front lighting CHRYSLER VOYAGER 2002 Service Manual

SUPPORT PLATE - DRUM BRAKE
REMOVAL.............................64
INSTALLATION.........................64
WHEEL CYLINDERS
REMOVAL.............................65
INSPECTION..........................65
INSTALLATION.........................65
PARKING BRAKE
DESCRIPTION
DESCRIPTION........................65
DESCRIPTION - EXPORT...............66
OPERATION...........................66
STANDARD PROCEDURE
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RELEASE...........................66
STANDARD PROCEDURE - PARKING
BRAKE AUTOMATIC ADJUSTER TENSION
RESET.............................67
CABLES - PARKING BRAKE
REMOVAL
REMOVAL - PARKING BRAKE CABLE
(FRONT)............................67
REMOVAL - PARKING BRAKE CABLE
(INTERMEDIATE)......................68
REMOVAL - PARKING BRAKE CABLE
(RIGHT REAR)........................69
REMOVAL - PARKING BRAKE CABLE (LEFT
REAR)..............................70INSTALLATION
INSTALLATION - PARKING BRAKE CABLE
(FRONT)............................71
INSTALLATION - PARKING BRAKE CABLE
(INTERMEDIATE)......................71
INSTALLATION - PARKING BRAKE CABLE
(RIGHT REAR)........................72
INSTALLATION - PARKING BRAKE CABLE
(LEFT REAR).........................72
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE CABLES . 72
CABLES - PARKING BRAKE (EXPORT)
REMOVAL - FRONT CABLE...............72
INSTALLATION - FRONT CABLE............72
LEVER - PARKING BRAKE
REMOVAL.............................72
INSTALLATION.........................73
LEVER - PARKING BRAKE (EXPORT)
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE.......................74
INSTALLATION - PARKING BRAKE LEVER
AND FRONT CABLE...................75
SHOES - PARKING BRAKE
REMOVAL.............................75
INSTALLATION.........................81
ADJUSTMENTS
ADJUSTMENT - PARKING BRAKE SHOES . . 83
BRAKES - BASE
DESCRIPTION
DESCRIPTION - BASE BRAKES
The base brake system consists of the following
components:
²Brake pedal
²Power brake booster
²Master cylinder
²Brake tubes and hoses
²Proportioning valve (non-ABS vehicles only)
²Disc brakes
²Drum brakes
²Brake lamp switch
²Brake fluid level switch
²Parking brakes
Front disc brakes control the braking of the front
wheels; rear braking is controlled by rear drum
brakes or rear disc brakes depending on options.
The hydraulic brake system is diagonally split on
both the non-antilock braking systems and antilock
braking systems. That means the left front and right
rear brakes are on one hydraulic circuit and the right
front and left rear are on the other.For information on the brake lamp switch, (Refer
to 8 - ELECTRICAL/LAMPS/LIGHTING - EXTERI-
OR/BRAKE LAMP SWITCH - DESCRIPTION)
Vehicles equipped with the optional antilock brake
system (ABS) use a system designated Mark 20e. It
is available with or without traction control. This
system shares most base brake hardware used on
vehicles without ABS. ABS components are described
in detail in ANTILOCK BRAKE SYSTEM.
DESCRIPTION - BASE BRAKES (EXPORT)
Four-Wheel Disc Antilock Brakes are standard on
all models.
OPERATION - BASE BRAKES
When a vehicle needs to be stopped, the driver
applies the brake pedal. The brake pedal pushes the
input rod of the power brake booster into the booster.
The booster uses vacuum to ease pedal effort as force
is transferred through the booster to the master cyl-
inder. The booster's output rod pushes in the master
cylinder's primary and secondary pistons applying
hydraulic pressure through the chassis brake tubes
to the brakes at each tire and wheel assembly.
