lock CHRYSLER VOYAGER 2005 Service Manual

REMOVAL
REMOVAL - 2.4L
The camshaft position sensor is mounted to the
rear of the cylinder head.
(1) Remove the negative battery cable.
(2) Disconnect electrical connectors from the cam-
shaft position sensor (Fig. 3).
(3) Remove camshaft position sensor mounting
screws. Remove sensor.
(4) Loosen screw attaching target magnet to rear
of camshaft and remove magnet (Fig. 4).
REMOVAL - 3.3/3.8L
(1) Disconnect the negative battery cable.
(2) Remove the air box cover and inlet tube (Fig.
5).
(3) Disconnect camshaft position sensor electrical
connector from the wiring harness connector (Fig. 6).
(4) Remove bolt holding sensor.
(5) Rotate sensor away from block.
Fig. 3 EGR/CAM SENSOR 2.4L
Fig. 4 Target Magnet Removal/Installation
1 - TARGET MAGNET
2 - MOUNTING BOLT
3 - REAR OF CYLINDER HEAD
Fig. 5 AIR BOX COVER
Fig. 6 CAMSHAFT POSITION SENSOR
RSIGNITION CONTROL8I-5
CAMSHAFT POSITION SENSOR (Continued)

INSTALLATION - 3.3/3.8L
(1) Install coil over studs on bracket.
(2) Install 2 nuts to the ignition coil studs. Tighten
nuts and bolts.
(3) Connect the electrical connector to the ignition
coil.
(4) Install the ignition cables to the ignition coil.
(5) Reposition the Power steering reservoir. Slide
bracket over the mounting stud (Fig. 11).
(6) Install 2 bolts to the Power steering reservoir
to intake manifold.
(7) Tighten the lower nut to stud on ignition coil
bracket.
(8) Install the throttle and speed control cables to
clip.
(9) Connect the negative battery cable.
KNOCK SENSOR
DESCRIPTION
The knock sensor threads into the cylinder block.
The knock sensor is designed to detect engine vibra-
tion that is caused by detonation.
OPERATION
When the knock sensor detects a knock in one of
the cylinders, it sends an input signal to the PCM. In
response, the PCM retards ignition timing for all cyl-
inders by a scheduled amount.
Knock sensors contain a piezoelectric material
which constantly vibrates and sends an input voltage
(signal) to the PCM while the engine operates. As the
intensity of the crystal's vibration increases, the
knock sensor output voltage also increases.
The voltage signal produced by the knock sensor
increases with the amplitude of vibration. The PCM
receives as an input the knock sensor voltage signal.
If the signal rises above a predetermined level, the
PCM will store that value in memory and retard
ignition timing to reduce engine knock. If the knock
sensor voltage exceeds a preset value, the PCM
retards ignition timing for all cylinders. It is not a
selective cylinder retard.
The PCM ignores knock sensor input during engine
idle conditions. Once the engine speed exceeds a
specified value, knock retard is allowed.
Knock retard uses its own short term and long
term memory program.
Long term memory stores previous detonation
information in its battery-backed RAM. The maxi-
mum authority that long term memory has over tim-
ing retard can be calibrated.
Short term memory is allowed to retard timing up
to a preset amount under all operating conditions (as
long as rpm is above the minimum rpm) except WOT.The PCM, using short term memory, can respond
quickly to retard timing when engine knock is
detected. Short term memory is lost any time the
ignition key is turned off.
NOTE: Over or under tightening affects knock sen-
sor performance, possibly causing improper spark
control.
REMOVAL
REMOVAL - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 12).
(1) Disconnect electrical connector from knock sen-
sor.
(2) Use a crow foot socket to remove the knock
sensors.
REMOVAL - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) On All Wheel Drive vehicles remove the PTU
(Power Transfer Unit), refer to the Transmission sec-
tion for more information.
(4) Disconnect electrical connector from knock sen-
sor.
(5) Use a crow foot socket to remove the knock
sensor.
INSTALLATION
INSTALLATION - 2.4L
The knock sensor threads into the side of the cyl-
inder block in front of the starter (Fig. 12).
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
INSTALLATION - 3.8L
The knock sensor threads into the side of the cyl-
inder block in the rear.
(1) Install knock sensor. Tighten knock sensor to
10 N´m (7 ft. lbs.) torque.Over or under tighten-
ing effects knock sensor performance, possibly
causing improper spark control.
(2) Attach electrical connector to knock sensor.
(3) On All Wheel Drive vehicles install the PTU
(Power Transfer Unit) for the rear wheels, refer to
the Transmission section for more information.
8I - 8 IGNITION CONTROLRS
IGNITION COIL (Continued)

