1996 CHRYSLER VOYAGER ignition

INTERIOR LAMPS
INDEX
page page
REMOVAL AND INSTALLATION
CONVENIENCE BIN LAMP................. 20
DOME LAMP BULB...................... 21
DOME LAMP........................... 21
FRONT DOOR COURTESY LAMP BULB...... 22
FRONT DOOR COURTESY LAMP........... 21
GLOVE BOX LAMP AND SWITCH........... 19
GLOVE BOX LAMP BULB.................. 19
HEADER READING/COURTESY LAMP BULB . . . 19HEADER READING/COURTESY LAMP....... 18
IGNITION HALO LAMP BULB............... 19
INSTRUMENT PANEL LAMPS AND SWITCHES . 20
LIFTGATE COURTESY LAMP BULB.......... 24
LIFTGATE COURTESY LAMP............... 23
OVERHEAD CONSOLE READING/COURTESY
LAMP BULB.......................... 18
RAIL LAMP MODULE BULB................ 23
REMOVAL AND INSTALLATION
OVERHEAD CONSOLE READING/COURTESY LAMP
BULB
REMOVAL
(1) Using a trim stick, lightly pry outward the for-
ward end of reading lamp lens.
(2) Rotate reading lamp bulb socket one quarter
turn counterclockwise.
(3) Pull socket out of lamp (Fig. 1).
(4) Pull bulb from socket.
INSTALLATION
(1) Push bulb into socket.
(2) Push socket into lamp.
(3) Rotate reading lamp bulb socket one quarter
turn clockwise.
(4) Insert tab on lamp lens between lamp switch
and overhead console.(5) Snap lens onto lamp lens pivots.
HEADER READING/COURTESY LAMP
REMOVAL
(1) Grasp outer edges of header reading/courtesy
lamp at headlining.
(2) Pull downward to disengage clips on reading/
courtesy lamp from roof header panel (Fig. 2).
(3) Disconnect wire connector from reading/cour-
tesy lamp.
(4) Remove lamp from vehicle.
INSTALLATION
(1) Position lamp on vehicle.
(2) Connect wire connector to reading/courtesy
lamp.
(3) Align clips on reading/courtesy lamp to mating
holes in roof header panel.
(4) Push upward to engage clips on reading/cour-
tesy lamp to roof header panel.
Fig. 1 Reading/Courtesy LampFig. 2 Header Reading/Courtesy Lamp
8L - 18 LAMPSNS

HEADER READING/COURTESY LAMP BULB
REMOVAL
(1) Insert a small, flat bladed pry tool at forward
position between reading/courtesy lamp lens and
lamp housing.
(2) Pry lamp lens from lamp housing (Fig. 3).
(3) Insert a small, flat bladed pry tool between
lamp light shield and lamp housing at inboard rear
corner of light shield.
(4) Pry light shield from housing (Fig. 4).
(5) Carefully press forward lamp bulb contact
toward opposite contact and rotate.
(6) Remove bulb from lamp bulb contacts.
INSTALLATION
(1) Carefully press forward lamp bulb contact
toward opposite contact and rotate bulb into position.
(2) Position bulb to lamp bulb contacts.
(3) Release lamp bulb contacts.
(4) Insert outer edge of light shield into lamp
housing (Fig. 4).(5) Rotate light shield upward and snap inboard
edge into lamp housing.
(6) Position lens switch tab to lamp switch.
(7) Press lens pivots to tabs on lamp housing until
both pivots are seated.
GLOVE BOX LAMP AND SWITCH
REMOVAL
(1) Open glove box door.
(2) Using a trim stick, lightly pry glove box lamp/
switch from instrument panel.
(3) Disconnect wire connector from glove box lamp
(Fig. 5).
(4) Remove glove box lamp from vehicle.
INSTALLATION
(1) Position glove box lamp in vehicle.
(2) Connect wire connector from glove box lamp.
(3) Position glove box lamp in instrument panel.
