1996 CHRYSLER VOYAGER manual transmission

vehicles with a manual transmission, the clutch
pedal must be fully depressed for this test. Check for
battery voltage at the cavity for relay terminal 86
with the ignition switch in the Start position, and no
voltage when the ignition switch is released to the
On position. If OK, go to Step 5. If not OK with an
automatic transmission, check for an open or short
circuit to the ignition switch and repair, if required.
If the circuit to the ignition switch is OK, see the
Ignition Switch Test procedure in this group. If not
OK with a manual transmission, check the circuit
between the relay and the clutch pedal position
switch for an open or a short. If the circuit is OK, see
the Clutch Pedal Position Switch Test procedure in
this group.
(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. On vehicles with an
automatic transmission, it is grounded through the
park/neutral position switch only when the gearshift
selector lever is in the Park or Neutral positions. On
vehicles with a manual transmission, it is grounded
at all times. Check for continuity to ground at the
cavity for relay terminal 85. If not OK with an auto-
matic transmission, check for an open or short circuit
to the park/neutral position switch and repair, if
required. If the circuit is OK, see the Park/Neutral
Position Switch Test procedure in this group. If not
OK with a manual transmission, repair the circuit to
ground as required.
SAFETY SWITCHES
For diagnostics,
²Clutch Pedal Position Switch, refer to Group 6,
Clutch.
²Park/Neutral Position Switch, refer to Group 21,
Transaxle
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Refer to Group 8D, Ignition
Systems or Group 8W, Wiring Diagrams. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.
BATTERY
Refer to Group 8A, Battery for proper procedures.
ALL RELATED WIRING AND CONNECTORS
Refer to Group 8W, Wiring Diagrams,
FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
(1) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(2) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp (Fig. 2). Rotate and
hold the ignition switch in the START position.
Observe the voltmeter. If voltage is detected, cor-
rect poor contact between cable clamp and post.
(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp. Rotate and hold the igni-
tion switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between the cable clamp and post.
(c) Connect negative lead of voltmeter to battery
negative terminal, and positive lead to engine
Fig. 2 Test Battery Connection Resistance
NSSTARTER 8B - 3
DIAGNOSIS AND TESTING (Continued)

INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER................... 1
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 2
HEADLAMP SWITCH..................... 2
SELF DIAGNOSTIC TEST.................. 2
TRACTION CONTROL SWITCH............. 17
REMOVAL AND INSTALLATION
BODY CONTROL MODULE (BCM).......... 18
CONVENIENCE BIN - CUP HOLDER......... 17
CONVENIENCE BIN LAMP................ 17
CONVENIENCE BIN TRACK............... 18
GLOVE BOX LAMP AND SWITCH.......... 19
GLOVE BOX LOCK STRIKER.............. 20
GLOVE BOX........................... 19
HEADLAMP SWITCH LAMP(S)............ 21
HEADLAMP SWITCH.................... 20
HVAC CONTROL LAMP.................. 21
INSTRUMENT CLUSTER BACK PANEL...... 21
INSTRUMENT CLUSTER BEZEL............ 21
INSTRUMENT CLUSTER ELECTRONIC
ODOMETER AND TRANSMISSION RANGE
INDICATOR.......................... 19
INSTRUMENT CLUSTER LAMPS........... 22
INSTRUMENT CLUSTER LENS - MECHANICAL
TRANSMISSION RANGE INDICATOR
(PRND21)........................... 19
INSTRUMENT CLUSTER LENS............. 22INSTRUMENT CLUSTER PRINTED CIRCUIT
BOARD.............................. 23
INSTRUMENT CLUSTER SUBDIAL.......... 23
INSTRUMENT CLUSTER SUBDIALÐ
MECHANICAL TRANSMISSION RANGE
INDICATOR.......................... 23
INSTRUMENT CLUSTER WITH ELECTRONIC
TRANSMISSION RANGE INDICATOR...... 23
INSTRUMENT CLUSTER WITH MECHANICAL
TRANSMISSION RANGE INDICATOR...... 24
INSTRUMENT PANEL LEFT END COVER..... 27
INSTRUMENT PANEL LOUVERS........... 27
INSTRUMENT PANEL RIGHT END COVER.... 29
INSTRUMENT PANEL TOP COVER.......... 29
INSTRUMENT PANEL.................... 25
JUNCTION BLOCK...................... 30
KNEE BLOCKER REINFORCEMENT......... 30
LOWER CONSOLE...................... 30
LOWER INSTRUMENT PANEL............. 31
LOWER STEERING COLUMN COVER........ 31
MECHANICAL TRANSMISSION RANGE
INDICATOR.......................... 32
MESSAGE CENTER LAMP................ 32
MESSAGE CENTER...................... 32
OUTLET (12 VOLT) BASE................. 32
OVER STEERING COLUMN BEZEL.......... 32
POWER MIRROR SWITCH LAMP.......... 34
POWER MIRROR SWITCH................ 34
RADIO BEZEL AND HVAC CONTROL........ 34
REAR HEATER-A/C SWITCH LAMP......... 35
REAR HEATER-A/C SWITCH............... 35
TRACTION CONTROL SWITCH............. 35
GENERAL INFORMATION
INTRODUCTION
The instrumentation gauges on NS vehicles are
contained in a subdial assemblies within the instru-
ment cluster. The individual gauges are not serviced
separately. If one of the cluster gauges becomes
faulty the entire subdial would require replacement
and all gauges will have to be calibrated. Refer to the
proper Body Diagnostic Procedure Manual for cali-
bration procedures.
