ignition CHRYSLER VOYAGER 1996 Manual Online

Fig. 5 Electronic Combination Flasher with DRL Circuit
JUNCTION BLOCK TERMINAL CALL-OUT
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
8J - 4 TURN SIGNAL AND FLASHERSNS
DIAGNOSIS AND TESTING (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)

WINDSHIELD WIPERS AND WASHERS
CONTENTS
page page
REAR WIPER AND WASHER................ 9WINDSHIELD WIPERS AND WASHER......... 1
WINDSHIELD WIPERS AND WASHER
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 1
FAILED PARK SWITCH.................... 2
MULTI-FUNCTION SWITCH................. 4
REMOVAL AND INSTALLATION
MULTI-FUNCTION SWITCH................. 4
WINDSHIELD WASHER BOTTLE............. 4
WINDSHIELD WIPER BLADE ELEMENT....... 6WINDSHIELD WIPER BLADE................ 5
WINDSHIELD WIPER MOTOR............... 6
WIPER ARM............................. 7
WIPER LINKAGE......................... 7
WIPER UNIT............................ 7
CLEANING AND INSPECTION
WIPER BLADES.......................... 8
ADJUSTMENTS
WIPER ARM ALIGNMENT.................. 8
GENERAL INFORMATION
INTRODUCTION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
SAFETY PRECAUTIONS. DISCONNECT THE NEGA-
TIVE CABLE FROM THE BATTERY BEFORE SER-
VICING COMPONENTS INVOLVING THE AIRBAG
SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG
AND PERSONAL INJURY CAN RESULT.
The windshield wipers can be operated with the
windshield wiper switch when the ignition switch is
in the RUN or ACCESSORY positions. The wind-
shield wiper system is protected by a 40 amp fuse (9)
located in the Power Distribution Center (PDC) in
the engine compartment. The windshield washer cir-
cuit is protected by a 6 amp fuse (9) located in the
Junction Block. The wiper motor has permanent
magnetic fields. The speeds are determined by cur-
rent flow to the appropriate set of brushes inside the
motor. The current flow is controlled by the multi-
function switch stalk mounted wiper switch, high
speed/low speed relays located in the PDC. The speed
sensitive intermittent wiper is controlled by the BodyControl Module (BCM). The intermittent mode, with
the vehicle traveling greater than 10.4 mph, has a
range of 0.5 to 18 seconds. With the vehicle traveling
less than 10.4 mph, and the time delay is not
adjusted, time delay doubles to a range of 1 to 36
seconds. The wiper arms will park at the base of the
windshield just above the cowl cover after the wiper
switch is turned OFF.
The windshield wiper motor and linkage is located
in an integral wiper unit at the rear of the engine
compartment. The wiper unit must be removed to
gain access to the wiper motor.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
The windshield wiper system operates in several
modes:
²Low and high speed normal wipe
²Speed sensitive intermittent wipe
²Wipe after wash
²Pulse wipe
²Park (switch OFF)
The windshield wiper circuits are continuously
monitored and controlled by the Body Control Mod-
NSWINDSHIELD WIPERS AND WASHERS 8K - 1

REAR WIPER AND WASHER
INDEX
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 9
REAR WINDOW WIPER/WASHER SWITCHES . . . 9
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 9
REMOVAL AND INSTALLATION
REAR GLASS RUBBER GROMMET........... 9REAR WINDOW WIPER MOTOR............ 10
REAR WIPER ARM...................... 10
REAR WIPER BLADE ELEMENT............ 10
REAR WIPER BLADE..................... 10
DESCRIPTION AND OPERATION
INTRODUCTION
When continuous rear wiper operation is required,
the Body Control Module (BCM) will provide ignition
ON voltage to the rear wiper motor. When the wiper
switch is turned OFF, the BCM provides circuit
ground to operate the motor until the wipe cycle is
complete and the wiper arm returns to the base of
the rear window.
When intermittent rear wiper mode is selected, the
wiper motor will cycle every 7 seconds. The intermit-
tent delay time is also adjusted based upon vehicle
speed. With the vehicle traveling greater at 50 mph,
the cycle changes to every 5 seconds.
REAR WINDOW WIPER/WASHER SWITCHES
The rear window wiper/washer switches are incor-
porated into the HVAC switch panel. Refer to Group
8E, Instrument Panel for proper service procedures.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
The rear window wiper system operates in several
modes:
²Continuous wipe
²Intermittent wipe
²Wash
²Wipe after wash
The windshield wiper circuits are continuously
monitored and controlled by the Body Control Mod-
ule (BCM). If a problem occurs in the electronic com-
ponents, wiring, switch (except integral motor park
switch) and wiper motor a Diagnostic Trouble Code
(DTC) will be stored in the BCM memory. The
DTC(s) can be retrieved using a scan tool (DRB).
Refer to proper Body Diagnostic Procedures manual
for DTC descriptions and retrieval information.
REMOVAL AND INSTALLATION
REAR GLASS RUBBER GROMMET
REMOVAL
(1) Remove rear window wiper motor.
(2) Peel wiper pivot seal grommet from rear glass.
(3) Remove grommets from vehicle (Fig. 1).
INSTALLATION
For installation, reverse the above procedure.
Fig. 1 Rear Glass Rubber Grommet
Fig. 2 Rear Glass Rubber Grommets
NSWINDSHIELD WIPERS AND WASHERS 8K - 9