(4) Press lamp into instrument panel until fully
seated.
GLOVE BOX LAMP BULB
REMOVAL
(1) Remove glove box lamp/switch from instrument
panel.
(2) Pull bulb from glove box lamp (Fig. 6).
INSTALLATION
(1) Push bulb into glove box lamp.
(2) Install glove box lamp/switch in instrument
panel.
IGNITION HALO LAMP BULB
REMOVAL
(1) Remove steering column trim covers. Refer to
Group 19, Steering, for proper procedures.
Fig. 3 Reading/Courtesy Lamp Lens
Fig. 4 Reading/Courtesy Lamp Light Shield
Fig. 5 Glove Box Lamp and Switch
NSLAMPS 8L - 19
REMOVAL AND INSTALLATION (Continued)

(2) Rotate bulb socket counterclockwise one quar-
ter turn (Fig. 7).
(3) Pull bulb socket from halo lamp.
INSTALLATION
(1) Push bulb socket into halo lamp.
(2) Rotate bulb socket clockwise one quarter turn.
(3) Install steering column trim covers. Refer to
Group 19, Steering, for proper procedures.
CONVENIENCE BIN LAMP
If the lamp is not used refer to (Fig. 8).
REMOVAL
(1) Pull out the convenience bin cup holder.
(2) Insert the trim stick between access cover
above cup holder and center console.
(3) Carefully pry the access cover from the center
console (Fig. 9).
(4) Remove the access cover from the vehicle.(5) Using needle-nose pliers, carefully squeeze the
vertical metal legs of the lamp hood.
(6) Lift the lamp hood upward from the cup holder
tray.
(7) Carefully pull the lamp and wiring rearward
from the instrument panel (Fig. 10).
(8) Pull the lamp hood from the lamp socket.
(9) Pull bulb from socket.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT PANEL LAMPS AND SWITCHES
For replacement of instrument panel lamps and
switches, refer to Group 8E, Instrument Panel and
Systems.
Fig. 6 Glove Box Lamp Bulb
Fig. 7 Ignition Halo Lamp Bulb
Fig. 8 Wiring for the Convenience Lamp
Fig. 9 Convenience Bin Access Cover
Fig. 10 Convenience Bin Lamp Bulb
8L - 20 LAMPSNS
REMOVAL AND INSTALLATION (Continued)

HEADLAMP LEVELING MOTOR
This vehicle is equipped with a remote headlamp
leveling system. This system allows the driver to
adjust the vertical headlamp aim from the interior of
the vehicle to compensate for passenger or cargo
load. A headlamp leveling switch is located in the
instrument panel and controls the headlamp leveling
motor found on the back of the headlamp module.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the head-
lamp system, verify the condition of the battery connec-
tions, charging system, headlamp bulbs, wire
connectors, relay, high beam dimmer switch and head-
lamp switch. Refer to Group 8W, Wiring Diagrams, for
component locations and circuit information.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS ARE DIM
WITH ENGINE IDLING OR
IGNITION TURNED OFF1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps
and posts.
2. Loose or worn alternator drive
belt.2. Adjust or replace alternator drive belt.
3. Charging system output too low. 3. Test and repair charging system. Refer
to Group 8A.
4. Battery has insufficient charge. 4. Test battery state-of -charge. Refer to
Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group 8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
HEADLAMP BULBS BURN
OUT FREQUENTLY1. Charging system output too high. 1. Test and repair charging system. Refer
to Group 8A.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and
splices. Refer to Group 8W.
HEADLAMPS ARE DIM
WITH ENGINE RUNNING
ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system. Refer
to Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across Z1-ground
locations. Refer to Group 8W.
3. High resistance in headlamp
circuit.3. Test amperage draw of headlamp circuit.
HEADLAMPS FLASH
RANDOMLY1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across Z1-ground
locations, refer to Group 8W.
2. High 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 Group 8W.
HEADLAMPS DO NOT
ILLUMINATE1. No voltage to headlamps. 1. Repair open headlamp circuit. Refer to
Group 8W.
