1996 CHRYSLER VOYAGER service

LAMPS
CONTENTS
page page
BULB APPLICATION...................... 25
EXTERIOR LAMP BULB SERVICE............ 9
EXTERIOR LAMP SERVICE................. 14HEADLAMP ALIGNMENT................... 5
INTERIOR LAMPS........................ 18
LAMP DIAGNOSIS........................ 1
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
ELECTRONIC DAYTIME RUNNING LIGHT (DRL).1
GENERAL INFORMATION.................. 1SAFETY PRECAUTIONS................... 1
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES................ 2
GENERAL INFORMATION
GENERAL INFORMATION
NS vehicles use lighting on the interior and exte-
rior of the vehicle for illuminating and indicating
purposes. Lighting circuits are protected by fuses.
Lighting circuits require an overload protected power
source, on/off device, lamps and body ground to oper-
ate properly. Plastic lamps require a wire in the har-
ness to supply body ground to the lamp socket.
Replace sockets and bulbs that are corroded.
Some of the interior and exterior lighting functions
are governed by the body controller. The headlamp,
dome, and the door ajar switches provide signals to
the body controller. The body controller in turn acti-
vates relay(s) in order to provide either a ground or
feed line to the appropriate lamp(s).
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 power distribution
center. Verify that bulbs are in good condition andtest continuity of the circuit ground. Refer to Group
8W, Wiring Diagrams, for component location and cir-
cuit information.SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
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.
ELECTRONIC DAYTIME RUNNING LIGHT (DRL)
The Combination Flasher/DRL is a module provid-
ing turn signal, hazard warning, and daytime run-
NSLAMPS 8L - 1

HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
HEADLAMP ALIGNMENT................... 5
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION....... 5ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN.................... 5
GENERAL INFORMATION
HEADLAMP ALIGNMENT
The headlamps are equipped with a bubble level
for up/down headlamp alignment. The bubble is cen-
tered with the vehicle on a level surface. A horizontal
gauge and magnifying window is located next to the
bubble level for left/right alignment (Fig. 1). Aim on
every headlamp assembly is calibrated at the head-
lamp manufacturer. At the vehicle assembly plant,
the vertical aim is set by centering the bubble with
the vehicle on a level surface. Horizontal aim is con-
trolled by the mounting pads on each headlamp
mounting panel.
When the vehicle is to be used with a heavy load,
the bubble level can be used to compensate for the
altered ride height.
SERVICE PROCEDURES
HEADLAMP 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) 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.
ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN
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. 2).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) From the floor up 1.27 meters (5 ft.), tape a
line on the wall at the center line of the vehicle.
Sight along the center line of the vehicle (from rear
of vehicle forward) to verify accuracy of the line
placement.
(4) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) 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.
(7) Measure distance from the center line of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
Fig. 1 Magnifying Window and Bubble Level
NSLAMPS 8L - 5

EXTERIOR LAMP BULB SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB........................ 13
FOG LAMP BULB ± TOWN and COUNTRY..... 11
FOG LAMP BULB........................ 10
FRONT PARKING AND TURN SIGNAL LAMP
BULB ± TOWN and COUNTRY............ 12
FRONT SIDE MARKER LAMP BULB TOWN and
COUNTRY............................ 11HEADLAMP BULB ± TOWN & COUNTRY....... 9
HEADLAMP BULB........................ 9
LICENSE PLATE LAMP BULB.............. 13
PARKING AND TURN SIGNAL BULB......... 11
TAIL, STOP, TURN SIGNAL AND BACK-UP
LAMP BULB.......................... 12
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) From behind radiator closure panel, disconnect
wire connector from back of headlamp bulb base.
(3) Rotate headlamp bulb retaining ring counter-
clockwise.
(4) Remove retaining ring from headlamp (Fig. 1).
(5) Pull headlamp bulb from back of headlamp.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) From behind radiator closure panel, insert
headlamp bulb into back of headlamp.
(2) Engage retaining ring onto headlamp (Fig. 1).(3) Rotate headlamp bulb retaining ring clockwise.
(4) Connect wire connector into headlamp bulb
base.
(5) Verify headlamp alignment.
HEADLAMP BULB ± TOWN & COUNTRY
HEADLAMP HIGH BEAM
REMOVAL
(1) Release hood latch and open hood.
(2) From behind radiator closure panel, disconnect
wire connector from back of high headlamp bulb
base.
(3) Rotate headlamp bulb counterclockwise and
pull bulb from back of headlamp module (Fig. 2).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) Insert bulb into the back of the headlamp mod-
ule.
(2) Rotate headlamp bulb clockwise to engage
bulb.
(3) Connect wire connector to the low beam head-
lamp. Verify headlamp bulb operation
(4) Verify headlamp alignment.
HEADLAMP LOW BEAM
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the three headlamp mounting nuts.
(3) Remove one attaching screw on top of the
crossmember.
(4) Disconnect wire connector from the back of the
low beam headlamp bulb base (Fig. 4).
Fig. 1 Headlamp Bulb
NSLAMPS 8L - 9

