1996 CHRYSLER VOYAGER service

INSTRUMENT PANEL AND SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION........................ 1
DESCRIPTION AND OPERATION
HEADLAMP AND POWER MIRROR
SWITCH LAMP(S)..................... 1
INSTRUMENT CLUSTER................. 2
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES.............. 2
HEADLAMP SWITCH.................... 2
SELF DIAGNOSTIC TEST................. 3
REMOVAL AND INSTALLATION
ASH RECEIVER ± CONVENIENCE
BIN LAMP MODULE.................. 15
BODY CONTROL MODULE (BCM)......... 16
CIGAR LIGHTER BASE.................. 16
CONVENIENCE BIN.................... 15
CONVENIENCE BIN - CUP HOLDER....... 15
GLOVE BOX.......................... 17
GLOVE BOX LAMP AND SWITCH......... 17
GLOVE BOX LOCK STRIKER............. 17
HEADLAMP SWITCH................... 18
HEADLAMP SWITCH LAMP(S)........... 18
HVAC CONTROL LAMP................. 18
INSTRUMENT CLUSTER................ 20INSTRUMENT CLUSTER BACK PANEL..... 18
INSTRUMENT CLUSTER BEZEL.......... 18
INSTRUMENT CLUSTER LENS........... 19
INSTRUMENT CLUSTER PRINTED
CIRCUIT BOARD..................... 19
INSTRUMENT CLUSTER SUBDIAL........ 20
INSTRUMENT PANEL................... 20
INSTRUMENT PANEL LEFT END COVER.... 22
INSTRUMENT PANEL LOUVERS.......... 22
INSTRUMENT PANEL RIGHT END COVER . . 25
INSTRUMENT PANEL TOP COVER........ 24
JUNCTION BLOCK..................... 25
KNEE BLOCKER REINFORCEMENT........ 25
LOWER CONSOLE..................... 26
LOWER INSTRUMENT PANEL............ 26
LOWER STEERING COLUMN COVER...... 27
MESSAGE CENTER.................... 27
OVER STEERING COLUMN BEZEL........ 28
POWER MIRROR SWITCH.............. 28
POWER MIRROR SWITCH LAMP......... 28
RADIO BEZEL AND HVAC CONTROL....... 29
REAR HEATER-A/C SWITCH............. 29
REAR HEATER-A/C SWITCH LAMP........ 29
GENERAL INFORMATION
INTRODUCTION
The instrumentation gauges on GS 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
HEADLAMP AND POWER MIRROR SWITCH
LAMP(S)
The Headlamp Switch and Power Mirror Switch
lamps are shown in (Fig. 1). For replacement of the
lamp(s) refer to Headlamp Switch Lamp(s) Removal
and Installation procedures below. Refer to Group 8T,
Power Mirrors for mirror test procedures.
NS/GSINSTRUMENT PANEL AND SYSTEMS 8E - 1

(5) Remove the screws holding printed circuit
board to the cluster shell.
(6) Remove the printed circuit board from the clus-
ter.
INSTALLATION
For installation, reverse the above procedures.
After installing the print circuit board it will have to
be calibrated using a scan tool (DRB III). Refer to the
proper Body Diagnostic Procedure Manual for cali-
bration procedures.
NOTE: Speedometer and/or Tachometer will not
operate properly until all gauges have been cali-
brated
INSTRUMENT CLUSTER SUBDIAL
REMOVAL
(1) Remove instrument cluster.
(2) Remove cluster lens.
(3) Disconnect temperature/fuel gauge and tachom-
eter terminals from connectors in cluster by pulling
subdial straight away from cluster (Fig. 21).
(4) Remove subdial from cluster.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT CLUSTER
REMOVAL
(1) Remove instrument cluster bezel (Fig. 22).
(2) Remove screws holding instrument cluster to
instrument panel.
(3) Rotate top of cluster outward.
(4) Remove instrument cluster from instrument
panel.(5) Disconnect wire connector from back of instru-
ment cluster.
(6) Remove instrument cluster.
INSTALLATION
For installation, reverse the above procedures.
INSTRUMENT PANEL
The instrument panel is removed as a unit. The
steering column and wiring harnesses are assembled
into the panel before installation. Service procedures
for interior trim not related to the instrument panel
can be found in Group 23, Body.
REMOVAL
(1) Disconnect the battery, negative cable first.
(2) Remove the lower console.
(3) Remove the screw holding the lower heat duct
to the instrument panel support (Fig. 23).
(4) Disconnect the heat duct from the vehicle.
(5) Remove the bolts holding the lower supports to
the instrument panel frame (Fig. 24).
Fig. 21 Instrument Cluster Subdial
Fig. 22 Instrument Panel
Fig. 23 Heat Duct
8E - 20 INSTRUMENT PANEL AND SYSTEMSNS/GS
REMOVAL AND INSTALLATION (Continued)