The parking brakes are foot-operated. When
applied, the parking brake lever pulls on cables that
actuate brake shoes at each rear wheel. These shoes
RSBRAKES - BASE5-3
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the brake pedal torque shaft pin where it contacts
the brake pedal link.
CAUTION: When installing the power brake booster
input rod on the brake pedal torque shaft pin, do
not reuse the old retaining clip.
(6) Install booster input rod on brake pedal torque
shaft pin and install a NEW retaining clip (Fig. 73).
CAUTION: When installing the brake pedal link on
the brake pedal torque shaft pin, do not reuse the
old retaining clip.
(7) Connect the brake pedal link to the torque
shaft. Install a NEW retaining clip at the torque
shaft end of the brake pedal-to-torque shaft link.
(8) Install the HVAC housing. (Refer to 24 - HEAT-
ING & AIR CONDITIONING/DISTRIBUTION/HVAC
HOUSING - INSTALLATION)
(9) Install the instrument panel. (Refer to 23 -
BODY/INSTRUMENT PANEL/INSTRUMENT
PANEL ASSEMBLY - INSTALLATION)CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(10) Remove and replace the brake lamp switch
with a NEW switch. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - REMOVAL), (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - INSTALLATION)
(11) Road test vehicle to ensure proper operation of
the brakes.
POWER BRAKE BOOSTER
DESCRIPTION
The power brake booster mounts on the engine
compartment side of the dash panel. It is connected
to the brake pedal by the input (push) rod (Fig. 75).
The master cylinder is bolted to the front of the
booster. A vacuum line connects the power brake
booster to the intake manifold.
Fig. 74 BOOSTER, TORQUE SHAFT AND PEDAL
MOUNTING
1 - PEDAL MOUNTING NUT
2 - BRAKE PEDAL ASSEMBLY
3 - PEDAL MOUNTING NUT
4 - PEDAL TORQUE SHAFT
5 - BOOSTER MOUNTING NUT
6 - BOOSTER BRACKET
7 - POWER BRAKE BOOSTER
8 - BOOSTER BRACKET MOUNTING NUT
Fig. 75 Power Brake Booster (Typical)
1 - VACUUM CHECK VALVE
2 - POWER BRAKE BOOSTER ASSEMBLY
3 - INPUT ROD
4 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING
STUDS (4)
5 - MASTER CYLINDER MOUNTING STUDS (2)
6 - OUTPUT ROD
5 - 48 BRAKES - BASERS
PEDAL TORQUE SHAFT - RHD (Continued)
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interior lamps after 15 minutes after the ignition is
turned off, if they are not turned off by the driver.
²Chime Driver
²Compass/Mini-Trip support.
²Interior Lighting (Courtesy/Reading Lamps)
²BCM Diagnostic Reporting
²Electronic Liftgate Release (with Power Door
Locks)
²Exterior Lighting
²Headlamp Time Delay (with/without Automatic
Headlamps)
²Illuminated Entry
²Fade to Off Interior Lamps - This feature dims
the interior lighting (courtesy lamps) gradually if theBCM does not receive any new inputs that would
cause the interior lamps to remain on.
²Pulse Width Modulated Instrument Panel Dim-
ming
²Door Lock Inhibit - This feature disables the
door lock functions if the key is in the ignition and
either front door is ajar. Pressing the Remote Keyless
Entry (RKE) lock/unlock button under these condi-
tions result in normal lock/unlock activation.
The BCM has the ability to LEARN additional fea-
tures in the vehicle, provided the appropriate switch
input and PCI data bus messages are received. Refer
to the LEARNED FEATURES table.