EXTERIOR LAMP SERVICE
INDEX
page page
GENERAL INFORMATION
HEADLAMP DIMMER SWITCH.............. 14
HEADLAMP MODULE.................... 14
HEADLAMP SWITCH..................... 14
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)............................. 17
FOG LAMP ± TOWN and COUNTRY......... 15
FOG LAMP............................. 14FRONT PARKING AND TURN SIGNAL LAMP ±
TOWN and COUNTRY.................. 15
FRONT SIDE MARKER LAMP TOWN and
COUNTRY............................ 15
HEADLAMP MODULE.................... 14
LICENSE PLATE LAMP................... 16
TAIL, STOP, TURN SIGNAL AND BACK-UP
LAMP............................... 16
GENERAL INFORMATION
HEADLAMP MODULE
Minor amounts of fogging may occur around the
edges of the headlamp lens when exposed to humid
conditions. This is considered normal. The fogging
will dissipate with increased ambient temperature or
headlamp usage.
HEADLAMP SWITCH
Service procedures for the headlamp switch can be
found in Group 8E, Instrument Panel and Gauges.
More information can be found in Group 8W, Wiring
Diagrams.
HEADLAMP DIMMER SWITCH
The headlamp dimmer switch is incorporated into
the multi-function (turn signal) switch. Proper proce-
dures can be found in Group 8J, Turn Signal and
Flashers. More information can be found in Group
8W, Wiring Diagrams.
REMOVAL AND INSTALLATION
HEADLAMP MODULE
REMOVAL
(1) Release hood latch and open hood.
(2) From inside engine compartment, remove nuts
holding headlamp module to radiator closure panel.
(3) Remove screw holding top of module to closure
panel.
(4) Remove headlamp module from radiator clo-
sure panel (Fig. 1).
(5) Disconnect wire connectors from back of head-
lamp module.
(6) Separate headlamp module from vehicle.
INSTALLATION
(1) Place headlamp module in position on vehicle.
(2) Connect wire connectors into back of headlamp
module.
(3) Place headlamp module in position on radiator
closure panel.
(4) Install nuts to hold headlamp module to radia-
tor closure panel.
(5) Install screw to hold top of module to closure
panel.
(6) Verify headlamp operation and alignment.
FOG LAMP
REMOVAL
(1) Remove screws holding fog lamp to front
bumper fascia (Fig. 2).
(2) Remove fog lamp from fascia.
(3) Disconnect wire connector from body wire har-
ness.
(4) Remove fog lamp from vehicle.
Fig. 1 Headlamp Module ± Typical
8L - 14 LAMPSNS

LAMPS
CONTENTS
page page
BULB APPLICATION..................... 17
HEADLAMP ALIGNMENT.................. 5
LAMP BULB SERVICE.................... 8LAMP DIAGNOSIS....................... 1
LAMP SERVICE........................ 13
LAMP DIAGNOSIS
INDEX
page page
GENERAL INFORMATION
HEADLAMP LEVELING MOTOR............. 2
INTRODUCTION........................ 1SAFETY PRECAUTIONS.................. 1
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES.............. 2
GENERAL INFORMATION
INTRODUCTION
GS vehicles use lighting on the interior and exte-
rior of the vehicle for illuminating and indicating
purposes. Lighting circuits are protected by fuses.
Lighting circuits require an overload protected power
source, on/off device, lamps and body ground to oper-
ate properly. Plastic lamps require a wire in the har-
ness to supply body ground to the lamp socket.
Replace sockets and bulbs that are corroded.
Some of the interior and exterior lighting functions
are governed by the body controller. The headlamp,
dome, and the door ajar switches provide signals to
the body controller. The body controller in turn acti-
vates relay(s) in order to provide either a ground or
feed line to the appropriate lamp(s).
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 power distribution
center. Verify that bulbs are in good condition and
test continuity of the circuit ground. Refer to Group
8W, Wiring Diagrams, for component location and cir-
cuit information.
SAFETY PRECAUTIONS
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
Do not use bulbs with higher candle power than
indicated in the Bulb Application table at the end of
this group. Damage to lamp and/or Daytime Run-
ning Lamp Module can result.
Do not use fuses, circuit breakers or relays hav-
ing greater amperage value than indicated on the
fuse panel or in the Owners Manual.
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.
NS/GSLAMPS 8L - 1