(5) Applying pressure on the housing, release the
upper right lock tab and the lower right.
(6) Push out the louver housing from the cluster
bezel.
INSTALLATION
(1) Verify the function of the vanes.
(2) Set louver housing into the cluster bezel.
(3) Using care do not push on the vanes, apply
pressure on outer edge of the housing and push lou-
ver housing into place.
(4) After in place check function of the vanes.
LEFT LOUVER HOUSING
REMOVAL
(1) Remove the instrument cluster bezel. Refer to
Instrument Cluster Bezel Removal and Installation
procedures.
(2) Place cluster bezel on a clean surface face down
with the head lamp switch to the right side (Fig. 30).(3) Using a flat bladed tool, release the louver
housing locks tabs.
(4) Release the upper left lock tab first, then the
other upper lock tab.
(5) Applying pressure on the housing, release the
lower lock tabs.
(6) Push out the louver housing from the cluster
bezel.
INSTALLATION
(1) Verify the function of the vanes.
(2) Set louver housing into the cluster bezel and
align the slot of the housing with the T location pins.
(3) Using care do not push on the vanes, apply
pressure on outer edge of the housing and push lou-
ver housing into place.
(4) After in place check function of the vanes.
PASSENGER SIDE LOUVERS
The inner, outer louver and inner, outer housing
are serviceable.
REMOVAL
(1) Using medium flat blade tool, position it in
between the right side of louver and the housing
(Fig. 32).
(2) Twist the tool to release the pivot pin from the
louver and pull outward till released from pin.
(3) Place tool on the other side of louver and
release the other pivot pin and pull housing free from
the instrument panel. Use the same procedure for
either inner or outer louver.
Fig. 30 Instrument Cluster Bezel
Fig. 31 Center Louver
Fig. 32 Removing Passenger Louver
NS/GSINSTRUMENT PANEL AND SYSTEMS 8E - 23
REMOVAL AND INSTALLATION (Continued)

CD/3-band graphic equalizer (RBR sales code), or an
AM/FM/CD/cassette/3-band graphic equalizer (RAZ
sales code).
All factory-installed radio receivers are stereo Elec-
tronically Tuned Radios (ETR) and include an elec-
tronic digital clock function.
All factory-installed radio receivers, except the
RAS model, communicate on the Chrysler Collision
Detection (CCD) data bus network through a sepa-
rate two-way wire harness connector. The CCD data
bus network allows the sharing of sensor informa-
tion. This helps to reduce wire harness complexity,
internal controller hardware, and component sensor
current loads. At the same time, this system provides
increased reliability, enhanced diagnostics, and
allows the addition of many new feature capabilities.
In addition, radios connected to the CCD data bus
have several audio system functions that can be diag-
nosed using a DRB scan tool. Refer to the proper
Diagnostic Procedures manual for more information
on DRB testing of the audio systems.
The radio can only be serviced by an authorized
radio repair station. Refer to the latest Warranty Pol-
icies and Procedures manual for a current listing of
authorized radio repair stations.
For more information on radio features, setting
procedures, and control functions refer to the owner's
manual in the vehicle glove box.
RADIO IGNITION INTERFERENCE
If receiving ignition/engine interference noise on
the radio stations, check and clean all engine and
body ground connections. Tighten properly after
cleaning. Example (Fig. 1), (Fig. 2), (Fig. 3) and (Fig.
4).
Ensure all ground connections are without corro-
sion.
CHOKEÐINFINITY SPEAKERS
If the audio system is lacking bass response, check
for continuity across the choke connector. If no conti-
nuity Replace choke. The choke is located on the
Fig. 1 Motor Mount to Frame Rail Ground
Fig. 2 2.4L Engine Block Ground
Fig. 3 3.0L Engine Block Ground
Fig. 4 3.3/3.8L Engine Block Ground
8F - 2 AUDIO SYSTEMSNS
DESCRIPTION AND OPERATION (Continued)

