2002 CHRYSLER VOYAGER front lighting

FOG LAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - FOG LAMP UNIT
ALIGNMENT
FOG LAMP UNIT ALIGNMENT
Prepare an alignment screen (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - STANDARD PROCEDURE). 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. 9). To
improve visual interpretation of the fog lamp patternon the alignment screen, the headlamps should be in
the ªoffº position.
The fog lamps are adjusted by a adjustment screw
located through the lens on Dodge vehicles, and by a
knob on the back of the lamp.
STANDARD PROCEDURE - FOG LAMP UNIT
ALIGNMENT - EXPORT
Prepare an alignment screen (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/HEAD-
LAMP UNIT - STANDARD PROCEDURE). A
properly aligned fog lamp will project a pattern on
the alignment screen 200 mm (8 in.) below the fog
lamp center line and straight ahead (Fig. 10). To
improve visual interpretation of the fog lamp pattern
on the alignment screen, the headlamps should be in
the ªoffº position.
Fig. 9 FOG LAMP UNIT ALIGNMENT
1 - HIGH INTENSITY AREA 4 - 100MM (4 IN.)
2 - CENTER OF VEHICLE 5 - 7.62 METERS (25 FT.)
3 - HORIZONTAL CENTER OF FOG LAMP 6 - FRONT OF FOG LAMP
8L - 10 LAMPS/LIGHTING - EXTERIORRS
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The fog lamps are adjusted by a adjustment screw
located on the underside of the fog lamp unit.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) From behind the bumper fascia, disconnect the
wire harness from the fog lamp bulb (Fig. 7).
(3) Remove mounting nuts.
INSTALLATION
(1) Install mounting nuts.
(2) Reconnect the wire harness to the fog lamp
bulb.
(3) Reconnect the battery negative cable.
FRONT POSITION LAMP -
EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the headlamp unit (Fig. 11).
(3) Remove the plastic cover from the back of the
headlamp unit.
(4) Pull front position lamp socket from headlamp
unit.
(5) Pull bulb straight out of socket.
INSTALLATION
(1) Push bulb into the bulb socket.
(2) Insert bulb socket into headlamp unit.
(3) Install cover to the back of the headlamp unit.
Fig. 10 FOG LAMP UNIT ALIGNMENT - EXPORT
1 - HIGH INTENSITY AREA 4 - 200 MM
2 - CENTER OF VEHICLE 5 - 10 METERS
3 - HORIZONTAL CENTER OF FOG LAMP UNIT 6 - FRONT OF FOG LAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-11
FOG LAMP UNIT (Continued)
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(4) Install the headlamp unit.
(5) Connect the battery negative cable.
HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP
When a vehicle experiences problems with the
headlamp system, verify the condition of the battery
connections, fuses, charging system, headlamp bulbs,
wire connectors, relay, high beam switch, dimmer
switch, and headlamp switch. Refer to the appropri-
ate wiring information.
Each vehicle is equipped with various lamp assem-
blies. A good ground is necessary for proper lighting
operation. Grounding is provided by the lamp socket
when it comes in contact with the metal body, or
through a separate ground wire.
When changing lamp bulbs check the socket for
corrosion. If corrosion is present, clean it with a wire
brush.
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.
HEADLAMP DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
HEADLAMPS 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 generator drive
belt.2. Adjust or replace generator drive belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery
System.
6. Poor lighting circuit Z343/Z344-
ground.6. Test for voltage drop across Z343/Z344-
ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS
BURN OUT
FREQUENTLY.1. Integrated Power Module (IPM)
not controlling voltage.1. Test and repair Integrated Power Module.
2. Loose or corroded terminals or
splices in circuit.2. Inspect and repair all connectors and splices.
Refer to Electrical, Wiring Information.
Fig. 11 FRONT POSITION LAMP
1 - TURN SIGNAL LAMP
2 - HIGH BEAM LAMP
3 - FRONT POSITION LAMP
4 - LOW BEAM LAMP
8L - 12 LAMPS/LIGHTING - EXTERIORRS
FRONT POSITION LAMP - EXPORT (Continued)
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HEADLAMP LEVELING
SWITCH - EXPORT
DESCRIPTION
Some vehicles are equipped with a remote head-
lamp 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.
The headlamp leveling switch is located next to the
headlamp switch on the instrument panel (Fig. 15).
If the headlamp leveling switch is faulty or damaged,
the headlamp switch must be replaced.
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING SWITCH - EXPORT
The headlamp leveling switch is located next to the
headlamp switch on the instrument panel. (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
HEADLAMP SWITCH - DIAGNOSIS AND TEST-
ING) for diagnosis of the headlamp leveling switch. If
the headlamp leveling switch is faulty, the headlamp
switch must be replaced.
HEADLAMP SWITCH
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH
Using a Digital Multi-meter, perform the HEAD-
LAMP SWITCH CONTINUITY test and refer to (Fig.
16).
If the Headlamp Switch is not within specifications
replace the switch.
