steering CHRYSLER VOYAGER 1996 Manual Online
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 1996, Model line: VOYAGER, Model: CHRYSLER VOYAGER 1996Pages: 1938, PDF Size: 55.84 MB
Page 366 of 1938
(2) Disengage clips holding right end cover to
instrument panel.
(3) Remove instrument panel end cover and foam
pad covering the A/C inlet projection of the end cover
if equipped.
INSTALLATION
For installation, reverse the above procedures.
JUNCTION BLOCK
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove lower steering column cover and knee
blocker reinforcement.
(3) Disconnect four, forty-way connectors from
Junction Block (Fig. 41).
(4) Disconnect two wire connectors from bottom of
Body Control Module.
(5) Remove bolts holding Junction Block to dash
panel mounting.
(6) Remove Junction Block from mounting bracket.
(7) Remove screws holding Body Control Module to
Junction Block.
(8) Slide Body Control Module downward to dis-
connect guide studs on Junction Block from BCM
ting bracket.
(9) Separate Junction Block from Body Control
Module.
INSTALLATION
For installation, reverse the above procedures.
KNEE BLOCKER REINFORCEMENT
REMOVAL
(1) Remove lower steering column cover (Fig. 42).
(2) Remove screws holding knee blocker reinforce-
ment to instrument panel.(3) Remove reinforcement.
INSTALLATION
(1) Place reinforcement in position.
(2) Install screws to hold knee blocker reinforce-
ment to instrument panel.
(3) Install lower steering column cover.
LOWER CONSOLE
REMOVAL
(1) Remove screws holding lower console to floor
bracket and instrument panel (Fig. 43).
(2) Slide console rearward from around instrument
panel supports.
(3) Remove lower console.
Fig. 41 Junction Block
Fig. 42 Knee Blocker Reinforcement
Fig. 43 Lower Console
8E - 30 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)
Page 367 of 1938
INSTALLATION
(1) Place lower console in position.
(2) Slide console forward around instrument panel
supports.
(3) Install screws to hold lower console to floor
bracket and instrument panel.
LOWER INSTRUMENT PANEL
REMOVAL
(1) Remove the right end cover.
(2) Remove the steering column bezel.
(3) Remove the radio bezel and the HVAC control.
(4) Remove the lower console.
(5) Remove the convenience cup holder and track.
(6) Remove the glove box.
(7) Remove the glove box latch striker.
(8) Remove the glove box lamp.
(9) Disconnect the wire connector from glove box
lamp.
(10) Remove the screws holding the lower instru-
ment panel to the reinforcement frame around the
glove box opening (Fig. 44).
(11) Remove the screw holding the lower instru-
ment panel to the right side of instrument panel.
(12) Remove the screw holding the lower instru-
ment panel to the upper instrument panel at the left
side panel above the accelerator pedal.
(13) Remove the instrument cluster bezel as neces-
sary to gain access to the lower instrument panel
screws.
(14) Remove the screw holding instrument panel
to the upper panel below the instrument cluster.
(15) Remove the screws holding rear of storage
pocket to the panel support frame.
(16) Remove the screws holding the lower instru-
ment panel to the upper instrument panel from
below radio.(17) Remove the screws holding lower instrument
panel to the support frame in floor console area.
(18) Separate the lower instrument from the upper
instrument panel.
(19) Disconnect the wire connectors from back of
the 12 volt outlet base.
(20) Remove the lower instrument from vehicle.
INSTALLATION
For installation, reverse the above procedures.
LOWER STEERING COLUMN COVER
REMOVAL
(1) Remove screws holding parking brake release
handle to instrument panel (Fig. 45).
(2) Remove screws holding bottom of lower steer-
ing column cover to instrument panel (Fig. 46).
(3) Remove screw holding right side of lower steer-
ing column cover to instrument panel.
Fig. 44 Lower Instrument Panel
Fig. 45 Park Brake Release Handle
Fig. 46 Lower Steering Column Cover
NSINSTRUMENT PANEL AND SYSTEMS 8E - 31
REMOVAL AND INSTALLATION (Continued)
Page 368 of 1938
(4) Disengage park brake release cable case from
groove on end of release handle (Fig. 47).
(5) Disengage cable end pivot from slot on release
handle (Fig. 47).
INSTALLATION
For installation, reverse the above procedures,
MECHANICAL TRANSMISSION RANGE INDICATOR
REMOVAL
(1) Remove instrument cluster.
(2) Remove cluster lens.
(3) Remove screws holding mechanical transmis-
sion range indicator to back of cluster lens.
(4) Remove mechanical transmission range indica-
tor from cluster lens.
INSTALLATION
(1) Position transmission range indicator on clus-
ter lens.
(2) Install mechanical range indicator and attach-
ing screws to back of cluster lens.
(3) Install cluster lens.
(4) Install instrument cluster.
MESSAGE CENTER
REMOVAL
(1) Remove A-pillar trim.
(2) Remove instrument panel top cover. Refer to
instrument panel top cover removal procedures.