bracket behind the junction block/body control mod-
ule (Fig. 5).
REMOTE RADIO SWITCHES
A remote radio control switch option is available on
LXI models sold in North America with the AM/FM/
cassette/5-band graphic equalizer with CD changer
control feature (RBN sales code), or the AM/FM/CD/
cassette/3-band graphic equalizer (RAZ sales code)
radio receivers. Two rocker-type switches are
mounted on the back (instrument panel side) of the
steering wheel spokes. The switch on the left spoke is
the seek switch and has seek up, seek down, and pre-
set station advance functions. The switch on the
right spoke is the volume control switch and has vol-
ume up, and volume down functions (Fig. 6).
These switches are resistor multiplexed units that
are hard-wired to the Body Control Module (BCM)
through the clockspring. The BCM sends the propermessages on the Chrysler Collision Detection (CCD)
data bus network to the radio receiver. For diagnosis
of the BCM or the CCD data bus, the use of a DRB
scan tool and the proper Diagnostic Procedures man-
ual are recommended. For more information on the
operation of the remote radio switch controls, refer to
the owner's manual in the vehicle glove box.
NAME BRAND SPEAKER RELAY
Relay is located in the junction block. To test relay
refer to the Audio Diagnostic Test Procedures or use
a known good relay.
DIAGNOSIS AND TESTING
ANTENNA
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
The following four tests are used to diagnose the
antenna with an ohmmeter:
²Test 1- Mast to ground test
²Test 2- Tip-of-mast to tip-of-conductor test
²Test 3- Body ground to battery ground test
²Test 4- Body ground to coaxial shield test.
The ohmmeter test lead connections for each test
are shown in Antenna Tests (Fig. 7).
NOTE: This model has a two-piece antenna coaxial
cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the
coaxial cable connection under the right end of the
instrument panel near the right cowl side panel to
the antenna base, and then from the coaxial cable
connection to the radio chassis connection.
TEST 1
Test 1 determines if the antenna mast is insulated
from the base. Proceed as follows:
(1) Unplug the antenna coaxial cable connector
from the radio chassis and isolate.
(2) Connect one ohmmeter test lead to the tip of
the antenna mast. Connect the other test lead to the
antenna base. Check for continuity.
(3) There should be no continuity. If continuity is
found, replace the faulty or damaged antenna base
and cable assembly.
Fig. 5 Choke Location
Fig. 6 Remote Radio Switch Operational View
NSAUDIO SYSTEMS 8F - 3
DESCRIPTION AND OPERATION (Continued)

TEST 2
Test 2 checks the antenna for an open circuit as
follows:
(1) Unplug the antenna coaxial cable connector
from the radio chassis.
(2) Connect one ohmmeter test lead to the tip of
the antenna mast. Connect the other test lead to the
center pin of the antenna coaxial cable connector.
(3) Continuity should exist (the ohmmeter should
only register a fraction of an ohm). High or infinite
resistance indicates damage to the base and cable
assembly. Replace the faulty base and cable, if
required.
TEST 3
Test 3 checks the condition of the vehicle body
ground connection. This test should be performed
with the battery positive cable removed from the bat-
tery. Disconnect both battery cables, the negative
cable first. Reconnect the battery negative cable and
perform the test as follows:
(1) Connect one ohmmeter test lead to the vehicle
fender. Connect the other test lead to the battery
negative post.
(2) The resistance should be less than (1) ohm.
(3) If the resistance is more than (1) ohm, check
the braided ground strap connected to the engine and
the vehicle body for being loose, corroded, or dam-
aged. Repair the ground strap connection, if required.
TEST 4
Test 4 checks the condition of the ground between
the antenna base and the vehicle body as follows:(1) Connect one ohmmeter test lead to the vehicle
fender. Connect the other test lead to the outer crimp
on the antenna coaxial cable connector.
(2) The resistance should be less then (1) ohm.
(3) If the resistance is more then (1) ohm, clean
and/or tighten the antenna base to fender mounting
hardware.
AUDIO SYSTEM
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
RADIO
If the vehicle is equipped with remote radio
switches located on the backs of the steering wheel
spokes, and the problem being diagnosed is related to
one of the symptoms listed below, be certain to check
the remote radio switches and circuits as described
in this group, prior to attempting radio diagnosis or
repair.
²Stations changing with no remote radio switch
input
²Radio memory presets not working properly
²Volume changes with no remote radio switch
input
²Remote radio switch buttons taking on other
functions
²CD player skipping tracks
²Remote radio switch inoperative.
For circuit descriptions and diagrams, refer to
Group 8W - Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
CAUTION: The speaker output of the radio is a
ªfloating groundº system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
Fig. 7 Antenna Tests
8F - 4 AUDIO SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

