clockwise one quarter turn.
(4) Engage hook to hold outer end of lamp to quar-
ter panel opening.
(5) Place lamp in position on quarter panel.
(6) Install screws to hold lamp to rear door open-
ing trough.
(7) Verify tail, stop, turn signal and back-up lamp
operation.
Fig. 9 Parking and Turn Signal Lamp Bulb
Fig. 10 Front Parking and Turn Signal Lamp ± T&C
Fig. 11 Front Parking and
Turn Signal Lamp Bulb(s) ± T&C
8L - 12 LAMPSNS
REMOVAL AND INSTALLATION (Continued)

LICENSE PLATE LAMP BULB
REMOVAL
(1) Remove screws attaching license plate lamp
lens to liftgate.
(2) Remove license plate lamp lens from lamp.
(3) Rotate lamp socket counterclockwise one quar-
ter turn.
(4) Pull socket from lens (Fig. 14).
(5) Pull bulb from socket.
INSTALLATION
(1) Install bulb into socket.
(2) Insert socket into lens.
(3) Rotate lamp socket clockwise one quarter turn.
(4) Place license plate lamp lens in position in
lamp.
(5) Install screws attaching license plate lamp
lens.
(6) Verify license plate lamp operation.
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB
REMOVAL
(1) Release liftgate latch and open liftgate.(2) Disengage clips holding CHMSL access trim
cover to liftgate.
(3) Remove trim cover from liftgate.
(4) Rotate bulb socket counterclockwise one quar-
ter turn.
(5) Pull socket from lamp (Fig. 15).
(6) Pull bulb from socket.
INSTALLATION
(1) Insert bulb into socket.
(2) Insert socket into lamp.
(3) Rotate bulb socket clockwise one quarter turn.
(4) Place CHMSL access trim cover in position on
liftgate.
(5) Engage clips to hold access cover to liftgate.
(6) Verify CHMSL operation.
Fig. 12 Tail, Stop, Turn Signal
and Back-up Lamp Bulb
Fig. 13 Pull Bulb From Socket
Fig. 14 License Plate Lamp Bulb
Fig. 15 CHMSL Bulb
NSLAMPS 8L - 13
REMOVAL AND INSTALLATION (Continued)