(3) Disconnect the wire connector from back of
message center.(4) Remove screws holding message center to
instrument panel top cover.
(5) Remove message center from instrument panel
top cover.
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.
MESSAGE CENTER LAMP
REMOVAL
(1) Remove instrument panel top cover. Refer to
Instrument Panel Top Cover Removal procedures.
(2) Locate the lamp in question (Fig. 48).
(3) Remove lamp and check lamp. If lamp is good
test the power supply to the lamp.
INSTALLATION
For installation, reverse the above procedures.
OUTLET (12 VOLT) BASE
REMOVAL
(1) Look inside and note position of the retaining
bosses (Fig. 49).
(2) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(3) Pull out the base through mounting ring by
gently rocking pliers. A tool can be made to do the
same. Refer to (Fig. 50).
(4) Disconnect the base wires.
(5) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Position mount ring to the instrument panel
and feed the wires through ring. Index the cap and
the mount ring with the index tab at 9 o'clock to the
key in the instrument panel. Install the ring.
(2) Connect wires to base. Orient base alignment
rib at 11 o'clock to mate the groove in mount ring at
the same location
(3) Push base into the bezel till it locks.
(4) Install 12 volt outlet cap and check operation of
outlet or element.
OVER STEERING COLUMN BEZEL
REMOVAL
(1) Remove the lower steering column cover.
Fig. 47 Park Brake Release Handle
8E - 32 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)
Page 369 of 1938
(2) Remove the screws holding over steering col-
umn bezel to the cluster bezel (Fig. 51).
(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
Fig. 48 Message Center Lamp Location
Fig. 49 Outlet Base Removal
Fig. 50 Tool For Outlet Removal
Fig. 51 Over Steering Column Bezel
NSINSTRUMENT PANEL AND SYSTEMS 8E - 33
REMOVAL AND INSTALLATION (Continued)
Page 370 of 1938
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. 52).
(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. 53).
(2) Rotate bulb socket counterclockwise one quar-
ter turn.
(3) Pull bulb socket from back of power mirror
switch.
INSTALLATION
For installation, reverse the above procedures.
RADIO BEZEL AND HVAC CONTROL
REMOVAL
(1) Remove convenience bin - cup holder. Refer to
Convenience Bin - Cup Holder Removal and Installa-
tion procedure in this section.(2) Insert the trim stick (special tool #C-4755)
between access cover and radio bezel, above conve-
nience bin - cup holder.
(3) Carefully pry the access cover from the instru-
ment panel (Fig. 54).
(4) Separate the access cover from the vehicle.
(5) Remove convenience bin - cup holder track.
Refer to Convenience Bin - Cup Holder Track
Removal and Installation procedures in this section.
(6) Remove the attaching screws holding bottom of
the bezel to instrument panel (Fig. 55).
(7) Remove the attaching screws holding top of the
bezel to the instrument panel.
(8) Remove the bezel from the instrument panel.
(9) Disconnect the wire connector from back of the
rear blower switch, if equipped.
(10) Disconnect the wire connector from the back
of the HVAC Control.
(11) Remove the bezel.
Fig. 52 Power Mirror Switch
Fig. 53 Power Mirror Switch Lamp
Fig. 54 Convenience Bin Access Cover
8E - 34 INSTRUMENT PANEL AND SYSTEMSNS
REMOVAL AND INSTALLATION (Continued)
Page 371 of 1938
INSTALLATION
(1) Hold the radio bezel up and connect the wire
connector into the back of the HVAC control.
(2) Connect the wire connector into back of the
rear blower switch, if equipped.
(3) Place the radio bezel in position on the instru-
ment panel.
(4) Install screws to hold the top of radio bezel to
instrument panel.
(5) Install screws to the hold bottom of the radio
bezel to the instrument panel.
(6) Install the access cover.
REAR HEATER-A/C SWITCH
REMOVAL
(1) Remove radio bezel and HVAC Control (Fig.
56).
(2) Remove screw holding rear heater-A/C switch
to radio bezel HVAC Control.
(3) Disengage hook holding bottom of switch to
radio bezel HVAC Control.
(4) Remove switch from radio bezel HVAC Control.
INSTALLATION
For instrument, reverse the above procedures.
REAR HEATER-A/C SWITCH LAMP
REMOVAL
(1) Remove radio bezel HVAC Control.(2) Rotate bulb socket counterclockwise one quar-
ter (Fig. 57).
(3) Pull bulb socket from switch.
INSTALLATION
For installation, reverse the above procedures.
TRACTION CONTROL SWITCH
REMOVAL
(1) Remove the over steering column bezel (Fig.
51). Refer to Over Steering Column Bezel Removal
procedure.
(2) Remove the two screws attaching traction con-
trol switch to the bezel.
INSTALLATION
For installation, reverse the above procedure.