(1) Check the fuse(s) in the junction block and the
Power Distribution Center (PDC). If OK, go to Step
2. If not OK, repair the shorted circuit or component
as required and replace the faulty fuse(s).
(2) Check for battery voltage at the fuse in the
PDC. If OK, go to Step 3. If not OK, repair the open
circuit to the battery as required.
(3) Turn the ignition switch to the ON position.
Check for battery voltage at the fuse in the junction
block. If OK, go to Step 4. If not OK, repair the open
circuit to the ignition switch as required.
(4) Turn the ignition switch to the OFF position.
Disconnect and isolate the battery negative cable.
Remove the instrument cluster center bezel. Remove
the radio, but do not unplug the wire harness connec-
tors. Check for continuity between the radio chassis
and a good ground. There should be continuity. If
OK, go to Step 5. If not OK, repair the open radio
chassis ground circuit as required.
(5) Connect the battery negative cable. Turn the
ignition switch to the ON position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the left (gray) radio wire harness connector.
If OK, go to Step 6. If not OK, repair the open circuit
as required.
(6) Turn the ignition switch to the OFF position.
Check for battery voltage at the fused B(+) circuit
cavity of the left (gray) radio wire harness connector.
If OK, replace the faulty radio. If not OK, repair the
open circuit to the Ignition-Off Draw (IOD) fuse as
required.
REMOTE RADIO SWITCHES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the airbag system capac-
itor to discharge before further service.
(2) Remove the remote radio switch(es) from the
steering wheel.
(3) Use an ohmmeter to check the switch resis-
tance as shown in the Remote Radio Switch Test
table (Fig. 8).
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.(4) If the switch resistance checks OK, go to Step
5. If not OK, replace the faulty switch.
(5) Check for continuity between the ground cir-
cuit cavity of the switch wire harness connector and
a good ground. There should be continuity. If OK, go
to Step 6. If not OK, repair the open circuit as
required.
(6) Unplug the 24-way white wire harness connec-
tor from the Body Control Module (BCM). Check for
continuity between the radio control circuit cavity of
the remote radio switch wire harness connector and a
good ground. There should be no continuity. If OK, go
to Step 7. If not OK, repair the short circuit as
required.
(7) Check for continuity between the radio control
circuit cavities of the remote radio switch wire har-
ness connector and the BCM wire harness connector.
There should be continuity. If OK, refer to the proper
Diagnostic Procedures manual to test the BCM and
the CCD data bus. If not OK, repair the open circuit
as required.
Fig. 8 Remote Radio Switches
REMOTE RADIO SWITCH TEST
SWITCH POSITION RESISTANCE
VOLUME UP 7320 OHMS
VOLUME DOWN 1210 OHMS
SEEK UP 4530 OHMS
SEEK DOWN 2050 OHMS
PRE-SET STATION ADVANCE 10 OHMS
8F - 6 AUDIO SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

FRONT DOOR SPEAKER
REMOVAL
(1) Remove front door trim panel as necessary to
gain access to door speaker. Refer to Group 23, Body
for proper procedures.
(2) Remove screws holding speaker to bracket (Fig.
16).
(3) Remove speaker from bracket.
(4) Disconnect wire connector from speaker.
(5) Remove speaker.
INSTALLATION
For installation, reverse the above procedure.
REMOTE RADIO SWITCHES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
REMOVAL
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the airbag system capac-
itor to discharge before further service.
(2) From the underside of the steering wheel,
remove the (3) bolts that secure the driver side air-
bag module to the steering wheel.
(3) Pull the airbag module away from the steering
wheel far enough to access the wire harness connec-
tors on the back of the airbag module.
(4) Unplug the airbag module and horn switch
wire harness connectors from the back of the airbag
module.
(5) Remove the driver side airbag module from the
vehicle.
(6) Remove the steering wheel from the steering
column. Refer to Group 19±Steering, for service pro-
cedure.
(7) Unplug the wire harness connector from the
remote radio switch (s).
(8) Remove three screws securing steering wheel
rear cover. Refer to Group 19, Steering for serivce
procedure.
(9) Remove the remote radio switch from the steer-
ing wheel by depressing tabs on each side of switch..
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.
INSTALLATION
For installation, reverse the above procedure. The
switches can only be installed one way. Be careful to
index them correctly before pressing them into place.
Tighten the airbag module mounting screws to 10.2
N´m (90 in. lbs.).
Fig. 15 Right Instrument Panel Speaker
Fig. 16 Front Door Speaker
NSAUDIO SYSTEMS 8F - 9
REMOVAL AND INSTALLATION (Continued)