front lighting CHRYSLER VOYAGER 2002 Owner's Manual

OPERATION
FRONT WIPER/WASHER SYSTEM
The windshield washer circuit is protected by a 15
amp Cartridge Fuse located in the IPM. The wiper
motor has permanent magnetic fields. The speeds are
determined by current flow to the appropriate set of
brushes inside the motor. The current flow is con-
trolled by the multi-function switch. The high speed/
low speed relays are located in the IPM. The speed
sensitive intermittent wiper is controlled by the Body
Control 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, the 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.
REAR WIPER/WASHER SYSTEM
When continuous rear wiper operation is required,
the 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 than 50
mph, the cycle changes to every 5 seconds.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - FRONT WIPER
SYSTEM
The windshield wiper system operates in several
modes:
²Low and high speed normal wipe²Speed sensitive intermittent wipe
²Wipe after wash
²Park (switch OFF)
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. DTC's can
be retrieved using a DRB IIItscan tool. Refer to the
proper Body Diagnostic Procedures manual for DTC
descriptions and retrieval information.
The windshield wiper park switch and circuit is
monitored by the BCM. The park switch and circuit
can be tested using the Wiper System Diagnosis
table.
DIAGNOSIS AND TESTING - FRONT
WIPER/WASHER SWITCH
(1) Remove the multi-function switch (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
MULTI-FUNCTION SWITCH - REMOVAL).
(2) Using an ohmmeter check resistance readings
between switch pins. Refer to the WIPER/WASHER
SWITCH RESISTANCE table.
WIPER/WASHER SWITCH RESISTANCE
SWITCH POSITION RESISTANCE BETWEEN
OFF 4 AND 3 = OPEN CIRCUIT
DELAY POSITION
1ST 3 AND 4 = 3.3KV 5%
2ND 3 AND 4 = 1.7KV 5%
3RD 3AND4=1KV 5%
4TH 3 AND 4 = 620V 5%
5TH 3 AND 4 = 620V 5%
LOW 3 AND 4 = 430V 5%
HIGH 3 AND4=240V 5%
WASH 1 AND 3 = 5.9KV 5%
8R - 2 WIPERS/WASHERSRS
WIPERS/WASHERS (Continued)
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WIRING
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION....... 8W-01-1
COMPONENT INDEX.................. 8W-02-1
POWER DISTRIBUTION............... 8W-10-1
GROUND DISTRIBUTION.............. 8W-15-1
BUS COMMUNICATIONS.............. 8W-18-1
CHARGING SYSTEM.................. 8W-20-1
STARTING SYSTEM.................. 8W-21-1
FUEL/IGNITION SYSTEM.............. 8W-30-1
TRANSMISSION CONTROL SYSTEM..... 8W-31-1
VEHICLE SPEED CONTROL............ 8W-33-1
ANTILOCK BRAKES................... 8W-35-1
VEHICLE THEFT SECURITY SYSTEM..... 8W-39-1
INSTRUMENT CLUSTER............... 8W-40-1
HORN/CIGAR LIGHTER/POWER OUTLET . . 8W-41-1
AIR CONDITIONING-HEATER........... 8W-42-1
AIRBAG SYSTEM.................... 8W-43-1
INTERIOR LIGHTING.................. 8W-44-1
BODY CONTROL MODULE............. 8W-45-1MESSAGE CENTER................... 8W-46-1
AUDIO SYSTEM..................... 8W-47-1
REAR WINDOW DEFOGGER............ 8W-48-1
OVERHEAD CONSOLE................. 8W-49-1
FRONT LIGHTING.................... 8W-50-1
REAR LIGHTING..................... 8W-51-1
TURN SIGNALS...................... 8W-52-1
WIPERS............................ 8W-53-1
TRAILER TOW....................... 8W-54-1
POWER WINDOWS................... 8W-60-1
POWER DOOR LOCKS................ 8W-61-1
POWER MIRRORS................... 8W-62-1
POWER SEATS...................... 8W-63-1
SPLICE INFORMATION................ 8W-70-1
CONNECTOR PIN-OUTS............... 8W-80-1
CONNECTOR/GROUND/SPLICE
LOCATION........................ 8W-91-1
POWER DISTRIBUTION SYSTEM........ 8W-97-1 RSWIRING
8W-1
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8W-44 INTERIOR LIGHTING
Component Page