INSTRUMENT CLUSTER
TABLE OF CONTENTS
page page
INSTRUMENT CLUSTER
DESCRIPTION..........................1
OPERATION............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - SELF-
DIAGNOSTICS.........................2
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS...........................3REMOVAL.............................11
INSTALLATION.........................11
CLUSTER LENS
REMOVAL.............................11
INSTALLATION.........................11
INSTRUMENT CLUSTER
DESCRIPTION
The instrumentation gauges are contained in a
subdial assembly within the instrument cluster. The
individual gauges are not serviceable. If one of the
cluster gauges becomes faulty, the entire cluster
would require replacement.
The Mechanical Instrument Cluster (MIC) with a
tachometer is equipped with a electronic vacuum flu-
orescent transmission range indicator (PRND3L),
odometer, and trip odometer display.
The MIC without a tachometer is equipped with a
Light Emitting Diode (LED) transmission range indi-
cator (PRND3L) and a vacuum fluorescent odometer
display.
The MIC is equipped with the following warning
lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
²Coolant Temperature
²Anti-Lock Brake
²Brake
²Oil Pressure
²MIL (Malfunction Indicator Lamp)
²VTSS/SKIS Indicator
²Airbag
²Traction Control
²Autostick
Export Only- uses a message center that displays
the following telltales:
²Turns Signals
²High Beam
²Tire Pressure Monitoring (TPM)²Glow Plug (Export Only)
²Supplemental Cabin Heater (Export Only)WATER IN FUEL LAMP - EXPORT
The Water In Fuel Lamp is located in the message
center. When moisture is found within the fuel sys-
tem, the sensor sends a message via the PCI data
bus to the instrument cluster. The MIC illuminates
the bulb in the message center, The sensor is located
underneath the vehicle, directly above the rear axle.
The sensor is housed within the fuel filter/water sep-
arator assembly cover. The sensor is not serviced sep-
arately. If found defective, the entire assembly cover
must be replaced.
OPERATION
Refer to the vehicle Owner's Manual for operation
instructions and conditions for the Instrument Clus-
ter Gauges.
WATER IN FUEL LAMP/SENSOR - EXPORT
The Water In Fuel Sensor is a resistive type
switch. It is calibrated to sense the different resis-
tance between diesel fuel and water. When water
enters the fuel system, it is caught in the bottom of
the fuel filter/water separator assembly, where the
sensor is located. Water has less resistance than die-
sel fuel. The sensor then sends a PCI data bus mes-
sage to the instrument cluster to illuminate the
lamp.
If the lamp is inoperative, perform the self diag-
nostic test on the instrument cluster to check the
lamp operation before continuing diagnosis.
RSINSTRUMENT CLUSTER8J-1

LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power and high
side drivers source, ON/OFF device, lamps and body
grounds to operate properly. Plastic lamps require a
wire in the harness to supply body ground to the
lamp socket. Replace sockets and bulbs that are cor-
roded.
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. Daytime run-
ning lamps are functional when 450 rpm's are
reached.
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-
sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body
Control Module (BCM). With the headlamp switch in
the AUTO position, the BCM will control the head-
lamp, parking, 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 Electrochromatic Mirror (ECM)
present from the Compass Mini Trip (CMTC) located
on the front windshield in front of the rear view mir-
ror ECM. Ambient light readings are averaged to
limit cycling the lamps ON and OFF when passing
through areas with varying light levels. The auto-
matic 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.
8L - 2 LAMPS/LIGHTING - EXTERIORRS

