1996 CHRYSLER VOYAGER high beam

CHARGING SYSTEM RESISTANCE TESTS
These tests will show the amount of voltage drop
across the generator output wire from the generator
output (B+) terminal to the battery positive post.
They will also show the amount of voltage drop from
the ground (-) terminal on the generator or case
ground (Fig. 1) to the battery negative post.
A voltmeter with a 0±18 volt DC scale should be
used for these tests. By repositioning the voltmeter
test leads, the point of high resistance (voltage drop)
can easily be found.
PREPARATION
(1) Before starting test, make sure battery is in
good condition and is fully-charged. See Group 8A,
Battery for more information.
(2) Check condition of battery cables at battery.
Clean if necessary.
(3) Start the engine and allow it to reach normal
operating temperature.
(4) Shut engine off.
(5) Connect an engine tachometer.
(6) Fully engage the parking brake.
TEST
(1) Start engine.
(2) Place heater blower in high position.
(3) Turn on headlamps and place in high-beam
position.
(4) Turn rear window defogger on.
(5) Bring engine speed up to 2400 rpm and hold.
(6) Testing (+ positive) circuitry:
(a) Touch the negative lead of voltmeter directly
to battery positivePOST(Fig. 2).
(b) Touch the positive lead of voltmeter to the
B+ output terminal stud on the generator (not the
terminal mounting nut). Voltage should be no
higher than 0.6 volts. If voltage is higher than 0.6
volts, touch test lead to terminal mounting stud
nut and then to the wiring connector. If voltage is
now below 0.6 volts, look for dirty, loose or poor
connection at this point. Also check condition of the
generator output wire-to-battery bullet connector.
Refer to Group 8, Wiring for connector location. A
voltage drop test may be performed at each (-
ground) connection in this circuit to locate the
excessive resistance.
(7) Testing (- ground) circuitry:
(a) Touch the positive lead of voltmeter directly
to battery negativePOST.
(b) Touch the negative lead of voltmeter to the
generator case. Voltage should be no higher than
0.3 volts. If voltage is higher than 0.3 volts, touch
test lead to generator case and then to the engine
block. If voltage is now below 0.3 volts, look for
dirty, loose or poor connection at this point. A volt-
age drop test may be performed at each connectionin this circuit to locate the excessive resistance.
This test can also be performed between the gener-
ator case and the engine. If test voltage is higher
than 0.3 volts, check for corrosion at generator
mounting points or loose generator mounting.
CURRENT OUTPUT TEST
The current output test will determine if the
charging system can deliver its minimum test cur-
rent (amperage) output. Refer to the Specifications
section at the end of this group for minimum test
current (amperage) requirements.
The first part of this test will determine the com-
bined amperage output of both the generator and the
Electronic Voltage Regulator (EVR) circuitry.
PREPARATION
(1) Determine if any Diagnostic Trouble Codes
(DTC) exist. To determine a DTC, refer to On-Board
Diagnostics in this group. For repair, refer to the
appropriate Powertrain Diagnostic Procedures man-
ual.
(2) Before starting test, make sure battery is in
good condition and is fully-charged. See Group 8A,
Battery for more information.
(3) Check condition of battery cables at battery.
Clean if necessary.
(4) Perform the Voltage Drop Test. This will
ensure clean and tight generator/battery electrical
connections.
(5) Be sure the generator drive belt is properly
tensioned. Refer to Group 7, Cooling System for
information.
(6) A volt/amp tester equipped with both a battery
load control (carbon pile rheostat) and an inductive-
type pickup clamp (ammeter probe) will be used for
this test. Refer to operating instructions supplied
with tester. When using a tester equipped with an
inductive-type clamp, removal of wiring at the gener-
ator will not be necessary.
(7) Start the engine and allow it to reach operating
temperature.
(8) Shut engine off.
(9) Turn off all electrical accessories and all vehicle
lighting.
(10) Connect the volt/amp tester leads to the bat-
tery. Be sure the carbon pile rheostat control is in the
OPEN or OFF position before connecting leads. See
Load Test in Group 8A, Battery for more information.
Also refer to the operating instructions supplied with
test equipment.
(11) Connect the inductive clamp (ammeter probe).
Refer to the operating instructions supplied with test
equipment.
(12) If volt/amp tester is not equipped with an
engine tachometer, connect a separate tachometer to
the engine.
8C - 4 CHARGING SYSTEMNS
DIAGNOSIS AND TESTING (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
TURN SIGNAL AND HAZARD
WARNING FLASHERS
FUNCTION PROPERLY BUT
DAYTIME RUNNING LIGHTS
(DRL) DO NOT COME ON WHILE
DRIVING
(The brake lamp in the message
center remains illuminated under
the circumstances noted to the
right in step #3.0 through 3.5
unless the lamp is burned out.)
(Headlamps, either low or high
beam, remain illuminated under
the circumstances noted to the
right in step #4.0 through 4.3 even
though the headlamp switch is
OFF.)1. FAULTY GROUND FEED TO
JUNCTION BLOCK FROM
GROUND STUD CONNECTOR
THROUGH I/P HARNESS.
2. FAULTY GROUND FEED
THROUGH JUNCTION BLOCK TO
CAVITY #11 IN POSITION #3 OF
THE JUNCTION BLOCK.
3.0. FAULTY PARK BRAKE
SWITCH.
3.1. PARK BRAKE INPUT CIRCUIT
FALSELY GROUNDED. COULD BE
THE G09 CIRCUIT WHICH IS A
(20) GA. GY/BK WIRE BETWEEN
THE MESSAGE CENTER AND THE
JUNCTION BLOCK,
3.2. OR BETWEEN THE PARK
BRAKE SWITCH AND THE
JUNCTION BLOCK,
3.3. OR BETWEEN THE BRAKE
PRESSURE SWITCH AND THE
JUNCTION BLOCK,
3.4. OR BETWEEN THE IGNITION
SWITCH AND THE JUNCTION
BLOCK,
3.5. OR A SHORTED IGNITION
SWITCH (CONTACT SHOULD
ONLY BE MADE WHEN IN START
POSITION).
4.0. L93 CIRCUIT FALSELY
GROUNDED BETWEEN JUNCTION
BLOCK AND MULTI-FUNCTION
SWITCH.
4.1. L307 CIRCUIT FALSELY
GROUNDED BETWEEN
HEADLAMP SWITCH AND BODY
CONTROL MODULE.
4.2. HEADLAMP SWITCH
SHORTED.
4.3. HEADLAMP CONTROL
OUTPUT FALSELY GROUNDED BY
BODY CONTROL MODULE.1. REPLACE GROUND CIRCUIT TO
JUNCTION BLOCK.
2. REPLACE JUNCTION BLOCK.
3.0. REPLACE THE PARK BRAKE
SWITCH.
3.1-3.4. REPAIR THE G09 CIRCUIT
TO ELIMINATE THE FALSE
GROUND SOURCE.
3.5. REPLACE IGNITION SWITCH.
4.0. REPAIR OR REPLACE FAULTY
WIRING CONNECTION BETWEEN
JUNCTION BLOCK AND MULTI-
FUNCTION SWITCH.
4.1. REPAIR OR REPLACE FAULTY
WIRING CONNECTION BETWEEN
HEADLAMP SWITCH AND BODY
CONTROL MODULE.
4.2. REPLACE SHORTED
HEADLAMP SWITCH.
4.3. REPLACE BODY CONTROL
MODULE.
8J - 10 TURN SIGNAL AND FLASHERSNS
DIAGNOSIS AND TESTING (Continued)