A/C- Heater Control.................. 8W-44-8
Accessory Relay..................... 8W-44-4
Auto Temp Control................... 8W-44-8
Body Control Module...... 8W-44-2, 3, 4, 5, 6, 7, 8
Center Dome Lamp................... 8W-44-5
Driver Door Courtesy Lamp............ 8W-44-2
Floor Console Lamp.................. 8W-44-4
Front Cigar Lighter.................. 8W-44-7
Front Control Module................. 8W-44-4
Front Reading Lamps/Switch......... 8W-44-4, 5
Fuse 6............................. 8W-44-4
G200........................ 8W-44-2, 5, 7, 8
G300............................ 8W-44-2, 8
G301........................ 8W-44-2, 3, 5, 6
G302.............................. 8W-44-4
G400.............................. 8W-44-2
Glove Box Lamp..................... 8W-44-5
Halo Lamp......................... 8W-44-2
Headlamp Switch............ 8W-44-3, 5, 6, 7, 8Component Page
Instrument Cluster................... 8W-44-7
Instrument Panel Switch Bank.......... 8W-44-7
Integrated Power Module.............. 8W-44-4
Left Liftgate Flood Lamp.............. 8W-44-2
Left Mid Reading Lamp............... 8W-44-3
Left Rear Reading Lamp............... 8W-44-3
Left Visor/Vanity Lamp................ 8W-44-6
Overhead Console.................... 8W-44-5
Passenger Door Courtesy Lamp......... 8W-44-2
Power Mirror Switch.................. 8W-44-8
Radio............................. 8W-44-7
Rear Auto Temp Control Switch......... 8W-44-8
Rear Blower Rear Control Switch........ 8W-44-8
Rear Dome Lamp.................... 8W-44-5
Right Liftgate Flood Lamp............. 8W-44-2
Right Mid Reading Lamp.............. 8W-44-3
Right Rear Reading Lamp............. 8W-44-3
Right Visor/Vanity Lamp............... 8W-44-6
RS8W-44 INTERIOR LIGHTING8W-44-1
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8W-50 FRONT LIGHTING
Component Page
Body Control Module............. 8W-50-2, 4, 5
Diagnostic Junction Port........... 8W-50-5, 6, 8
Front Control Module . . 8W-50-3, 4, 6, 7, 8, 9, 10, 11
Front Fog Lamp Relay............... 8W-50-11
Fuse 1............................ 8W-50-11
Fuse 2........................... 8W-50-4, 6
Fuse 3.......................... 8W-50-4, 8
G102......................... 8W-50-4, 8, 11
G200........................... 8W-50-2, 10
G300.............................. 8W-50-3
Headlamp Switch................. 8W-50-2, 10
Integrated Power
Module......... 8W-50-3, 4, 5, 6, 7, 8, 9, 10, 11
Left Fog Lamp..................... 8W-50-11
Left Front Park/Turn Signal Lamp....... 8W-50-4Component Page
Left Headlamp...................... 8W-50-3
Left Headlamp Leveling Motor....... 8W-50-6, 10
Left High Beam Lamp.............. 8W-50-6, 7
Left Low Beam Lamp................. 8W-50-7
Left Park Lamp................... 8W-50-6, 7
Multi- Function Switch................ 8W-50-5
Park Lamp Relay................ 8W-50-4, 6, 8
Right Fog Lamp.................... 8W-50-11
Right Front Park/Turn Signal Lamp...... 8W-50-4
Right Headlamp..................... 8W-50-3
Right Headlamp Leveling Motor...... 8W-50-8, 10
Right High Beam Lamp............. 8W-50-8, 9
Right Low Beam Lamp................ 8W-50-9
Right Park Lamp.................. 8W-50-8, 9
RS8W-50 FRONT LIGHTING8W-50-1
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8W-51 REAR LIGHTING
Component Page
Back-Up Lamp Switch................ 8W-51-5
Battery............................ 8W-51-5
Body Control Module............ 8W-51-2, 3, 4, 5
Brake Lamp Switch................ 8W-51-2, 4
Center High Mounted Stop Lamp........ 8W-51-6
Front Control Module............. 8W-51-2, 4, 5
Fuse 2........................... 8W-51-2, 4
Fuse 3......................... 8W-51-2, 4, 5
Fuse 26.......................... 8W-51-2, 4
G101.............................. 8W-51-5
G103.............................. 8W-51-5Component Page