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. Daytime running lamps are
functional when 450 rpm's are reached.
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 or PCI data bus communication between
the BCM and the FCM fails. The system will return
to normal operation 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.
NOTE: For RG - Export vehicles, the low beams and
front fog lamps will remain ON when high beams
are activated.
WARNING
Eye protection should be used when servicing
glass components. Personal injury or death can
result.
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. Damage to lamp and/or Daytime Running
Lamp Module can result. Do not use fuses, cir-
cuit breakers or relays having greater amper-
age value than indicated on the fuse panel or in
the Owners Manual.
Do not use bulbs other than those listed in
the Bulb Application Table. Damage to lamp
can result. Do not touch halogen bulbs with fin-
gers or other oily surfaces. Bulb life will be
reduced.
SPECIFICATIONS
EXTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3057
CHMSL 921
FRONT SIDE MARKER/PARK/
TURN (DODGE)3157A
FRONT SIDE MARKER/PARK/
TURN (CHRYSLER)3157AK
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)

LAMP BULB
FRONT FOG 9145
HEADLAMP (DODGE) 9007
HEADLAMP (CHRYSLER H13
LICENSE 168
TAIL, STOP, TURN SIGNAL 3057
BULB APPLICATION TABLE - EXPORT
LAMP BULB
HEADLAMP LOW BEAM H7
HEADLAMP HIGH BEAM H9
FRONT FOG H3
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 via a brake switch
input to the BCM. The BCM will then activate the
stop lamps. Other functions include speed control
deactivation, brake sense for the antilock brake sys-
tem 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.
(1) Remove the switch from the vehicle. (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL)
(2) With the switch in the released position
(plunger extended), use an ohmmeter to test each of
the three internal switches as shown (Fig. 1). You
should achieve the results as listed in the figure.
8L - 4 LAMPS/LIGHTING - EXTERIORRS
LAMPS/LIGHTING - EXTERIOR (Continued)

(3) Gently push the plunger on the brake lamp
switch in until it stops.
(4) With the switch in this depressed position
(plunger pushed in), use an ohmmeter to test each of
the three internal switches as shown (Fig. 2). You
should achieve the results as listed in the figure.
If you do not achieve the results as listed in both
figures, the switch is faulty and must be replaced.
Refer to Removal And Installation in this section.
If the switch is found to be operating properly, it
may be misadjusted. Do not reinstall the switch,
replace it. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION)
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 beenremoved for any reason, a new switch must be
installed and adjusted.
REMOVAL
(1) Disconnect and isolate the battery negative
cable from its post on the battery.
(2) Remove silencer panel below steering column
and knee blocker.
(3) Remove the brake lamp switch by rotating the
switch in a counterclockwise direction approximately
30 degrees and pulling it out of the bracket (Fig. 3).
(4) Release the locking tab and disconnect the wir-
ing connector from the switch.
(5) Discard the brake lamp switch. It must not be
reused.
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.
(1) Mount and adjust the NEW brake lamp switch
using the following procedure:
(a) Connect the wiring connector to the switch
and latch the locking tab.
Fig. 1 SWITCH TEST - RELEASED POSITION
Fig. 2 SWITCH TEST - DEPRESSED POSITION
Fig. 3 Brake Lamp Switch And Pedal With Bracket
1 - BRAKE LAMP SWITCH
2 - WIRING CONNECTOR
3 - PEDAL AND BRACKET
RSLAMPS/LIGHTING - EXTERIOR8L-5
BRAKE LAMP SWITCH (Continued)