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)

INTERIOR LAMPS
INDEX
page page
REMOVAL AND INSTALLATION
CONVENIENCE BIN LAMP................. 20
DOME LAMP BULB...................... 21
DOME LAMP........................... 21
FRONT DOOR COURTESY LAMP BULB...... 22
FRONT DOOR COURTESY LAMP........... 21
GLOVE BOX LAMP AND SWITCH........... 19
GLOVE BOX LAMP BULB.................. 19
HEADER READING/COURTESY LAMP BULB . . . 19HEADER READING/COURTESY LAMP....... 18
IGNITION HALO LAMP BULB............... 19
INSTRUMENT PANEL LAMPS AND SWITCHES . 20
LIFTGATE COURTESY LAMP BULB.......... 24
LIFTGATE COURTESY LAMP............... 23
OVERHEAD CONSOLE READING/COURTESY
LAMP BULB.......................... 18
RAIL LAMP MODULE BULB................ 23
REMOVAL AND INSTALLATION
OVERHEAD CONSOLE READING/COURTESY LAMP
BULB
REMOVAL
(1) Using a trim stick, lightly pry outward the for-
ward end of reading lamp lens.
(2) Rotate reading lamp bulb socket one quarter
turn counterclockwise.
(3) Pull socket out of lamp (Fig. 1).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Push socket into lamp.
(3) Rotate reading lamp bulb socket one quarter
turn clockwise.
(4) Insert tab on lamp lens between lamp switch
and overhead console.(5) Snap lens onto lamp lens pivots.
HEADER READING/COURTESY LAMP
REMOVAL
(1) Grasp outer edges of header reading/courtesy
lamp at headlining.
(2) Pull downward to disengage clips on reading/
courtesy lamp from roof header panel (Fig. 2).
(3) Disconnect wire connector from reading/cour-
tesy lamp.
(4) Remove lamp from vehicle.
INSTALLATION
(1) Position lamp on vehicle.
(2) Connect wire connector to reading/courtesy
lamp.
(3) Align clips on reading/courtesy lamp to mating
holes in roof header panel.
(4) Push upward to engage clips on reading/cour-
tesy lamp to roof header panel.
Fig. 1 Reading/Courtesy LampFig. 2 Header Reading/Courtesy Lamp
8L - 18 LAMPSNS

HEADER READING/COURTESY LAMP BULB
REMOVAL
(1) Insert a small, flat bladed pry tool at forward
position between reading/courtesy lamp lens and
lamp housing.
(2) Pry lamp lens from lamp housing (Fig. 3).
(3) Insert a small, flat bladed pry tool between
lamp light shield and lamp housing at inboard rear
corner of light shield.
(4) Pry light shield from housing (Fig. 4).
(5) Carefully press forward lamp bulb contact
toward opposite contact and rotate.
(6) Remove bulb from lamp bulb contacts.
INSTALLATION
(1) Carefully press forward lamp bulb contact
toward opposite contact and rotate bulb into position.
(2) Position bulb to lamp bulb contacts.
(3) Release lamp bulb contacts.
(4) Insert outer edge of light shield into lamp
housing (Fig. 4).(5) Rotate light shield upward and snap inboard
edge into lamp housing.
(6) Position lens switch tab to lamp switch.
(7) Press lens pivots to tabs on lamp housing until
both pivots are seated.
GLOVE BOX LAMP AND SWITCH
REMOVAL
(1) Open glove box door.
(2) Using a trim stick, lightly pry glove box lamp/
switch from instrument panel.
(3) Disconnect wire connector from glove box lamp
(Fig. 5).
(4) Remove glove box lamp from vehicle.
INSTALLATION
(1) Position glove box lamp in vehicle.
(2) Connect wire connector from glove box lamp.
(3) Position glove box lamp in instrument panel.
(4) Press lamp into instrument panel until fully
seated.
GLOVE BOX LAMP BULB
REMOVAL
(1) Remove glove box lamp/switch from instrument
panel.
(2) Pull bulb from glove box lamp (Fig. 6).
INSTALLATION
(1) Push bulb into glove box lamp.
(2) Install glove box lamp/switch in instrument
panel.
IGNITION HALO LAMP BULB
REMOVAL
(1) Remove steering column trim covers. Refer to
Group 19, Steering, for proper procedures.
Fig. 3 Reading/Courtesy Lamp Lens
Fig. 4 Reading/Courtesy Lamp Light Shield
Fig. 5 Glove Box Lamp and Switch
NSLAMPS 8L - 19
REMOVAL AND INSTALLATION (Continued)