G302........................ 8W-51-2, 3, 4, 5
G400.............................. 8W-51-6
Integrated Power Module.......... 8W-51-2, 4, 5
Left Rear Lamp Assembly........ 8W-51-2, 3, 4, 5
Left Stop/Turn Signal Relay............ 8W-51-3
License Lamp....................... 8W-51-6
Park Lamp Relay................ 8W-51-2, 4, 5
Right Combination Relay.............. 8W-51-3
Right Rear Lamp Assembly......... 8W-51-2, 4, 5
Trailer Tow Connector................. 8W-51-3
RS8W-51 REAR LIGHTING8W-51-1
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C102 (3.3L/3.8L) - BLACK (POWERTRAIN SIDE)
CAV CIRCUIT
1 K342 16BR/WT
2 K1 18VT/BR
3 K11 16BR/YL
4 K12 16BR/DB
5 K13 16BR/LB
6 K14 16BR/TN
7 K900 18DB/DG
8 K38 16BR/OR
9 K58 16BR/VT
10 F855 18PK/YL
C103 (DIESEL) - BLACK (POWERTRAIN SIDE)
CAV CIRCUIT
1 K342 16BR/WT
2 K342 16BR/WT
3 N122 20DB/YL
4 N210 20DB/DG
5 A201 12RD/LG
6-
C103 (DIESEL) - BLACK (FRONT END LIGHTING
SIDE)
CAV CIRCUIT
1 K342 16BR/WT
2 K342 16BR/WT
3 N122 20DB/YL
4 N210 18DB/DG
5 A201 12RD/LG
6-
C106 (BUILT-UP-EXPORT) - BLACK (FRONT END
LIGHTING SIDE)
CAV CIRCUIT
1 L43 18WT/DB
2 L33 18WT/LG
3 L77 18WT/BR
4 L61 16WT/LG
5 Z343 18BK/LG
6 L13 20WT/YL
7 Z203 20BK/YL
8 Z377 18BK/BR
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTSRS
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C106 (BUILT-UP-EXPORT) - BLACK/YELLOW
(COMPONENT SIDE)
CAV CIRCUIT
1 L43 16WT
2 L33 16GY
3 L77 16BK
4 L61 16YL
5 Z343 16BR
6 L13 16RD
7 Z203 16BR
8-
C107 (BUILT-UP-EXPORT) - BLACK (FRONT END
LIGHTING SIDE)
CAV CIRCUIT
1 L44 16WT/TN
2 L34 16WT/GY
3 L78 18WT/OR
4 L60 16WT/TN
5 Z344 16BK/TN
6 L13 20WT/YL
7 Z203 20BK/YL
8 Z378 18BK/TN (DIESEL)
8 Z378 18BK/LB (GAS)
C107 (BUILT-UP-EXPORT) - BLACK/YELLOW
(COMPONENT SIDE)
CAV CIRCUIT
1 L44 16WT
2 L34 16GY
3 L78 16BK
4 L60 16YL
5 Z344 16BR
6 L13 16RD
7 Z203 16BR
8-
RS8W-80 CONNECTOR PIN-OUTS8W-80-19
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FRAME & BUMPERS
TABLE OF CONTENTS
page page
BUMPERS
SPECIFICATIONS - TORQUE...............1
FRONT FASCIA
REMOVAL.............................1
INSTALLATION..........................1
FRONT BUMPER REINFORCEMENT
REMOVAL.............................2
INSTALLATION..........................2
REAR FASCIA
REMOVAL.............................3
INSTALLATION..........................3
REAR BUMPER REINFORCEMENT
REMOVAL.............................3
INSTALLATION..........................3
REAR FASCIA - SCUFF PAD
REMOVAL.............................4INSTALLATION..........................4
FRAME
SPECIFICATIONS
FRAME DIMENSIONS...................4
SPECIFICATIONS - TORQUE.............9
FRONT CRADLE CROSSMEMBER
DESCRIPTION
DESCRIPTION - FRONT CRADLE
CROSSMEMBER.......................9
DESCRIPTION - FRONT CRADLE
CROSSMEMBER THREAD REPAIR.........9
REMOVAL.............................10
INSTALLATION.........................12
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL.............................12
INSTALLATION.........................12
BUMPERS
SPECIFICATIONS - TORQUE
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Front bumper reinforcement attaching nut 54 40 Ð
Rear bumper reinforcement attaching nut 27 20 Ð
FRONT FASCIA
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the headlamp assemblies (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - REMOVAL).
(3) Hoist vehicle and support with safety stands.
(4) Remove the five bolts attaching bottom of fas-
cia/air dam to radiator closure panel.
(5) Remove front wheels.
(6) Remove front wheelhouse splash shields fasten-
ers as necessary to gain access to bolts attaching
front fascia to fender. (Refer to 23 - BODY/EXTERI-
OR/ WHEELHOUSE SPLASH SHIELD - REMOV-
AL).
(7) Remove the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1).