2. No Z1-ground at headlamps. 2. Repair circuit ground. Refer to Group
8W.
3. Faulty headlamp switch. 3. Replace headlamp switch.
4. Faulty headlamp dimmer
(multi-function) switch.4. Replace multi-function switch.
5. Broken connector terminal or wire
splice in headlamp circuit.5. Repair connector terminal or wire splice.
6. Defective or burned out bulb. 6. Replace bulb.
7. Body controller malfunction. 7. Refer to appropriate body controller
diagnostics.
8L - 2 LAMPSNS/GS
GENERAL INFORMATION (Continued)

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 alternator drive
belt.2. Adjust or replace alternator drive
belt.
3. Charging system output too low. 3. Test and repair charging system.
Refer to Group 8A,
4. Battery has insufficient charge. 4. Test battery state-of -charge.
Refer to Group 8A.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Group
8A.
6. Poor lighting circuit Z1-ground. 6. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
FOG LAMP BULBS BURN OUT
FREQUENTLY1. Charging system output too high. 1. Test and repair charging system.
Refer to Group 8A.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS ARE DIM WITH
ENGINE RUNNING ABOVE IDLE1. Charging system output too low. 1. Test and repair charging system.
Refer to Group 8A.
2. Poor lighting circuit Z1-ground. 2. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
3. High resistance in fog lamp
circuit.3. Test amperage draw of fog lamp
circuit.
FOG LAMPS FLASH RANDOMLY 1. Poor lighting circuit Z1-ground. 1. Test for voltage drop across
Z1-ground locations. Refer to Group
8W.
2. High resistance in fog lamp
circuit.2. Test amperage draw of fog lamp
circuit.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Loose or corroded terminals or
splices in circuit.4. Inspect and repair all connectors
and splices. Refer to Group 8W.
FOG LAMPS DO NOT
ILLUMINATE1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Group 8W.
2. No Z1-ground at fog lamps. 2. Repair circuit ground. Refer to
Group 8W.
3. Faulty fog lamp switch. 3. Replace fog lamp switch.
4. Broken connector terminal or wire
splice in fog lamp circuit.4. Repair connector terminal or wire
splice.
5. Defective or burned out bulb. 5. Replace bulb.
NS/GSLAMPS 8L - 3
DIAGNOSIS AND TESTING (Continued)

ACM monitors the system to determine the system
readiness. The ACM contains on-board diagnostics
and will light the AIRBAG warning lamp in the mes-
sage center when a problem occurs.
The driver and passenger airbag system is a safety
device designed to reduce the risk of fatality or seri-
ous injury, caused by a frontal impact of the vehicle.
The impact sensor provides verification of the
direction and severity of the impact. One impact sen-
sor is used. It is located inside the Airbag Control
Module (ACM) which is mounted on a bracket, just
forward of the center console. The impact sensor is
an accelerometer that senses deceleration. The decel-
eration pulses are sent to a microprocessor which
contains a decision algorithm. When an impact is
severe enough to require airbag protection, the ACM
micro processor sends a signal that completes the
electrical circuit to the driver and passenger airbags.
The sensor is calibrated for the specific vehicle and
reacts to the severity and direction of the impact.
CLOCKSPRING
The clockspring is snapped into a plastic mounting
platform on the steering column behind the steering
wheel. The clockspring is used to maintain a contin-
uous electrical circuit between the wiring harness
and the driver's airbag module. This assembly con-
sists of a flat ribbon like electrically conductive tape
which winds and unwinds with the steering wheel
rotation.
DRIVER AND PASSENGER AIRBAG MODULES
The Driver Airbag Module is located in the center
of the steering wheel. The Passenger Airbag Module
is located in the instrument panel above the glove
box (Fig. 1). The Driver Airbag Module cover contains
the horn switch, inflator device, and a fabric bag. The
airbag cover/horn switch is serviced separately from
the inflator and bag components. Refer to Group 8G,
Horns for proper service procedure for horn switch.
