1996 CHRYSLER VOYAGER bulb

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)

To adjust headlamp alignment, rotate alignment
screws to achieve the specified low beam hot spot
pattern (Fig. 2).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 200 mm (8 in.) below the fog
lamp centerline and straight ahead (Fig. 3). 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.
Fig. 3 Fog Lamp Alignment
Fig. 2 Headlamp AdjustersÐLeft Side Shown
NS/GSLAMPS 8L - 7
ADJUSTMENTS (Continued)

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

(2) Rotate front turn signal lamp socket one quar-
ter turn counterclockwise.
(3) Pull socket from back of lamp.
(4) Pull bulb from socket (Fig. 4).
INSTALLATION
(1) Align key on bulb base to groove in socket and
insert bulb into socket.
(2) Insert socket into back of headlamp.
(3) Rotate front turn signal socket clockwise one
quarter turn.
(4) Install headlamp module into vehicle.
(5) Verify lamp operation.
CITYLIGHT LAMP BULB
REMOVAL
(1) Remove the headlamp module.
(2) Pull citylight lamp from rubber bushing in
headlamp housing (Fig. 5).
(3) Pull bulb from socket (Fig. 6).
INSTALLATION
(1) Position citylight lamp bulb to lamp socket.
(2) Push bulb into socket.
(3) Push citylight lamp into bushing in headlamp
housing.
(4) Install headlamp module to vehicle.
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. 7).
(4) Hinge wire retainer clip out of bulb removal
path.
(5) Pull bulb from lamp.
(6) Disengage wire connector from fog lamp wire
harness.
Fig. 4 Front Turn Signal Lamp Bulb
Fig. 5 Citylight Lamp Socket
Fig. 6 Citylight Lamp Bulb
Fig. 7 Fog Lamp Bulb
NS/GSLAMPS 8L - 9
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other oily surfaces, reduced bulb life
will result.
(1) Engage wire connector into fog lamp wire har-
ness.
(2) Insert bulb into lamp so index notches on bulb
engage with bosses in lamp (Fig. 7).
(3) Hinge wire retainer clip over bulb base.
(4) Engage wire clip to hold bulb into lamp.
(5) Install rear cover on fog lamp.
(6) Install fog lamp on vehicle.
SIDE REPEATER LAMP BULB
REMOVAL
(1) Push side repeater lamp to one side and
release retaining tab (Fig. 8).(2) Pull side repeater lamp out and disengage bulb
socket from lamp (Fig. 9).
(3) Rotate and pull bulb from socket.
INSTALLATION
(1) Push and twist bulb into socket.
(2) Push side repeater lamp socket into side
repeater lamp.
(3) Position side repeater lamp to hole in fender.
(4) Push side repeater lamp to one side and seat
retaining tab into fender.
(5) Verify lamp operation.
TAIL LAMP BULB
The tail lamp houses the tail/stop lamp, rear turn
signal lamp, back-up lamp, and rear fog lamp bulbs.
Fig. 8 Side Repeater Lamp
Fig. 9 Side Repeater Lamp Bulb
8L - 10 LAMPSNS/GS
REMOVAL AND INSTALLATION (Continued)

REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Remove screws holding tail lamp to rear door
opening trough (Fig. 10).
(3) Separate inner end of lamp from quarter panel.
(4) Disengage hook holding outer end of lamp to
quarter panel opening.
(5) Separate lamp from quarter panel.
(6) Remove screws holding bulb holder to lamp
housing (Fig. 11).
(7) Separate bulb holder from lamp housing.
(8) Retrieve the rubber washers that seal the bulb
holder to the lamp housing at the bulb holder screw
locations.
(9) Pull bulb from bulb holder socket (Fig. 12).
INSTALLATION
(1) Align key on bulb base to groove in bulb holder
socket and insert bulb into socket (Fig. 12).
(2) Position bulb holder to lamp housing.
(3) Verify that the rubber washers are properly
positioned between the bulb holder and lamp housing
at the screw locations.
(4) Install screws to hold bulb holder to lamp hous-
ing.
(5) Position lamp to quarter panel.
(6) Engage hook to hold outer end of lamp to quar-
ter panel opening.
(7) Install screws to hold lamp to rear door open-
ing trough.
(8) Verify tail lamp operation.
Fig. 10 Tail Lamp
Fig. 11 Tail Lamp Bulb Holder
Fig. 12 Pull Bulb From Bulb Holder
NS/GSLAMPS 8L - 11
REMOVAL AND INSTALLATION (Continued)

LICENSE PLATE LAMP BULB
REMOVAL
(1) Press one retaining tab on license plate lamp
housing toward center of lens (Fig. 13).
(2) Separate lamp lens from lamp housing.
(3) Pull lamp bulb from socket.
INSTALLATION
(1) Align license plate lamp bulb to lamp socket.
(2) Push bulb into socket.
(3) Position lamp lens to lamp housing.
(4) Snap lamp lens onto tabs on lamp housing.
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
BULB
REMOVAL
(1) Release liftgate latch and open liftgate.
(2) Disengage clips holding CHMSL cover to lift-
gate trim panel (Fig. 14).
(3) Separate CHMSL cover from liftgate trim
panel.
(4) Depress plastic tab holding bulb holder to lamp
housing (Fig. 15).
(5) Separate bulb holder from lamp housing.
(6) Pull bulb or if equipped bulbs from lamp socket
(Fig. 16).
INSTALLATION
(1) Align bulb to bulb holder socket.
(2) Push bulb into bulb holder socket.
(3) Position bulb holder to CHMSL housing.
(4) Snap bulb holder into CHMSL housing.
(5) Position CHMSL cover to liftgate trim panel.
(6) Engage clips to hold CHMSL cover to liftgate
trim panel.
Fig. 13 License Plate Lamp Lens
Fig. 14 CHMSL Cover
Fig. 15 CHMSL Bulb Holder
Fig. 16 CHMSL Bulb
8L - 12 LAMPSNS/GS
REMOVAL AND INSTALLATION (Continued)