(8) Disconnect fog lamp wire connectors, if neces-
sary.
(9) Lower vehicle.(10) Remove two bolts attaching the upper grille
support to the headlamp mounting panel at each side
of the grille.
(11) Remove bumper fascia from vehicle.
INSTALLATION
(1) Position front bumper fascia on vehicle.
(2) Install the two bolts attaching fascia to head-
lamp mounting panel at each side of grille.
(3) Hoist vehicle and support with safety stands.
(4) Install the two bolts and two nuts attaching
fascia to the front fenders (Fig. 1). The fascia should
be flush to fender.
(5) Install front wheelhouse splash shields fasten-
ers. (Refer to 23 - BODY/EXTERIOR/ WHEEL-
HOUSE SPLASH SHIELD - INSTALLATION).
(6) Install front wheels.
(7) Connect fog lamp wire connectors, if necessary.
(8) Install the five bolts attaching bottom of fascia
to radiator closure panel.
(9) Lower the vehicle.
RSFRAME & BUMPERS13-1
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(10) Install the headlamp assemblies. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP - INSTALLATION).
FRONT BUMPER
REINFORCEMENT
REMOVAL
(1) Remove front bumper fascia. (Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- REMOVAL)
(2) Support front bumper reinforcement on a suit-
able lifting device.
(3) Remove the four nuts attaching front bumper
reinforcement to frame rail (Fig. 2).
(4) Remove front bumper reinforcement from vehi-
cle.
INSTALLATION
NOTE: Check position of the arrows molded into
the foam for correct orientation.
(1) Support front bumper reinforcement using a
suitable lifting device and lift into position.
(2) Install the four nuts attaching reinforcement to
frame rails. Tighten nuts to 54 N´m (40 ft. lbs.)
torque.
(3) Install front fascia. (Refer to 13 - FRAMES &
BUMPERS/BUMPERS/FRONT FASCIA - INSTAL-
LATION).
Fig. 1 FRONT BUMPER FASCIA
1 - FRONT BUMPER FASCIA
2 - FRONT BUMPER REINFORCEMENT
3 - RADIATOR ENCLOSURE
Fig. 2 FRT BUMPER REINFORCEMENT
1 - FRONT BUMPER REINFORCEMENT
2 - FRAME RAILS
13 - 2 FRAME & BUMPERSRS
FRONT FASCIA (Continued)
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(4) Clean off all traces of adhesive or double sided
tape from the panel with a general purpose adhesive
remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Align badgeing to reference points.
(3) Install and press securely to full adhesive con-
tact
(4) Clean away any reference points.
EXTERIOR NAME PLATES -
ADHESIVE ATTACHED
REMOVAL
(1) Mark reference points before removing.
(2) Using a heat gun gently apply heat in a circu-
lar motion to loosen the adhesive bond.
(3) With your fingernail lift up and peel away
badgeing/tape from panel, using a heat gun as you
go.
(4) Clean off all traces of adhesive from the pan-
el(s) with a general purpose adhesive remover.
INSTALLATION
(1) Clean panel surface with isopropy alcohol.
(2) Remove paper carrier and align badgeing/tape
to reference points or adjacent panel.
(3) Install and press securely, using a plastic
spreader to eliminate all air bubbles.
(4) Remove top protective carrier.
(5) Clean away any reference points.
FRONT FENDER
REMOVAL
(1) Remove headlamp housing. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - REMOVAL)
(2) Remove mud guard.
(3) Remove inner splash shield.
(4) Remove fender to fascia nuts.
(5)
Remove outboard cowl grille/fender bracket screw.
(6) Remove fender bolt to lower rocker panel.
(7) Remove fender bolt to lower cowl.
(8) Pull fascia away from fender.
(9) Remove bolts attaching fender to upper rail.
(10) Remove fender from vehicle (Fig. 8).
INSTALLATION
(1) Place fender in position on vehicle.
(2) From inside engine compartment, start the
center upper rail bolt. install all the bolts attaching
fender to upper rail and tighten.
(3) Install fender to lower cowl panel bolt.
(4) Install fender to rocker panel bolt.
(5) Place fascia into position.
(6) Install outboard cowl grille/fender bracket
screw.
(7) Install fender to fascia nuts.
(8) Install inner splash shield.
(9) Install mud guard.
(10) Install headlamp assembly. (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - INSTALLATION)
(11) Check fender for flush and gap.
Fig. 8 FENDER
1 - FASTENERS 2 - FENDER
3 - FASTENERS
RSEXTERIOR23-51
EXTERIOR NAME PLATES - TAPE ATTACHED (Continued)
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