HEADLAMP SWITCH CONTINUITY
HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
OFF 11 TO 6 3651 - 3729V
PARKING LAMPS
ON11 TO 6 1697 - 2517V
PARKING LAMPS
WITH FRONT
FOG LAMPS ON11 TO 6 5765 - 5886V
HEADLAMPS ON 11 TO 6 788 - 809V
AUTO ON 11 TO 6 10056 - 10264V
HEADLAMPS ON
WITH FRONT
FOG LAMPS11 TO 6 1171 - 1200V
AUTO ON WITH
FRONT FOG
LAMPS ON11 TO 6 24278 - 24773V
Fig. 15 HEADLAMP LEVELING SWITCH
1 - POWER MIRROR SWITCH
2 - HEADLAMP SWITCH
3 - INTERIOR DIMMER
4 - HEADLAMP LEVELING SWITCH
Fig. 16 HEADLAMP SWITCH CONNECTOR
8L - 16 LAMPS/LIGHTING - EXTERIORRS
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DIMMER
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
DOME 12 TO 6 15568 - 23357V
PARADE 12 TO 6 5168 - 7757V
DIM HIGH 12 TO 6 2288 - 3437V
DIM LOW 12 TO 6 688 - 1037V
OFF 12 TO 6 240 - 365V
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH - EXPORT
Using a Digital Multi-meter, refer to the HEAD-
LAMP SWITCH CONTINUITY table and (Fig. 17).
If the Headlamp Switch is not within specifica-
tions, replace as necessary.
HEADLAMP SWITCH CONTINUITY
HEADLAMP
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
OFF 11 TO 6 3651 - 3729V
PARKING LAMPS
ON11 TO 6 1697 - 2517V
PARKING LAMPS
WITH FRONT
FOG LAMPS ON11 TO 6 5765 - 5886V
HEADLAMPS ON 11 TO 6 788 - 809V
HEADLAMPS ON
WITH FRONT
FOG LAMPS11 TO 6 1171 - 1200V
REAR FOG
LAMPS11 TO 6 271 - 277V
FRONT FOG
INDICATOR10 TO 4 LED
REAR FOG
INDICATOR5 TO 4 LED
ILLUMINATION 8 TO 4 CONTINUITY
DIMMER
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
DOME 12 TO 6 15568 - 23357V
PARADE 12 TO 6 5168 - 7757V
DIM HIGH 12 TO 6 2288 - 3437V
DIM LOW 12 TO 6 688 - 1037V
OFF 12 TO 6 240 - 365V
HEADLAMP
LEVELING
SWITCH
POSITION13-WAY
CONNECTOR
TERMINALRESISTANCE
01 TO 7 3238 - 3456V
1 TO 2 3181 - 3400V
1 1 TO 7 1195 - 1225V
2 1 TO 7 746 - 765V
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Removal.
(3) Reach up behind the left side of the instrument
panel and depress spring clip on top or bottom of
headlamp switch. Firmly push out on the headlamp
switch assembly.
(4) Disconnect the wiring connectors.
(5) Remove switch from vehicle.
INSTALLATION
(1) Connect the wiring connectors.
(2) Place headlamp switch assembly into position
and firmly snap into place.
(3) Install the Instrument Panel Lower Steering
Column Cover. Refer to Body, Instrument Panel,
Lower Steering Column Cover, Installation.
(4) Connect the battery negative cable.
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT
HEADLAMP UNIT 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.
Fig. 17 HEADLAMP SWITCH CONNECTOR
RSLAMPS/LIGHTING - EXTERIOR8L-17
HEADLAMP SWITCH (Continued)
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(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.
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. 18).(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) 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.
Fig. 18 HEADLAMP ALIGNMENT SCREEN
1 - CENTER OF HEADLAMPS 3 - FRONT OF HEADLAMP
2 - HEADLAMP BEAM 4 - 7.62 METERS (25 FT.)
8L - 18 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP UNIT (Continued)
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HEADLAMP ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp centerline   50 mm (2 in.). Horizontal aim is
preset and can not be adjusted. The high beam pat-
tern should be correct when the low beams are
aligned properly (Fig. 19). To adjust headlamp verti-
cal alignment, rotate adjustment screw to achieve the
specified low beam cut-off location.
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT - EXPORT
HEADLAMP UNIT 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.
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. 20).
(2) If necessary, tape a line on the floor 10 meters
(32.8 ft.) away from and parallel to the wall.
(3) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(4) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(5) 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.
HEADLAMP UNIT ADJUSTMENT
The low beam headlamp will project on the screen
upper edge of the beam (cut-off) at the horizontal
lamp centerline   20 mm (0.75 in.). The high beam
pattern should be correct when the low beams are
aligned properly (Fig. 21). To adjust headlamp align-
ment, rotate adjustment screws to achieve the speci-
fied low beam cut-off location.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the three retaining screws (Fig. 22).
(3) Disconnect the wiring harness from the bulbs
(Fig. 23).
(4) Remove wire harness retainer from back of
headlamp unit.
(5) Remove the headlamp unit.
Fig. 19 HEADLAMP ADJUSTMENT
1 - ADJUSTMENT LOCATION
2 - HEADLAMP UNIT
RSLAMPS/LIGHTING - EXTERIOR8L-19
HEADLAMP UNIT (Continued)
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INSTALLATION
(1) Reconnect wire harness to the bulbs.
(2) Install wire harness retainer to headlamp unit.
(3) Install the three retaining screws.
Fig. 20 HEADLAMP UNIT ALIGNMENT SCREEN - EXPORT
1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 FT.)
2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE
3 - 15É CUT-OFF LINE 7 - 110 mm (4.3 in.)
4 - FRONT OF HEADLAMP
Fig. 21 HEADLAMP UNIT ADJUSTMENT
1 - HEADLAMP ADJUSTMENT - HORIZONTAL
2 - HEADLAMP ADJUSTMENT - VERTICAL
Fig. 22 HEADLAMP UNIT FASTENERS
1 - HEADLAMP UNIT RETAINING SCREW
2 - HEADLAMP UNIT
8L - 20 LAMPS/LIGHTING - EXTERIORRS
HEADLAMP UNIT (Continued)
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