DESCRIPTION AND OPERATION
INSTRUMENT CLUSTER
The mechanical instrument cluster with a tachom-
eter is equipped with a electronic vacuum fluorescent
transmission range indicator (PRND3L), odometer,
and trip odometer display.
The mechanical instrument cluster without a
tachometer is equipped with a cable operated trans-
mission range indicator (PRND21).
NSINSTRUMENT PANEL AND SYSTEMS 8E - 1

The instrument cluster is equipped with the follow-
ing warning lamps.
²Lift Gate Ajar
²Low Fuel Level
²Low Windshield Washer Fluid Level
²Cruise
²Battery Voltage
²Fasten Seat Belt
²Door Ajar
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
NS vehicle instrument clusters are equipped with a
self diagnostic test feature to help identify electronic
problems. Prior to any test, perform Self Diagnostic
Test. The self diagnostic system monitors the CCD
bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in
the odometer window of the cluster.
The following CCD bus messages are continuously
monitored by the diagnostic system:
²Body Control Module
²Powertrain Control Module
²Transmission Control Module, if equipped
HEADLAMP SWITCH
Using a Digital Multimeter, equipped with a diode
test to perform the Headlamp Switch Test below (Fig.
1).
Switch position possibilities are open (no continu-
ity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine
meter setting. If Headlamp Switch is not within spec-
ifications replace as necessary.
The Chrysler Town and Country is available with
optional Automatic Headlamps. For diagnosis, refer
to the proper Body Diagnostic Procedures Manual.
SELF DIAGNOSTIC TEST
To activate self diagnostic program:
(1) With the ignition switch in the OFF position,
depress the TRIP and RESET buttons.
(2) While holding the TRIP and RESET button
turn the ignition switch to the ON position.
(3) Continue to hold the TRIP and RESET buttons
until the word CODE appears in the odometer win-
dows (about five seconds) then release the buttons. If
a problem exists, the system will display Diagnostic
Trouble Codes (DTC's). If no problem exists, the code
999 (End Test) will momentarily appear.
DIM TEST
When CHEC-0 is displayed in the odometer win-
dow, the cluster's vacuum fluorescent (VF) displayswill dim down. If the VF display brightness does no
change, a problem exists in the cluster.
Fig. 1 Headlamp Switch Test
8E - 2 INSTRUMENT PANEL AND SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)

CLUSTER CALIBRATION TABLE
Speedometer Calibration Point
1 ............................0mph(0Km/h)
2 ..........................20mph(40Km/h)
3 ..........................55mph(80Km/h)
4 .........................75mph(120 Km/h)
Tachometer Calibration Point
1....................................0rpm
2 .................................1000 rpm
3 .................................3000 rpm
4 .................................6000 rpm
Fuel Gauge Calibration Point
1.................................Empty (E)
2 .................................1/8 Filled
3 .................................1/4 Filled
4...................................Full (F)
Temperature Gauge Calibration Point
1 ..................................Cold (C)
2...............................Low Normal
3 ..............................High Normal
4...................................Hot (H)
CALIBRATION TEST
When CHEC-1 is displayed in the odometer win-
dow, each of the cluster's gauge pointers will move
sequentially through each calibration point. The Cal-
ibration Table contains the proper calibration points
for each gauge. If the gauge pointers are not cali-
brated, a problem exists in the cluster. If any gauge
is out of calibration it will have to be calibrated using
a scan tool (DRB III). Refer to the proper Body Diag-
nostic Procedure Manual for calibration procedures.
ODOMETER SEGMENT TEST
When CHEC-2 is displayed in the odometer win-
dow, each digit of the odometer will illuminate
sequentially. If a segment in the odometer does not
illuminate normally, a problem exists in the display.
ELECTRONIC TRANSMISSION RANGE
INDICATOR SEGMENT TEST
When CHEC-3 is displayed in the odometer win-
dow, each segment of the transmission range indica-
tor will illuminate sequentially. If a segment in the
transmission range indicator does not illuminate nor-
mally, a problem exists in the display board.