LEARNED FEATURES
FEATURE LEARNING KEY
CENTRAL LOCKING (WITH VTSS ONLY) DRIVER/PASSENGER KEY CYLINDER SWITCH
PRESENT
AUTOMATIC HEADLAMPS PCI MESSAGE FROM OVERHEAD OR HEADLAMP
SWITCH POSITION (AUTO)
REMOTE KEYLESS ENTRY RKE MESSAGE RECEIVED FROM MODULE
FRONT FOG LAMPS HEADLAMP SWITCH POSITION (PARK W/FRONT
FOG LAMPS)
POWER SLIDING DOOR PCI IFR RECEIVED FROM MODULE
THE BCM HAS FOUR SWITCH INPUTS FOR THE POWER SLIDING DOOR FEATURE; LOCATED IN THE
OVERHEAD CONSOLE ARE THE LEFT AND RIGHT SIDE SLIDING DOOR SWITCHES TO ACTIVATE EITHER
OR BOTH SLIDING DOORS UNDER THE PROPER CONDITIONS. ALSO ARE B-PILLAR SWITCHES LOCATED
ON THE LEFT AND RIGHT B-PILLAR POSTS.
POWER LIFTGATE PCI IFR RECEIVED FROM MODULE
THE BCM HAS ONE LIFTGATE INPUT LOCATED IN THE OVERHEAD CONSOLE.
POWER LOCKOUT SWITCH INPUT
THE BCM HAS ONE LOCKOUT SWITCH INPUT THAT WHEN ENABLED WILL DISABLE THE B-PILLAR
SLIDING DOOR SWITCHES FROM ACTIVATING EITHER SLIDING DOOR WHEN DEPRESSED.
PCI AUDIO SYSTEM PCI MESSAGE RECEIVED FROM MODULE
NOTE: SWAPPING OUT A HIGHLINE RADIO FOR A NON-PCI BUS RADIO (RAS) WILL RESULT IN IMPROPER
HARDWIRE COMMUNICATION BETWEEN THE BCM AND THE NEW RAS RADIO. THE LCD DISPLAY WILL
NOT ILLUMINATE PROPERLY DUE TO THE BCM LEARNING THAT A PCI RADIO EXISTS. HOWEVER, THE
BCM CAN RE-INITIALIZE LEARNED FEATURES VIA THE USE OF THE DRB IIITSCAN TOOL.
REMOTE RADIO CONTROLS REMOTE RADIO SWITCHES PRESENT
VEHICLE THEFT SECURITY DRIVER/PASSENGER DOOR CYLINDER LOCK
SWITCH
MEMORY SEAT AND MIRRORS MEMORY SEAT SWITCH PRESENT AND OR PCI
MESSAGE RECEIVED FROM MEMORY MODULE
ABS W/TRACTION CONTROL PCI MESSAGE RECEIVED FROM CAB
SENTRY KEY IMMOBILIZER SYSTEM PCI MESSAGE RECEIVED FROM SKIM OR VTSS
PRESENT
ADJUSTABLE PEDAL MODULE PCI MESSAGE RECEIVED FROM ADJUSTABLE
PEDAL MODULE (APM)
8E - 4 ELECTRONIC CONTROL MODULESRS
BODY CONTROL MODULE (Continued)
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Programming Key Failed (Possible Used Key From
Wrong Vehicle) - SKIM is unable to program key due
to one of the following:
²faulty ignition key transponder
²ignition key is programmed to another vehicle.
8 Keys Already Learned, Programming Not Done -
SKIM transponder ID memory is full.
(5) Obtain ignition keys to be programmed from
customer (8 keys maximum).
(6) Using the DRB III, erase all ignition keys by
selecting MISCELLANEOUS and ERASE ALL CUR-
RENT IGN. KEYS.
(7) Program all ignition keys.
Learned Key In Ignition - Ignition key transponder
ID is currently programmed in SKIM memory.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove left front headlamp module (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - REMOVAL).
(3) Remove lower headlamp assembly mounting
bolt (Fig. 2).(4) Remove ECM upper mounting bolts (Fig. 3).
(5) Lift ECM from radiator support.
(6) Disconnect ECM electrical connectors.
(7) Separate ECM from mounting bracket.
INSTALLATION
(1) Install ECM on mounting bracket.