ning light functions (for Canadian vehicles), and has
been designed with internal relays to take advantage
of low current switching requirements in the vehicle.
It is plugged into the junction block at positions
three and four (Fig. 1), where all wiring associated
with its operation is terminated. The junction block
is adjacent to and left of the steering column of the
vehicle. For diagnostic information refer to Group 8J,
Turn Signal and Flashers.
On vehicles built for use in the United States, only
position four is used. Vehicles built for use in Canada
utilize both positions three and four.
To gain access to the device, remove the lower
steering column cover and knee blocker. Refer to
Group 8E, Instrument Panel and Gauges.SYSTEM FUNCTION
The combination-flasher/DRL may be operated in
its hazard warning mode either with or without the
ignition circuit being active. However, in order to
operate in the turn signal mode or the DRL mode,
the ignition circuit must be completed to the module.
While the combination-flasher portion is idle, there
is no current drawn through the module. The device
does not become active in the turn signal or hazard
warning modes until a signal ground circuit is sup-
plied to either of the turn signal inputs or the hazard
warning input. With the ignition OFF, there is no
current drawn through the module.
While the ignition is ON, the front turn signal fil-
aments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by
applying a signal ground input from either the park
brake circuit or the headlamp relay activation circuit.
DIAGNOSIS AND TESTING
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, charging system, headlamp bulbs, wire
connectors, relay, high beam dimmer switch and
headlamp switch. Refer to Group 8W, Wiring Dia-
grams, for component locations and circuit informa-
tion.
Fig. 1 Junction Block Terminal PINS
8L - 2 LAMPSNS
GENERAL INFORMATION (Continued)

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 generator drive belt. 2. Adjust or replace generator 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.
7. Low beam headlamp / foglamp fuse
blown.7. Locate cause of blown fuse and repair.
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.
4. Low beam headlamp / fog lamp
fuse blown.4. Locate cause of blown fuse and repair.
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.
NSLAMPS 8L - 3
DIAGNOSIS AND TESTING (Continued)

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

side of vehicle center line. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen 229 mm (9 in.)650 mm (2 in.) below the
headlamp center line. The center of the hot spot
should be 100 mm (4 in.)650 mm (2 in.) right of the
headlamp center line (Fig. 2). 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.
To adjust headlamp alignment, rotate adjusting
screws to achieve the specified low beam hot spot
location (Fig. 3).
HEADLAMP ADJUSTMENT ± TOWN AND
COUNTRY
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen 152 mm (6 in.)650 mm (2 in.) below the
headlamp center line. The center of the hot spot
should be 254 mm (10 in.)650 mm (2 in.) right of
the headlamp center line (Fig. 4). The high beams on
a vehicle with aero headlamps cannot be aligned. Thehigh beam pattern should be correct when the low
beams are aligned properly.
Fig. 2 Headlamp Alignment Screen
Fig. 3 Headlamp Bubble Level and Adjusters
8L - 6 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)