CHRYSLER VOYAGER 2005 Service Manual

(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)

(3) Install the retaining screws.
(4) Reconnect the battery negative cable.
FRONT FOG LAMP
DIAGNOSIS AND TESTING - FRONT FOG LAMP
When a vehicle experiences problems with the
front fog lamp system, verify the condition of the bat-
tery connections, fuses, charging system, fog lamp
bulbs, wire connectors, relay, high beam switch, and
headlamp switch. Refer to the appropriate wiring
information.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
FRONT 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
Electrical, Charging,
4. Battery has insufficient charge. 4. Test battery state-of-charge. Refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical, Battery
System.
6. Poor lighting circuit Z349/Z248
ground.6. Test for voltage drop across Z349/248
ground locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS
BURN OUT
FREQUENTLY1. Charging system output too
high.1. Test and repair charging system. Refer to
Electrical, Charging.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
Fig. 7 CHMSL ELECTRICAL CONNECTOR
1 - CHMSL UNIT
2 - CHMSL ELECTRICAL CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-7
CENTER HIGH MOUNTED STOP LAMP UNIT (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)

FRONT FOG LAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - FRONT 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. 8). To
improve visual interpretation of the fog lamp pattern
on the alignment screen, the headlamps should be in
the ªoffº position.The fog lamps are adjusted by a adjustment screw
at the top of the lamp.
STANDARD PROCEDURE - FRONT 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. 9). To
improve visual interpretation of the fog lamp pattern
on the alignment screen, the headlamps should be in
the ªoffº position.
The fog lamps are adjusted by a adjustment screw
located on the front side of the fog lamp unit.
Fig. 8 FRONT 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
RSLAMPS/LIGHTING - EXTERIOR8L-9

REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) From behind the bumper fascia, disconnect the
wire harness from the fog lamp bulb.
(3) Remove mounting screws.
INSTALLATION
(1) Install mounting screws.
(2) Reconnect the wire harness to the fog lamp
bulb.
(3) Reconnect the battery negative cable.
Fig. 9 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
8L - 10 LAMPS/LIGHTING - EXTERIORRS
FRONT FOG LAMP UNIT (Continued)

HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, fuses, charging system, headlamp bulbs,
wire connectors, relay, high beam switch, dimmer
switch, and headlamp switch. Refer to the appropri-
ate wiring information.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socketwhen it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
When it is necessary to remove components to ser-
vice another, it should not be necessary to apply
excessive force or bend a component to remove it.
Before damaging a trim component, verify hidden
fasteners or captured edges are not holding the com-
ponent in place.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS 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
Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery
System.
6. Poor lighting circuit Z343/Z344-
ground.6. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS
BURN OUT
FREQUENTLY.1. Integrated Power Module (IPM)
not controlling voltage.1. Test and repair Integrated Power Module.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
HEADLAMPS ARE DIM
WITH ENGINE
RUNNING ABOVE IDLE.1. Charging system output too low. 1. Test and repair charging system, refer to
Electrical, Wiring Information.
2. Poor lighting circuit Z343/Z344-
ground.2. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
RSLAMPS/LIGHTING - EXTERIOR8L-11

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)

(4) Remove wiring connector from bulb by sliding
red latch lock rearward and then depressing release
tab.
(5) Rotate headlamp bulb retaining ring counter-
clockwise.
INSTALLATION
DODGE
(1) Install headlamp bulb to the headlamp unit.
(2) Install headlamp bulb retaining ring.
(3) Connect wiring connector to bulb.
(4) Install the headlamp unit.
(5) Install headlamp unit retaining screws.
(6) Connect the battery negative cable.
CHRYSLER
(1) Install headlamp bulb to the headlamp unit.
(2) Rotate bulb clockwise to lock bulb in headlamp
unit.
(3) Connect wiring connector to bulb and slide red
latch lock forward.
(4) Install the headlamp unit.
(5) Install headlamp unit retaining screws.
(6) Connect the battery negative cable.
HEADLAMP SWITCH
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH
Using a Digital Multi-meter, perform the HEAD-
LAMP SWITCH CONTINUITY test and refer to (Fig.
11).
If the Headlamp Switch is not within specifications
replace the switch.
HEADLAMP SWITCH CONTINUITY
HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
OFF 11 TO 6 3651 - 3729V
PARKING
LAMPS ON11 TO 6 1697 - 2517V
PARKING
LAMPS WITH
FRONT FOG
LAMPS ON11 TO 6 5765 - 5886V
HEADLAMPS
ON11 TO 6 788 - 809V
AUTO ON 11 TO 6 10056 - 10264V
HEADLAMPS
ON WITH
FRONT FOG
LAMPS11 TO 6 1171 - 1200V
AUTO ON WITH
FRONT FOG
LAMPS ON11 TO 6 24278 - 24773V
DIMMER
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
DOME 12 TO 6 15568 - 23357V
PARADE 12 TO 6 5168 - 7757V
DIM HIGH 12 TO 6 2288 - 3437V
DIM LOW 12 TO 6 688 - 1037V
OFF 12 TO 6 240 - 365V
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Removal.
(3) Reach up behind the left side of the instrument
panel and depress spring clip on top or bottom of
headlamp switch. Firmly push out on the headlamp
switch assembly.
(4) Disconnect the wiring connectors.
(5) Remove switch from vehicle.
INSTALLATION
(1) Connect the wiring connectors.
(2) Place headlamp switch assembly into position
and firmly snap into place.
(3) Install the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Installation.
(4) Connect the battery negative cable.
Fig. 11 HEADLAMP SWITCH CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-13
HEADLAMP (Continued)

HEADLAMP UNIT
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 12).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
Fig. 12 HEADLAMP ALIGNMENT SCREEN
1 - CENTER OF HEADLAMPS 3 - FRONT OF HEADLAMP
2 - HEADLAMP BEAM 4 - 7.62 METERS (25 FT.)
8L - 14 LAMPS/LIGHTING - EXTERIORRS

HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp centerline   50 mm (2 in.). Horizontal aim is
preset and can not be adjusted. The high beam pat-
tern should be correct when the low beams are
aligned properly (Fig. 12). To adjust headlamp verti-
cal alignment, rotate adjustment screw (Fig. 13) to
achieve the specified low beam cut-off location.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws (Fig. 14).
(3) Disconnect the wiring harness from the bulbs
(Fig. 15).(4) Remove wire harness retainer from back of
headlamp unit.
(5) Remove the headlamp unit.
INSTALLATION
(1) Reconnect wire harness to the bulbs.
(2) Install wire harness retainer to headlamp unit.
(3) Install the three retaining screws.
(4) Reconnect the battery negative cable.
HEADLAMP UNIT - EXPORT
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT - EXPORT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Verify that the headlamp leveling switch is in
the ª0º position.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) Vehicles equipped with automatic load leveling
suspension should be driven normally for approxi-
mately 5 km (3 miles) before attempting a proper
headlamp unit alignment.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
Fig. 13 HEADLAMP UNIT ADJUSTMENT
1 - ADJUSTMENT LOCATION
2 - HEADLAMP UNIT
Fig. 14 HEADLAMP UNIT FASTENERS
1 - HEADLAMP UNIT RETAINING SCREW
2 - HEADLAMP UNIT
Fig. 15 HEADLAMP UNIT
1 - HEADLAMP UNIT
2 - HEADLAMP
3 - PARK/TURN SIGNAL LAMP
4 - WIRE HARNESS RETAINER
RSLAMPS/LIGHTING - EXTERIOR8L-15
HEADLAMP UNIT (Continued)