(2) Connect ECM electrical connectors.
(3) Place ECM and bracket assembly in position on
radiator support.
(4) Install upper and lower mounting bolts.
(5) Install left headlamp module (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP UNIT - INSTALLATION).
(6) Connect negative battery cable.
(7) Program ECM as necessary (Refer to 8 - ELEC-
TRICAL/ELECTRONIC CONTROL MODULES/EN-
GINE CONTROL MODULE - STANDARD
PROCEDURE).
Fig. 2 ENGINE CONTROL MODULE-LOWER
MOUNTING BOLT
1 - ENGINE CONTROL MODULE (ECM)
2 - INTEGRATED POWER MODULE
3 - ECM LOWER MOUNTING BOLT
Fig. 3 ENGINE CONTROL MODULE-UPPER
MOUNTING BOLTS
1 - BATTERY
2 - INTEGRATED POWER MODULE
3 - ENGINE CONTROL MODULE
4 - RADIATOR SUPPORT
5 - ECM UPPER MOUNTING BOLTS
6 - ECM ELECTRICAL CONNECTORS
8Ea - 4 ELECTRONIC CONTROL MODULESRG
ENGINE CONTROL MODULE (Continued)
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LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR............... 1LAMPS/LIGHTING - INTERIOR............... 25
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION..........................2
OPERATION............................3
WARNING.............................3
SPECIFICATIONS
EXTERIOR LAMPS.....................4
BRAKE LAMP SWITCH
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH.............................4
REMOVAL.............................5
INSTALLATION..........................6
CENTER HIGH MOUNTED STOP LAMP
REMOVAL.............................6
INSTALLATION..........................6
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL.............................6
INSTALLATION..........................6
FOG LAMP
DIAGNOSIS AND TESTING - FOG LAMP......7
REMOVAL.............................9
INSTALLATION..........................9
FOG LAMP - EXPORT
REMOVAL.............................9
INSTALLATION..........................9
FOG LAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - FOG LAMP
UNIT ALIGNMENT.....................10
STANDARD PROCEDURE - FOG LAMP
UNIT ALIGNMENT - EXPORT.............10
REMOVAL.............................11
INSTALLATION.........................11
FRONT POSITION LAMP - EXPORT
REMOVAL.............................11
INSTALLATION.........................11HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP.....12
REMOVAL.............................14
INSTALLATION.........................14
HEADLAMP - EXPORT
REMOVAL.............................14
INSTALLATION.........................14
HEADLAMP LEVELING MOTOR - EXPORT
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING MOTOR - EXPORT............15
REMOVAL.............................15
INSTALLATION.........................15
HEADLAMP LEVELING SWITCH - EXPORT
DESCRIPTION.........................16
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING SWITCH - EXPORT...........16
HEADLAMP SWITCH
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH............................16
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH - EXPORT....................17
REMOVAL.............................17
INSTALLATION.........................17
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP
UNIT ALIGNMENT.....................17
STANDARD PROCEDURE - HEADLAMP
UNIT ALIGNMENT - EXPORT.............19
REMOVAL.............................19
INSTALLATION.........................20
LICENSE LAMP
REMOVAL.............................21
INSTALLATION.........................21
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM.....21
RSLAMPS8L-1
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OPERATION - TURN SIGNAL SYSTEM.......21
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH...................22
REMOVAL.............................22
INSTALLATION.........................22
PARK/TURN SIGNAL LAMP
REMOVAL.............................22
INSTALLATION.........................22
PARK/TURN SIGNAL LAMP - EXPORT
REMOVAL.............................22
INSTALLATION.........................23
REAR FOG LAMP - EXPORT
DESCRIPTION.........................23REPEATER LAMP - EXPORT
REMOVAL.............................23
INSTALLATION.........................23
TAIL LAMP
REMOVAL.............................23
INSTALLATION.........................23
TAIL LAMP - EXPORT
REMOVAL.............................23
INSTALLATION.........................24
TAIL LAMP UNIT
REMOVAL.............................24
INSTALLATION.........................24
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power source,
on/off device, lamps and body ground to operate prop-
erly. Plastic lamps require a wire in the harness to
supply body ground to the lamp socket. Replace sock-
ets and bulbs that are corroded.