Fig. 55 Radio Bezel and HVAC Control
Fig. 56 Rear Heater ± A/C Switch
Fig. 57 Rear Heater-A/C Switch Lamp Bulb
NSINSTRUMENT PANEL AND SYSTEMS 8E - 35
REMOVAL AND INSTALLATION (Continued)
Page 373 of 1938
INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION........................ 1
DESCRIPTION AND OPERATION
HEADLAMP AND POWER MIRROR
SWITCH LAMP(S)..................... 1
INSTRUMENT CLUSTER................. 2
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES.............. 2
HEADLAMP SWITCH.................... 2
SELF DIAGNOSTIC TEST................. 3
REMOVAL AND INSTALLATION
ASH RECEIVER ± CONVENIENCE
BIN LAMP MODULE.................. 15
BODY CONTROL MODULE (BCM)......... 16
CIGAR LIGHTER BASE.................. 16
CONVENIENCE BIN.................... 15
CONVENIENCE BIN - CUP HOLDER....... 15
GLOVE BOX.......................... 17
GLOVE BOX LAMP AND SWITCH......... 17
GLOVE BOX LOCK STRIKER............. 17
HEADLAMP SWITCH................... 18
HEADLAMP SWITCH LAMP(S)........... 18
HVAC CONTROL LAMP................. 18
INSTRUMENT CLUSTER................ 20INSTRUMENT CLUSTER BACK PANEL..... 18
INSTRUMENT CLUSTER BEZEL.......... 18
INSTRUMENT CLUSTER LENS........... 19
INSTRUMENT CLUSTER PRINTED
CIRCUIT BOARD..................... 19
INSTRUMENT CLUSTER SUBDIAL........ 20
INSTRUMENT PANEL................... 20
INSTRUMENT PANEL LEFT END COVER.... 22
INSTRUMENT PANEL LOUVERS.......... 22
INSTRUMENT PANEL RIGHT END COVER . . 25
INSTRUMENT PANEL TOP COVER........ 24
JUNCTION BLOCK..................... 25
KNEE BLOCKER REINFORCEMENT........ 25
LOWER CONSOLE..................... 26
LOWER INSTRUMENT PANEL............ 26
LOWER STEERING COLUMN COVER...... 27
MESSAGE CENTER.................... 27
OVER STEERING COLUMN BEZEL........ 28
POWER MIRROR SWITCH.............. 28
POWER MIRROR SWITCH LAMP......... 28
RADIO BEZEL AND HVAC CONTROL....... 29
REAR HEATER-A/C SWITCH............. 29
REAR HEATER-A/C SWITCH LAMP........ 29
GENERAL INFORMATION
INTRODUCTION
The instrumentation gauges on GS vehicles are
contained in a subdial assemblies within the instru-
ment cluster. The individual gauges are not serviced
separately. If one of the cluster gauges becomes
faulty the entire subdial would require replacement
and all gauges will have to be calibrated. Refer to the
proper Body Diagnostic Procedure Manual for cali-
bration procedures.
DESCRIPTION AND OPERATION
HEADLAMP AND POWER MIRROR SWITCH
LAMP(S)
The Headlamp Switch and Power Mirror Switch
lamps are shown in (Fig. 1). For replacement of the
lamp(s) refer to Headlamp Switch Lamp(s) Removal
and Installation procedures below. Refer to Group 8T,
Power Mirrors for mirror test procedures.
NS/GSINSTRUMENT PANEL AND SYSTEMS 8E - 1
Page 388 of 1938
INSTALLATION
For installation, reverse the above procedures.
BODY CONTROL MODULE (BCM)
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove lower steering column cover and knee
blocker reinforcement.
(3) Disconnect two wire connectors from bottom of
Body Control Module (BCM)
(4) Remove bolts holding Junction Block to dash
panel mounting bracket (Fig. 8).
(5) Remove Junction Block from mounting bracket.
(6) Remove screws holding Body Control Module to
Junction Block.(7) Slide Body Control Module downward to disen-
gage guide studs on Junction Block from channels on
BCM mounting bracket.
(8) Remove Body Control Module from Junction
Block.
INSTALLATION
For installation, reverse the above procedures.
CIGAR LIGHTER BASE
REMOVAL
(1) Look inside and note position of the retaining
bosses (Fig. 9).
(2) Using external snap ring pliers with 90 degree
tips. Insert pliers with tips against bosses and
squeeze forcing bosses out of base.
(3) Pull out base, through mounting ring, gently
rocking pliers.
(4) Disconnect the base wires.
(5) Set base aside. Remove light ring and discon-
nect wire.
INSTALLATION
(1) Connect wire to light ring and install ring.
(2) Connect wires to base.
(3) Push base into the bezel till it locks.
(4) Install lighter element and check operation of
element.
Fig. 7 Ash Receiver/Cup Holder Track RHD
Fig. 8 Body Control Module Location
Fig. 9 Cigar Lighter Base Removal
8E - 16 INSTRUMENT PANEL AND SYSTEMSNS/GS
REMOVAL AND INSTALLATION (Continued)
Page 390 of 1938
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)
Page 391 of 1938
(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)