CONDITIONS
Refer to the following tables:
²Instrument Cluster
²Speedometer
²Tachometer
²Fuel Gauge
²Temperature Gauge
²Odometer
²Electronic Transmission Range Indicator
(PRND3L)
²Mechanical Transmission Range Indicator
(PRND21)
for possible/problems/causes and corrections.
INSTRUMENT CLUSTER DTC TABLE
DTC DESCRIPTION
110 Memory Fault in cluster
111 Calibration fault in cluster
905 No CCD bus messages from TCM
921 Odometer fault from BCM
940 No CCD bus messages from PCM
999 End of Codes
INSTRUMENT CLUSTER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
INSTRUMENT CLUSTER
INOPERATIVE-NO
RESPONSENo CCD bus messages
from the Body Control
Module (BCM).1. Use a scan tool to check the BCM. If OK, look for
another possible cause for cluster failure. If not OK,
refer to the proper Body Diagnostic Procedure Manual.
Spread terminal(s) on
wiring harness cluster
connector.1. Remove cluster from instrument panel and check
wiring harness connector for spread terminal. If OK,
look for another possible cause for the cluster failure. If
not OK, repair connector.
Body Control Module
(BCM) is not receiving
proper input from the
ignition switch.1. Use a scan tool to verify ignition switch status into
the BCM. If not OK, go to Step (2). If OK, look at
another possible cause of failure.
2. Check ignition switch function and wiring.
Internal cluster failure. 1. Replace main cluster pc board and use a scan tool
to calibrate cluster.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 3
DIAGNOSIS AND TESTING (Continued)

SPEEDOMETER DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
NO POINTER
MOVEMENT1. Internal cluster failure. 1. (a) Perform cluster self diagnostic test and check for
fault codes.
²If speedometer pointer moves to calibration points
during test and fault codes 110 or 111 don't appear in
the odometer display then failure is not in the cluster.
Look for another possible cause of failure.
²If the pointer doesn't move during test, go to Step
(b).
²If fault code 110 is displayed in the odometer, go to
Step (b).
²If fault code 111 is displayed in the odometer then go
to Step (f).
²If fault codes 905, 920, or 940 are displayed in the
odometer display refer to the fault code chart to identify
which module is causing the fault and repair module.
(b) Replace main cluster pc board. Go to Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, complete installation. If not OK,
go to Step (e).
(e) Replace subdial assembly and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the speedometer failure.
(f) Use a scan tool to calibrate speedometer and
perform Self Diagnostic Test. If OK, stop. If not OK, go
to Step (b).
2. No speed CCD Bus
Message or Zero mph
CCD Speed Bus
Message.2. (a) Check the Body Control Module (BCM) using a
scan tool. If OK, go to Step (b). If not OK, refer to the
BCM section of the service manual to repair the BCM.
(b) Check the Powertrain Control Module (PCM) using
a scan tool. If OK, go to Step (c). If not OK, refer to the
PCM section of the service manual to repair the PCM.
(c) Check the speed signal input into the PCM. The
speed signal originates from one of the following
sources:
²A distance sensor for vehicles with 3 speed automatic
transmission. Check continuity from distance sensor to
PCM. If OK, replace distance sensor. If not OK, repair
wiring.
²The Electronic Transmission Control Module (TCM)
for vehicles with the 4 speed electronic transmissions.
Check continuity from TCM to PCM. If OK, use a scan
tool to check TCM. Refer to the electronic TCM section
of the service manual to repair the TCM. If not OK,
repair wiring.
8E - 4 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC POINTER
MOVEMENT1. Erratic Message from
another Module.1. (a) Check the BCM using a scan tool If OK, go to
Step (b). If not OK, refer to the BCM section of the
service manual to repair the BCM.
(b) Check the PCM using a scan tool. If OK, go to Step
(c). If not OK, refer to the PCM section of the service
manual to repair the PCM.
(c) Check the speed signal input into the PCM. The
speed signal originates from one of the following
sources:
²A distance sensor for vehicles with 3 speed automatic
transmission. Check continuity from distance sensor to
PCM. If OK, replace distance sensor. If not OK, repair
wiring.
²The Electronic Transmission Control Module (TCM)
vehicles with the 4 speed electronic transmissions.
Check continuity from TCM to engine controller. If OK,
use a scan tool to check TCM. Refer to the electronic
section of the service manual to repair the TCM. If not
OK, repair wiring.
2. Internal Cluster Failure. 2. (a) Perform cluster self diagnostic test and check for
fault codes.
²If the pointer moves during test but still appears
erratic and fault codes 110 or 111 don't appear in the
odometer display, then go to Step (b).