Some of the interior and exterior lighting functions
are governed by the Body Control Module (BCM).
The headlamp, dome, and the door ajar switches pro-
vide signals to the BCM. The BCM in turn sends a
Programmable Communication Interface (PCI) bus
message to the Front Control Module (FCM) to
enable the necessary drivers to set the required illu-
mination configuration.
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 intelligent power
module. Verify that bulbs are in good condition and
test continuity of the circuit ground. Refer to the
appropriate wiring information.
AUTOMATIC HEADLAMP SYSTEM
The Automatic Headlamp system turns the instru-
mentation and exterior illumination lamps ON when
the ambient light levels are Night and the engine
RPM is 450 or above, and OFF when light levels are
Day.
DAYTIME RUNNING LAMPS
Operating the high-beam headlamps at reduced
power provides daytime running lamps, which are
required on all new Canadian vehicles.
HEADLAMPS ON WITH WINDSHIELD WIPERS
For vehicles equipped with the Automatic Head-
lamp System, the instrumentation and exterior illu-
mination lamps will be turned ON when the
headlamp switch is in the AUTO position, RPM >
450 and the windshield wipers have been in the
intermittent, low or high mode of operation for more
than ten seconds. When the windshield wipers are
turned OFF the Body Control Module will determine
if the instrumentation and exterior illumination
lamps should remain ON base upon the current
ambient light level.
HEADLAMP SYSTEM
The configuration of the headlamp system of head-
lamps, park lamps and fog lamps is determined by
the BCM. The BCM determines the lighting configu-
ration as a result of the inputs from the ignition
switch, headlamp switch and multi-function switch. A
PCI bus is transmitted from the BCM to the FCM to
enable the necessary drivers to set the illumination
configuration. Four wires are connected between the
headlamp switch and the BCM. The first wire con-
tains information regarding the position of the head-
lamp switch (Off, Automatic Headlamps, Automatic
Headlamp switch fog, Park with Fog, Head, or Head
with Fog Lamps). The second wire contains informa-
tion regarding the position of the dimmer switch
(Dome Lamp, Daytime Brightness, Dimming Level or
Off). The third wire is a dedicated signal return
(ground) wire. The fourth wire provides power to the
front fog lamp indicator.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is controlled by
the Body Control Module (BCM) via a PCI bus mes-
8L - 2 LAMPS/LIGHTING - EXTERIORRS
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sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body Con-
trol Module (BCM). With the headlamp switch in the
AUTO position, the BCM will control the headlamp, park-
ing, side marker, tail and instrumentation lamps based on
ambient light levels. Ambient light levels are monitored
by the BCM using the Day/Night signal and Electrochro-
matic Mirror (ECM) present from the Compass Mini Trip
(CMTC) located on the front windshield in front of the
rear view mirror ECM. Ambient light readings are aver-
aged to limit cycling the lamps ON and OFF when pass-
ing through areas with varying light levels. The
automatic headlamps will only function when the engine
is running with RPM > 450. When the headlamp switch is
in the AUTO position (Automatic mode), the Headlamp
Time Delay system will function when the ignition switch
is placed in any position other than run/start.
DAYTIME RUNNING LAMPS
Power is reduced using pulse-width modulation to
the high beams, where by the power is switched on
and off rapidly instead of remaining on continuously.
The duration and interval of the power pulses is pro-
grammed into the FCM.
HEADLAMP SYSTEM
The headlamp system will default to headlamps
ON position when ignition switch is ON and when an
open or short circuit failure occurs on the headlamp
switch input. The system will return to normal oper-
ation when the open or short is repaired. A fault will
be reported by the BCM when a failure occurs on the
dimmer or headlamp switch input.
