CHRYSLER VOYAGER 1996 Service Manual

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)

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)

HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
HEADLAMP ALIGNMENT................... 5
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION....... 5ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN.................... 5
GENERAL INFORMATION
HEADLAMP ALIGNMENT
The headlamps are equipped with a bubble level
for up/down headlamp alignment. The bubble is cen-
tered with the vehicle on a level surface. A horizontal
gauge and magnifying window is located next to the
bubble level for left/right alignment (Fig. 1). Aim on
every headlamp assembly is calibrated at the head-
lamp manufacturer. At the vehicle assembly plant,
the vertical aim is set by centering the bubble with
the vehicle on a level surface. Horizontal aim is con-
trolled by the mounting pads on each headlamp
mounting panel.
When the vehicle is to be used with a heavy load,
the bubble level can be used to compensate for the
altered ride height.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 2).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) From the floor up 1.27 meters (5 ft.), tape a
line on the wall at the center line of the vehicle.
Sight along the center line of the vehicle (from rear
of vehicle forward) to verify accuracy of the line
placement.
(4) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the center line of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
Fig. 1 Magnifying Window and Bubble Level
NSLAMPS 8L - 5

side of vehicle center line. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen 229 mm (9 in.)650 mm (2 in.) below the
headlamp center line. The center of the hot spot
should be 100 mm (4 in.)650 mm (2 in.) right of the
headlamp center line (Fig. 2). The high beams on a
vehicle with aero headlamps cannot be aligned. The
high beam pattern should be correct when the low
beams are aligned properly.
To adjust headlamp alignment, rotate adjusting
screws to achieve the specified low beam hot spot
location (Fig. 3).
HEADLAMP ADJUSTMENT ± TOWN AND
COUNTRY
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen 152 mm (6 in.)650 mm (2 in.) below the
headlamp center line. The center of the hot spot
should be 254 mm (10 in.)650 mm (2 in.) right of
the headlamp center line (Fig. 4). The high beams on
a vehicle with aero headlamps cannot be aligned. Thehigh beam pattern should be correct when the low
beams are aligned properly.
Fig. 2 Headlamp Alignment Screen
Fig. 3 Headlamp Bubble Level and Adjusters
8L - 6 LAMPSNS
ADJUSTMENTS (Continued)

To adjust headlamp alignment, rotate adjusting
screws to achieve the specified low beam hot spot
location (Fig. 3).
BUBBLE LEVEL CALIBRATION
(VERTICAL AIM)
After the headlamp alignment has been verified or
set and the bubble level is not centered, calibrate the
bubble level.
NOTE: Any calibration of the headlamp bubble
level must be done on a level surface and the head-
lamp cool. Do not operate the headlamps for a min-
imum of 20 minutes prior to beginning adjustments.
(1) Remove screws holding magnifying window to
top of headlamp module (Fig. 5).
(2) Position magnifying window to the side
between headlamp module and radiator closure
panel.
(3) Through slotted hole in magnifying window,
insert small screw driver into bubble level calibration
screw.(4) Rotate calibration screw in proper direction
until bubble is centered on the ªOº.
(5) Install magnifying window, making sure O-ring
seal is in place.
(6) If necessary, calibrate magnifying window.MAGNIFYING WINDOW CALIBRATION
(HORIZONTAL AIM)
After the headlamp alignment has been verified or
set and the magnifying window is not centered, cali-
brate the magnifying window.
(1) Loosen screws holding magnifying window to
top of headlamp module (Fig. 5).
(2) Using the calibration knob above headlamp
lens, rotate magnifying window until window is cen-
tered over the ªOº on the gauge below the window.
Fig. 4 Headlamp Alignment Screen ± T&C
NSLAMPS 8L - 7
ADJUSTMENTS (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)