The Passenger Airbag Module is serviced as an
assembly.
WARNING: WHEN THE AIRBAG SYSTEM IS
DEPLOYED BECAUSE OF A COLLISION, THE FOL-
LOWING MUST BE REPLACED:
²COMPLETE STEERING COLUMN ASSEMBLY
²LOWER STEERING COUPLER
²STEERING WHEEL
²STEERING COLUMN CLOCKSPRING
²DRIVER AIRBAG COVER/HORN SWITCH
²DRIVER AIRBAG MODULE
²PASSENGER AIRBAG MODULE
²UPPER INSTRUMENT PANEL WITH PAD
DIAGNOSIS AND TESTING
AIRBAG SYSTEM TEST
(1) Disconnect and isolate the battery negative
cable.
WARNING: DISCONNECT AND ISOLATE THE BAT-
TERY NEGATIVE CABLE BEFORE BEGINNING AIR-
BAG SYSTEM COMPONENT SERVICE
PROCEDURES. THIS WILL DISABLE THE AIRBAG
SYSTEM. FAILURE TO DISCONNECT THE BATTERY
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY. ALLOW
SYSTEM CAPACITOR TO DISCHARGE FOR TWO
MINUTES BEFORE REMOVING AIRBAG COMPO-
NENTS.
(2) Connect scan tool (DRB) to Data Link connec-
tor, located at left side of the steering column and at
the lower edge of the lower instrument panel.
(3) Turn the ignition key to ON position. Exit vehi-
cle with scan tool. Use the latest version of the
proper cartridge.
(4) After checking that no one is inside the vehicle,
connect the battery negative terminal.
(5) Using the scan tool, read and record active
diagnostic code data.
(6) Read and record any stored diagnostic codes.
(7) Refer to the proper Body Diagnostic Procedures
Manual if any diagnostic codes are found in Step 5 or
Step 6.
(8) Erase stored diagnostic codes if there are no
active diagnostic codes. If problems remain, diagnos-
tic codes will not erase. Refer to the Passive
Restraint Diagnostic Test Manual to diagnose the
problem.If airbag warning lamp either fails to
light, or goes on and stays on, there is a system
malfunction. Refer to the proper Body Diagnos-
tic Procedures Manual to diagnose the problem.
Fig. 1 Airbag Module Locations
8M - 2 RESTRAINT SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

ELECTRICALLY HEATED SYSTEMS
CONTENTS
page page
DESCRIPTION AND OPERATION
HVAC MOUNTED SWITCH................. 1
INTRODUCTION......................... 1
DIAGNOSIS AND TESTING
GRID LINE TEST......................... 2SYSTEM TEST.......................... 2
SERVICE PROCEDURES
GRID LINE AND TERMINAL REPAIR......... 3
DESCRIPTION AND OPERATION
INTRODUCTION
The electrically heated Rear Window Defogger (Fig.
1), Heated Power Side View Mirrors, and Heated
Windshield Wiper De-icer (Fig. 2) is available on NS
vehicles.
The Rear Window Defogger system consists of two
vertical bus bars linked by a series of grid lines on
the inside surface of the rear window. The electrical
circuit consists of the rear defogger switch in the
HVAC and a relay with timer switch to turn OFF the
system after ten minutes. The main feed circuit is
protected by fuse one (40 amp) in the Junction Block.
The rear defogger switch and relay also activates the
heated power side view mirrors and heated wind-
shield wiper de-icer. The HVAC rear defogger switch
is protected by fuse ten (10 amp) in the Junction
Block. The heated mirror circuit is protected by fuse
12 (10 amp) in the junction block. The heated wind-
shield wiper de-icer circuit is protected by fuse 21 (25
amp) in the Junction Block.