If the exterior lamps are ON and the headlamp
switch is in any position other than OFF or AUTO
and with the ignition switch OFF (LOCK) after 3
minutes the BCM sends a message via PCI bus to
the FCM informing the FCM to turn off the head-
lamps, park lamps and fog lamps. This feature pre-
vents the vehicle battery from being discharged when
the vehicle lights have been left ON.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is activated by
turning the headlamps ON (high or low beam) while
the engine is running, turning the ignition switch
OFF, and then turning the headlamp switch OFF
within 45 seconds. The system will not activate if
more than 45 seconds elapse between ignition switch
OFF and headlamp switch OFF. The BCM will allow
the headlamps to remain ON for 90 seconds (config-urable) before they automatically turn off (If the key
is in the ignition during the headlamp time delay
mode, then both the headlamps and park lamps
(including panel dimming) will be ON). Refer to the
Owner's Manual for more information.
If the headlamp switch is in the Auto Headlamp
Position, the headlamps are ON due to the night sig-
nal from the CMTC and the ignition switch is in any
position other than run/start, the BCM shall enter a
90 second (configurable) Auto Headlamps time delay
mode. If the key is in the ignition during the head-
lamp time delay mode, then both the headlamps and
park lamps (including panel dimming) will be ON. If
the key is not in the ignition, then only the head-
lamps will be ON. The BCM will allow the head-
lamps to remain ON for 90 seconds before they
automatically turn OFF. Refer to the Owner's Man-
ual for more information.
OPTICAL HORN/HIGH BEAMS
When the multi-function switch is pulled to the
first detent (optical horn) signal, the headlamps are
ON, key-in the ignition the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers to illuminate all four filaments (Low
and High beams). When the multi-function switch is
pulled to the second detent (high beam) signal and
the headlamps are ON, the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers. The High Beams are illuminated and
the Low Beams and Fog Lamps (if ON) are extin-
guished. If the headlamps were in the high beam
configuration when power was removed from the
headlamps, the headlamps will be configured as low
beam the next time they are activated.
WARNING
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 other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
CAUTION: Do not use bulbs other than those listed
in the Bulb Application Table. Damage to lamp can
result. Do not touch halogen bulbs with fingers or
other oily surfaces. Bulb life will be reduced.
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)
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SPECIFICATIONS
EXTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3057
CHMSL 921
FRONT SIDE MARKER/PARK/
TURN3157A
FOG LAMP 9040
HEADLAMP 9007
LICENSE 168
TAIL, STOP 3057
TURN SIGNAL 3057
BULB APPLICATION TABLE - EXPORT
LAMP BULB
HEADLAMP H7
FRONT POSITION W5W
FRONT TURN SIGNAL PY21W
SIDE REPEATER T4W
LICENSE PLATE W5W/168
REAR TAIL AND STOP P21/5W
REAR TURN SIGNAL PY21W
BACK-UP P21W
REAR FOG P21W
CHMSL W16W/921
BRAKE LAMP SWITCH
DESCRIPTION
The brake lamp switch is located under the instru-
ment panel, at the brake pedal arm (Fig. 3). It has
three internal switches controlling various functions
of the vehicle. It's main function is to control opera-
tion of the vehicle's brake lamps. Other functions
include speed control deactivation, brake sense for
the antilock brake system and brake sense for the
brake transmission shift interlock.
CAUTION: The switch can only be adjusted once.
That is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
OPERATION
When the brake pedal is pressed, the plunger on
the outside of the brake lamp switch extends out-
ward. This action opens or closes the contacts of the
three switches inside the brake lamp switch.
With the brake pedal pressed down (plunger
extended), the switch for terminals 1 and 2 is closed
completing the circuit. The switch for terminals 3
and 4 is open and so is the switch for terminals 5
and 6.
