1996 CHRYSLER VOYAGER headlamp

(3) Tighten screws to hold magnifying window to
headlamp module. Do not over tighten.FOG LAMP ALIGNMENT
Prepare an alignment screen. Refer to the Align-
ment Screen Preparation paragraph in this section. 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. 6). To
improve visual interpretation of the fog lamp pattern
on the alignment screen, disable the headlamps by
disengaging the wire connectors from the headlamp
bulbs.
The Town and Country fog lamp adjustment screw
is located through the lens (Fig. 7).
Fig. 6 Fog Lamp Alignment
Fig. 5 Magnifying Window and Bubble Level
Calibration
Fig. 7 Fog Lamp Adjustment Screw
8L - 8 LAMPSNS
ADJUSTMENTS (Continued)

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

(5) Rotate headlamp bulb retainer counterclock-
wise and disengage retainer from headlamp (Fig. 3).
(6) Pull headlamp bulb from back of the headlamp
module.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) Place headlamp bulb into headlamp module.
(2) Rotate headlamp bulb retainer clockwise to
engage retainer.
(3) Connect wire connector to the low beam head-
lamp. Verify headlamp bulb operation
(4) Install the headlamp module.
(5) Verify headlamp alignment.
FOG LAMP BULB
REMOVAL
(1) Remove fog lamp from vehicle.
(2) Remove rear cover from fog lamp.
(3) Disengage wire clip holding bulb in fog lamp
(Fig. 5).
(4) Hinge wire retainer clip out of bulb removal
path.
(5) Pull bulb from lamp.
(6) Disconnect wire connector from fog lamp wire
harness.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other oily surfaces, reduced bulb life
will result.
Fig. 2 Headlamp High Beam Bulb ± T&C
Fig. 3 Low Beam Headlamp Retainer
Fig. 4 Headlamp Low Beam Bulb ± T&C
Fig. 5 Fog Lamp Bulb
8L - 10 LAMPSNS
REMOVAL AND INSTALLATION (Continued)

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

BULB APPLICATION
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 25SPECIFICATIONS
EXTERIOR LAMP BULBS.................. 25
INTERIOR LAMP BULBS.................. 25
GENERAL INFORMATION
INTRODUCTION
The following Bulb Application Tables list the lamp
title on the left side of the column and trade number
or part number on the right.
CAUTION: Do not use bulbs that have a higher
candle power than the bulb listed in the Bulb Appli-
cation Table. Damage to lamp can result.
Do not touch halogen bulbs with fingers or other
possibly oily surfaces. Bulb life will be reduced.
If a halogen bulb is contaminated with oil, clean
bulb with denatured alcohol or ammonia based sol-
vent.
SPECIFICATIONS
EXTERIOR LAMP BULBS
LAMP BULB
Back-up...............................3057
CHMSL................................921
Fog Lamp...............................H3
FogLamp±T&C ........................9040
Headlamp..............................9007
Headlamp high beam ± T&C...............9005
Headlamp low beam ± T&C............9005 SLL
License Plate............................168
Parking/Turn Signal/Front Side Marker. . . .3157NA
Parking/Turn Signal ± T&C............4157NAK
Tail, Stop, Turn Signal and Side Marker......3057
Front Side Marker......................194NA
INTERIOR LAMP BULBS
LAMP BULB
ABS.................................PC194
AirBag ..............................PC194
Alarm Set (Security)....................PC194
Brake Warning.........................PC194
Center/Rear Reading Lamps.................578
Center/Rear Dome Lamps...................579
Check Engine Ind.......................PC194
Front Door Courtesy.......................567
Door Ajar Ind..........................PC194
Front Header Reading Lamp................567
Glove Box Lamp..........................194
High Beam Ind.........................PC194
Instrument Cluster.....................PC194
IP Bin/Ash Tray..........................161
Liftgate Flood Lamps......................567
Liftgate Ajar Ind.........................PC74
Low Fuel Ind..........................PC194
Oil Pressure Ind........................PC194
O/H Console Reading Lamps................579
Seat Belt Ind...........................PC74
Engine Temp Ind.......................PC194
Turn Signal...........................PC194
Engine Compartment Lamps................579
Visor Vanity Lamp....................6501966
Low Washer Fluid.......................PC74
Low Volts Warning.......................PC74
Cruise Indicator........................PC194
NSLAMPS 8L - 25

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 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)

HEADLAMP LEVELING MOTOR DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
ONE MOTOR DOES NOT
OPERATE1. Poor connection at motor. 1. Secure connector on motor.
2. No voltage at motor. 2. Repair circuit. Refer to Group 8W,
Wiring.
3. Defective motor. 3. Replace motor.
BOTH MOTORS DO NOT
OPERATE1. No voltage at headlamp leveling
switch.1. Repair circuit or replace fuse.
Refer to Group 8W, Wiring.
2. No voltage at both motors. 2. Repair circuit or replace fuse.
Refer to Group 8W, Wiring.
3. Poor connection at motors. 3. Secure connectors on motors.
4. Both motors defective. 4. Replace motors.
8L - 4 LAMPSNS/GS
DIAGNOSIS AND TESTING (Continued)