HEADLAMP ALIGNMENT
INDEX
page page
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION...... 5ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN.................. 5
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Verify that the headlamp leveling switch is in
the ª0º position.
(3) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(4) Verify proper tire inflation.
(5) Clean headlamp lenses.
(6) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(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.
ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 1).
(2) Place 75 kg in the driver's seat to simulate the
ride height of the vehicle when driven.
(3) If necessary, tape a line on the floor 10 meters
(32.8 ft) away from and parallel to the wall.
(4) From the floor up 1.27 meters (5 ft), tape a line
on the wall at the centerline of the vehicle. Sight
along the centerline of the vehicle (from rear of vehi-
cle forward) to verify accuracy of the line placement.
NS/GSLAMPS 8L - 5

LAMP BULB SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB....................... 12
CITYLIGHT LAMP BULB.................. 9
FOG LAMP BULB........................ 9FRONT TURN SIGNAL LAMP BULB.......... 8
HEADLAMP BULB....................... 8
LICENSE PLATE LAMP BULB............. 12
SIDE REPEATER LAMP BULB............. 10
TAIL LAMP BULB....................... 10
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) Remove headlamp module from vehicle.
(3) Remove rubber seal boot (Fig. 1).
(4) Disengage retaining spring clip from headlamp
(Fig. 2).
(5) Pivot spring clip from headlamp bulb removal
path.
(6) Pull headlamp bulb from back of headlamp
(Fig. 3).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers of other possibly oily surface. Reduced
bulb life will result.
(1) Insert headlamp bulb to headlamp.
(2) Pivot spring clip over headlamp bulb.
(3) Engage retaining spring clip to headlamp.
(4) Install rubber seal boot.(5) Engage wire connector to headlamp bulb base.
(6) Install headlamp module into vehicle
(7) Verify headlamp alignment.
FRONT TURN SIGNAL LAMP BULB
REMOVAL
(1) Remove headlamp module from vehicle
Fig. 1 Rubber Boot Seal
Fig. 2 Headlamp Bulb Spring Clip
Fig. 3 Headlamp Bulb
8L - 8 LAMPSNS/GS

LAMP SERVICE
INDEX
page page
GENERAL INFORMATION
HEADLAMP DIMMER SWITCH............. 13
HEADLAMP SWITCH.................... 13
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL)............................ 16FOG LAMP............................ 14
HEADLAMP LEVELING MOTOR............ 14
HEADLAMP MODULE................... 13
LICENSE PLATE LAMP.................. 15
SIDE REPEATER LAMP.................. 14
TAIL LAMP............................ 15
GENERAL INFORMATION
HEADLAMP SWITCH
Service procedures for the headlamp switch can be
found in Group 8E, Instrument Panel and Gauges.
More information can be found in Group 8W, Wiring
Diagrams.
HEADLAMP DIMMER SWITCH
The headlamp dimmer switch is incorporated into
the multi-function (turn signal) switch. Proper proce-
dures can be found in Group 8J, Turn Signal and
Flashers. More information can be found in Group
8W, Wiring Diagrams.
REMOVAL AND INSTALLATION
HEADLAMP MODULE
REMOVAL
(1) Release hood latch and open hood.
(2) Remove bolt holding headlamp module to radi-
ator closure panel (Fig. 1).
(3) From behind the radiator closure panel, remove
the nuts holding the headlamp module to the radia-
tor closure panel.
(4) Separate headlamp module from radiator clo-
sure panel.
(5) Disengage wire connector from headlamp bulb.
(6) Disengage wire connector from headlamp level-
ing motor.
(7) Disengage wire connector for front turn signal
and citylight lamps.(8) Separate headlamp module from vehicle.
INSTALLATION
(1) Position headlamp module to vehicle.
(2) Engage wire connector for front turn signal and
citylight lamps.
(3) Engage wire connector to headlamp leveling
motor.
(4) Engage wire connector to headlamp bulb.
(5) Position headlamp module to radiator closure
panel.
(6) Press headlamp module rearward until module
is fully seated onto mounting studs.
(7) Install nuts to hold headlamp module to radia-
tor closure panel.
(8) Verify lamp operation.
Fig. 1 Headlamp Module
NS/GSLAMPS 8L - 13