When the brake pedal is released (plunger pushed
in), the three switches assume the opposite positions.
The switch for terminals 1 and 2 is now open while
the other two switches are now closed, completing
their circuits.
A lever on the back of the switch is used to set the
switch into the ªadjustedº position. A non-adjusted
switch will have the lever set to the diagonal position
in relation to the switch housing. The plunger can be
moved in and out, but the states of the internal
switches will not change.
CAUTION: Never move the adjustment lever of the
new brake lamp switch without it being properly
installed in the vehicle first. Such action will render
the switch unusable and the switch must be dis-
carded.
Once installed in the vehicle as described in the
brake lamp switch installation procedure (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION), the new
switch's adjustment lever is rotated to the adjusted
position as indicated (Fig. 4). This action locks the
plunger to the internal switches.Once in this posi-
tion the switch is permanently adjusted (or
locked) and cannot be readjusted or released
even if the lever is moved back.
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
NOTE: Before proceeding with this diagnostic test,
verify the adjustment lever on the back of the
switch is in the adjusted position. If the lever is in
the non-adjusted (diagonal) position it may have
never been adjusted (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - OPERATION). For adjustment, (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION)
If the electrical circuit has been tested and the
brake lamp switch is suspected of being faulty, it can
be tested using the following method.
8L - 4 LAMPS/LIGHTING - EXTERIORRS
LAMPS/LIGHTING - EXTERIOR (Continued)
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FOG LAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - FOG LAMP UNIT
ALIGNMENT
FOG LAMP UNIT ALIGNMENT
Prepare an alignment screen (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - STANDARD PROCEDURE). 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. 9). To
improve visual interpretation of the fog lamp patternon the alignment screen, the headlamps should be in
the ªoffº position.
The fog lamps are adjusted by a adjustment screw
located through the lens on Dodge vehicles, and by a
knob on the back of the lamp.
STANDARD PROCEDURE - FOG LAMP UNIT
ALIGNMENT - EXPORT
Prepare an alignment screen (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - STANDARD PROCEDURE). A
properly aligned fog lamp will project a pattern on
the alignment screen 200 mm (8 in.) below the fog
lamp center line and straight ahead (Fig. 10). To
improve visual interpretation of the fog lamp pattern
on the alignment screen, the headlamps should be in
the ªoffº position.
Fig. 9 FOG LAMP UNIT ALIGNMENT
1 - HIGH INTENSITY AREA 4 - 100MM (4 IN.)
2 - CENTER OF VEHICLE 5 - 7.62 METERS (25 FT.)
3 - HORIZONTAL CENTER OF FOG LAMP 6 - FRONT OF FOG LAMP
8L - 10 LAMPS/LIGHTING - EXTERIORRS
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The fog lamps are adjusted by a adjustment screw
located on the underside of the fog lamp unit.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) From behind the bumper fascia, disconnect the
wire harness from the fog lamp bulb (Fig. 7).
(3) Remove mounting nuts.
INSTALLATION
(1) Install mounting nuts.
(2) Reconnect the wire harness to the fog lamp
bulb.
(3) Reconnect the battery negative cable.
FRONT POSITION LAMP -
EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the headlamp unit (Fig. 11).
(3) Remove the plastic cover from the back of the
headlamp unit.
(4) Pull front position lamp socket from headlamp
unit.
(5) Pull bulb straight out of socket.
INSTALLATION
(1) Push bulb into the bulb socket.
(2) Insert bulb socket into headlamp unit.
(3) Install cover to the back of the headlamp unit.
Fig. 10 FOG LAMP UNIT ALIGNMENT - EXPORT
1 - HIGH INTENSITY AREA 4 - 200 MM
2 - CENTER OF VEHICLE 5 - 10 METERS
3 - HORIZONTAL CENTER OF FOG LAMP UNIT 6 - FRONT OF FOG LAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-11
FOG LAMP UNIT (Continued)
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