(b) Install the switch in its bracket by aligning
the index tab on the switch with the slot in the
mounting bracket.
(c) When the switch is fully seated in its
bracket, rotate the switch clockwise approximately
30É to lock the switch into place.
(d) With the brake pedal in the fully released
position, move the lever on the back of the brake
lamp switch from the angled non-adjusted position
to the full vertical position as shown (Fig. 4). This
will adjust the brake lamp switch to the vehicle.
(2) Install silencer panel below steering column
knee blocker.
(3) Reconnect the battery negative terminal.
(4) Check the stop lamps to verify they are operat-
ing properly and not staying on when the pedal is in
the released position.
(5) Road test the vehicle to ensure proper opera-
tion of the brakes including ABS and speed control (if
equipped).
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two retaining screws (Fig. 5).
(3) Twist socket counter-clockwise and remove
from lamp.
(4) Pull bulb from socket (Fig. 7).
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into the lamp unit.
(3) Install the retaining screws.
(4) Reconnect the battery negative cable.
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the two retaining screws (Fig. 5).
(3) Disconnect the rear window washer nozzle
assembly (Fig. 6).
(4) Disconnect CHMSL electrical connector from
bulb socket (Fig. 7).
INSTALLATION
(1) Connect electrical connector to CHMSL bulb
socket.
(2) Reconnect the rear window washer nozzle
assembly.
Fig. 4 Adjustment Lever Movement
Fig. 5 CHMSL UNIT
1 - CHMSL UNIT
2 - LIFTGATE
Fig. 6 REAR WASHER NOZZLE ASSEMBLY
1 - BARREL IN CHMSL
2 - NOZZLE ASSEMBLY
3 - SQUEEZE ARMS TO RELEASE NOZZLE ASSEMBLY
4 - HOSE
8L - 6 LAMPS/LIGHTING - EXTERIORRS
BRAKE LAMP SWITCH (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
FOG LAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system. Refer to
Electrical, Charging.
2. Poor lighting circuit Z349/Z248
ground.2. Test for voltage drop across Z349/Z248
ground locations. Refer to Electrical, Wiring
Information.
3. High resistance in fog lamp
circuit.3. Test amperage draw of fog lamp circuit.
FOG LAMPS FLASH
RANDOMLY1. Poor lighting circuit Z349/Z248
ground.1. Test for voltage drop across Z349/Z248
ground locations. Refer to Electrical, Wiring
Information.
2. Variable resistance in fog lamp
circuit.2. Test amperage draw of fog lamp circuit.
3. Faulty fog lamp switch (part of
headlamp switch).3. Replace headlamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM.
6. PCI Bus Communication. 6. Verify PCI bus message (fog lamp info)
transmitted from BCM and received by FCM.
FOG LAMPS DO NOT
ILLUMINATE1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring
Information.
2. No Z349/Z248 ground at fog
lamps.2. Repair circuit ground. Refer to Electrical,
Wiring Information.
3. Faulty fog lamp switch (part of
headlamp switch).3. Replace headlamp switch.
4. Broken connector terminal or
wire splice in fog lamp circuit.4. Repair connector terminal or wire splice.
5. Faulty or burned out bulb. 5. Replace bulb.
6. Is relay engaging? 6. Verify function of fog lamp relay in IPM.
7. PCI Bus Communication. 7. Verify PCI bus message (fog lamp info)
transmitted from BCM and received by FCM.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) From behind the bumper fascia, twist bulb
counter-clockwise, and remove bulb.
(3) Remove the wire connector from the fog lamp
bulb.
INSTALLATION
(1) Reconnect wire harness to bulb.
(2) Install bulb and twist clockwise.
(3) Install battery negative cable.
8L - 8 LAMPS/LIGHTING - EXTERIORRS
FRONT FOG LAMP (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z343/Z344-
ground.1. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
2. Variable 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 Electrical, Wiring Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
HEADLAMPS DO NOT
ILLUMINATE.1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to
Electrical, Wiring Information.
2. No Z343/Z344-ground at
headlamps.2. Repair circuit ground, refer to Electrical,
Wiring Information.
3. Broken connector terminal or
wire splice in headlamp circuit.3. Repair connector terminal or wire splice.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Body Control Module
malfunction.5. Refer to appropriate Body Control Module
diagnostics.
6. PCI Bus Communication 6. Verify messages being transmitted by BCM
and received by FCM.
7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM diagnostics.
HEADLAMPS ON WITH
IGNITION IN RUN, WITH
HEADLAMP SWITCH
OFF.1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM
logged faults).
2. Diagnostic tool indicates (4.7 -
5.0V) on headlamp switch input to
BCM.2. Inspect and repair terminals, connectors and
open circuits.
3. PCI Bus Communication. 3. Verify messages being transmitted by BCM
and received by FCM.
REMOVAL
DODGE
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit retaining screws.
(3) Remove headlamp unit to expose back of unit.
(4) Remove wiring connector from bulb.
(5) Rotate headlamp bulb retaining ring counter-
clockwise.
(6) Pull headlamp bulb and remove from headlamp
unit (Fig. 10).
CHRYSLER
(1) Disconnect and isolate the battery negative
cable.
(2) Remove headlamp unit retaining screws.
(3) Remove headlamp unit to expose back of unit.
Fig. 10 HEADLAMP - DODGE
1 - HEADLAMP
2 - HEADLAMP UNIT
8L - 12 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP (Continued)