The Heated Windshield Wiper Deicer is also acti-
vated when the DEFROST mode is selected on the
HVAC. In the DEFROST mode the rear defogger
relay/timer is bypassed, the heated windshield wiper
de-icer will stay ON until the another mode is
selected. For circuit information and component loca-
tion refer to Group 8W, Wiring Diagrams.
CAUTION: Since grid lines can be damaged or
scraped off with sharp instruments, care should be
taken in cleaning the glass or removing foreign
materials, decals or stickers. Normal glass cleaning
solvents or hot water used with rags or toweling is
recommended.
HVAC MOUNTED SWITCH
The rear window defogger switch is integrated into
the HVAC (Fig. 3). An LED indicator will illuminate
when the switch is activated. The switch energizesthe timing circuit and activates the rear window
defogger relay. The relay controls the current to flow
to the grids of the rear window defogger, heated
power side view mirrors and the heated windshield
wiper de-icer. The defogger relay will be on for
approximately 10 minutes or until the control switch
or ignition is turned off.
Fig. 1 Rear Window Defogger
Fig. 2 Heated Windshield Wiper De-icer
NSELECTRICALLY HEATED SYSTEMS 8N - 1

DIAGNOSIS AND TESTING
SYSTEM TEST
Electrically heated rear window defogger or the
heated windshield wiper deicer operation can be
checked on the vehicle in the following manner:
(1) Turn the ignition switch to the ON position.
(2) Using a ammeter on the battery, turn the rear
defogger control switch to the ON position, a distinct
increase in amperage draw should be noted.
(3) The rear window defogger or the heated wind-
shield wiper deicer operation can be checked by feel-
ing the glass. A distinct difference in temperature
between the grid lines and adjacent clear glass can
be detected in 3 to 4 minutes of operation.
(4) Using a DC voltmeter (Fig. 4) contact terminal
B with the negative lead, and terminal A with the
positive lead. The voltmeter should read 10-14 volts.
(5) Indicator light illumination means that there is
power available at the switch only and does not nec-
essarily verify system operation.
(6) If turning the defogger switch ON, no distinct
current draw on the ammeter the problem should be
isolated in the following manner:
²Confirm that ignition switch is ON.
²Ensure that the heated rear window or the
heated windshield wiper deicer feed pigtail is con-
nected to the wiring harness and that the ground
pigtail is in fact grounded.
²Ensure that the proper fuse in the Junction
Block is OK.(7) When the above steps have been completed and
the system is still inoperative, one or more of the fol-
lowing is defective:
²HVAC switch
²Rear window defogger relay in the relay bank.
²Check for loose connector or a wire pushed out
of connector.
²Rear window or the windshield grid lines (all
grid lines would have to be broken, or one of the feed
pigtails not connected to the bus bar, for no ammeter
deflection).
(8) If turning the switch ON produces severe volt-
meter deflection, the circuit should be closely checked
for a shorting condition.
(9) If the system operation has been verified but
indicator LED does not light, replace switch.
(10) For detailed wiring information, refer to
Group 8W, Wiring Diagrams.
GRID LINE TEST
The horizontal grid lines and vertical bus bar lines
printed and baked on inside surface of the window
glass makes up an electrical parallel circuit. The
electrically conductive lines are composed of a silver
ceramic material which when baked on glass
becomes bonded to the glass and is highly resistant
to abrasion. It is possible, however, that a break may
exist or occur in an individual grid line resulting in
no current flow through the line. To detect breaks in
grid lines, the following procedure is required:
(1) Turn ignition and rear window defogger control
switch ON. The indicator light should come on.
(2) Using a DC voltmeter with 0-15 volt range,
contact vertical bus bar connecting grid lines on pas-
senger side of vehicle at terminal A with negative
lead of voltmeter (Fig. 4). With positive lead of volt-
meter, contact vertical bus bar on driver side of vehi-
cle at terminal B. The voltmeter should read 10-14
volts.
Fig. 3 HVAC Rear Window Defogger Switch
Fig. 4 Grid Line Test
8N - 2 ELECTRICALLY HEATED SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)