²If fault code 110 is displayed in the odometer, go to
Step (e).
²If fault code 111 appears in the odometer display go
to Step (d).
²If fault codes 905, 920, or 940 are displayed in the
odometer display refer to the fault code chart to identify
which module is causing the fault and repair module.
(b) Replace cluster subdial assembly. To Step (c).
(c) Connect cluster into instrument panel wiring
harness. Place it back into the proper position in the
instrument panel. Put in the top two mounting screws to
hold the cluster in place. DO NOT COMPLETELY
INSTALL CLUSTER TO INSTRUMENT PANEL UNTIL
UNIT IS CALIBRATED AND TESTED. Go to Step (d).
(d) Use a scan tool to calibrate cluster and perform Self
Diagnostic Test. If OK, continue installation. If not OK,
go to Step (e).
Replace main cluster pc board and use a scan tool to
calibrate cluster. If not OK, look at another possible
cause for the speedometer failure.
NSINSTRUMENT PANEL AND SYSTEMS 8E - 5
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
SPEEDOMETER
INACCURATE.1. Speedometer Out of
Calibration.1. (a) Perform Cluster Self Diagnostic Test.
²If speedometer is accurate to the calibration points
then look for another possible cause of inaccuracy.
²If speedometer is not accurate to the calibration
points, go to Step (b).
(b) Use a scan tool to calibrate speedometer.
2. Wrong Speedometer
Pinion Size For Tire Size.2. (a) If vehicle has a 4 speed electronic transmission
go to Step (c). Otherwise go to Step (b).
(b) Check if correct speedometer pinion is being used
with tires on vehicle. Refer to transmission section of
manual for test and repair procedure.
²If the incorrect pinion is in transmission then replace
with correct pinion.
²If the correct pinion is in the transmission calibrate
speedometer using a scan tool to correct for the
inaccuracy.
(c) use a scan tool to check the TCM to see if the
correct tire size has been programmed into the TCM.
²If the incorrect tire size was selected, select the
proper tire size.
²If the correct tire size was selected, calibrate
speedometer to correct for the inaccuracy.
3. Bad Speed Sensor. 3. Refer to the proper section of the service manual for
test and repair procedure.
8E - 6 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

CONDITIONPOSSIBLE
CAUSESCORRECTION
ERRATIC DISPLAY 1. Internal Cluster
Failure.1. (a) Perform Cluster Self Diagnostic Test and check for fault
codes.
²If PRND3L passes the dim test and segment check and fault
codes 110 or 111 don't appear in the odometer display then failure
is not in the cluster. Look for another possible cause of failure.
²If PRND3L doesn't work go to Step (b).
²If fault code 110 is displayed in the odometer, go to Step (f).
²If fault code 111 is displayed in the odometer display then use a
scan tool to calibrate cluster.
²If fault code 905 is displayed use a scan tool to check electronic
TCM.
(b) Remove cluster from instrument panel and verify that odometer
assembly is properly connected to main pc board. If OK, go to
Step (c). If not OK, reconnect PRND3L assembly to main pc board.
(c) Replace PRND3L assembly. Go to Step (d).
(d) Connect cluster into instrument panel wiring harness. Place it
back into the proper position in the instrument panel. DO NOT
COMPLETELY INSTALL CLUSTER TO INSTRUMENT PANEL
UNTIL UNIT IS TESTED. Go to Step (e).
(e) Perform Self Diagnostic Test. If OK, continue installation. If not
OK, go to Step (f).
(f) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the PRND3L
failure.
2. Bad CCD Bus
Message from the
Electronic
Transmission
Control Module
(TCM).2. Use a scan tool to check the electronic TCM. Refer to the
electronic TCM section of the manual to properly diagnose and
repair.
ALL SEGMENTS
ARE ON1. No CCD bus
message from the
electronic
Transmission
Control Module
(TCM).1. (a) Perform Cluster Self Diagnostic test. If PRND3L passes test
go to Step (b). If PRND3L fails test go to Step (c).
(b) Check electronic TCM using a scan tool. Refer to the electronic
TCM section of the manual to properly diagnose and repair.
(c) Replace PRND3L assembly. Connect cluster into instrument
panel wiring harness. Place it back into the proper position in the
instrument panel. DO NOT COMPLETELY INSTALL CLUSTER TO
INSTRUMENT PANEL UNTIL UNIT IS TESTED. Go to Step (d).
(d) Perform Self Diagnostic Test. If OK, continue installation. If not
OK, go to Step (e).
(e) Replace main cluster pc board and use a scan tool to calibrate
cluster. If not OK, look at another possible cause for the PRND3L
failure.
8E - 16 INSTRUMENT PANEL AND SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)