1996 CHRYSLER VOYAGER Service Manual

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)

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)

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

(5) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(6) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(7) 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.
(8) Place a tape line 130 mm below and parallel to
the center of headlamp line.
(9) Measure distance from the centerline of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
side of vehicle centerline. Use these lines for left/
right adjustment reference.HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project a
high intensity light pattern on the screen with the
horizontal cut-off line aligned with the tape line 130
mm (5.12 in.) below the headlamp centerline (Fig. 1).
The intersection of the horizontal and 15 degree cut-
off lines in the projected pattern should align to the
intersection of the headlamp centerline vertical tape
line and the tape line 130 mm (5.12 in.) below the
headlamp horizontal centerline. The high beams on a
vehicle with aero headlamps cannot be aligned. The
high beam pattern should be correct when the low
beams are aligned properly.
Fig. 1 Headlamp Alignment Screen
8L - 6 LAMPSNS/GS
ADJUSTMENTS (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