2002 CHRYSLER VOYAGER brake light

(3) To disable the ignition and fuel systems, dis-
connect the Automatic Shutdown Relay (ASD). The
ASD relay is located in the Power Distribution Cen-
ter (PDC). Refer to the PDC cover for proper relay
location.
(4) Verify that all lights and accessories are OFF,
and the transmission shift selector is in the PARK
and SET parking brake.
CAUTION: Do not overheat the starter motor or
draw the battery voltage below 9.6 volts during
cranking operations.
(5) Rotate and hold the ignition switch in the
START position. Observe the volt-ampere tester (Fig.
3).
²If voltage reads above 9.6 volts, and amperage
draw reads above 280 amps, check for engine seizing
or faulty starter.
²If voltage reads 12.4 volts or greater and amper-
age reads 0 to 10 amps, check for corroded cables
and/or bad connections.
²Voltage below 9.6 volts and amperage draw
above 300 amps, the problem is the starter. Replace
the starter refer to starter removal.
(6) After the starting system problems have been
corrected, verify the battery state-of-charge and
charge battery if necessary. Disconnect all testing
equipment and connect ASD relay. Start the vehicle
several times to assure the problem has been cor-
rected.SPECIFICATIONS
STARTER
MANUFACTURER NIPPONDENSO
Engine Application 2.4L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional Gear Train
Free running Test
Voltage 11
Amperage Draw 73 Amp
Minimum Speed 3401 RPM
SolenoidClosing Voltage 7.5 Volts
Cranking Amperage Draw
test150 - 200 Amps.
Engine should be up to operating temperature.
Extremely heavy oil or tight engine will increase
starter amperage draw.
Torques
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Starter Mounting Bolts 47.4 35
Starter Solenoid Battery Nut 11.3 8.3 100
RGSTARTING8Fa-37
STARTING (Continued)
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LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR............... 1LAMPS/LIGHTING - INTERIOR............... 25
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION..........................2
OPERATION............................3
WARNING.............................3
SPECIFICATIONS
EXTERIOR LAMPS.....................4
BRAKE LAMP SWITCH
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH.............................4
REMOVAL.............................5
INSTALLATION..........................6
CENTER HIGH MOUNTED STOP LAMP
REMOVAL.............................6
INSTALLATION..........................6
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL.............................6
INSTALLATION..........................6
FOG LAMP
DIAGNOSIS AND TESTING - FOG LAMP......7
REMOVAL.............................9
INSTALLATION..........................9
FOG LAMP - EXPORT
REMOVAL.............................9
INSTALLATION..........................9
FOG LAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - FOG LAMP
UNIT ALIGNMENT.....................10
STANDARD PROCEDURE - FOG LAMP
UNIT ALIGNMENT - EXPORT.............10
REMOVAL.............................11
INSTALLATION.........................11
FRONT POSITION LAMP - EXPORT
REMOVAL.............................11
INSTALLATION.........................11HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP.....12
REMOVAL.............................14
INSTALLATION.........................14
HEADLAMP - EXPORT
REMOVAL.............................14
INSTALLATION.........................14
HEADLAMP LEVELING MOTOR - EXPORT
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING MOTOR - EXPORT............15
REMOVAL.............................15
INSTALLATION.........................15
HEADLAMP LEVELING SWITCH - EXPORT
DESCRIPTION.........................16
DIAGNOSIS AND TESTING - HEADLAMP
LEVELING SWITCH - EXPORT...........16
HEADLAMP SWITCH
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH............................16
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH - EXPORT....................17
REMOVAL.............................17
INSTALLATION.........................17
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP
UNIT ALIGNMENT.....................17
STANDARD PROCEDURE - HEADLAMP
UNIT ALIGNMENT - EXPORT.............19
REMOVAL.............................19
INSTALLATION.........................20
LICENSE LAMP
REMOVAL.............................21
INSTALLATION.........................21
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM.....21
RSLAMPS8L-1
ProCarManuals.com

SPECIFICATIONS
EXTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3057
CHMSL 921
FRONT SIDE MARKER/PARK/
TURN3157A
FOG LAMP 9040
HEADLAMP 9007
LICENSE 168
TAIL, STOP 3057
TURN SIGNAL 3057
BULB APPLICATION TABLE - EXPORT
LAMP BULB
HEADLAMP H7
FRONT POSITION W5W
FRONT TURN SIGNAL PY21W
SIDE REPEATER T4W
LICENSE PLATE W5W/168
REAR TAIL AND STOP P21/5W
REAR TURN SIGNAL PY21W
BACK-UP P21W
REAR FOG P21W
CHMSL W16W/921
BRAKE LAMP SWITCH
DESCRIPTION
The brake lamp switch is located under the instru-
ment panel, at the brake pedal arm (Fig. 3). It has
three internal switches controlling various functions
of the vehicle. It's main function is to control opera-
tion of the vehicle's brake lamps. Other functions
include speed control deactivation, brake sense for
the antilock brake system and brake sense for the
brake transmission shift interlock.
CAUTION: The switch can only be adjusted once.
That is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
OPERATION
When the brake pedal is pressed, the plunger on
the outside of the brake lamp switch extends out-
ward. This action opens or closes the contacts of the
three switches inside the brake lamp switch.
With the brake pedal pressed down (plunger
extended), the switch for terminals 1 and 2 is closed
completing the circuit. The switch for terminals 3
and 4 is open and so is the switch for terminals 5
and 6.
When the brake pedal is released (plunger pushed
in), the three switches assume the opposite positions.
The switch for terminals 1 and 2 is now open while
the other two switches are now closed, completing
their circuits.
A lever on the back of the switch is used to set the
switch into the ªadjustedº position. A non-adjusted
switch will have the lever set to the diagonal position
in relation to the switch housing. The plunger can be
moved in and out, but the states of the internal
switches will not change.
CAUTION: Never move the adjustment lever of the
new brake lamp switch without it being properly
installed in the vehicle first. Such action will render
the switch unusable and the switch must be dis-
carded.
Once installed in the vehicle as described in the
brake lamp switch installation procedure (Refer to 8 -
ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION), the new
switch's adjustment lever is rotated to the adjusted
position as indicated (Fig. 4). This action locks the
plunger to the internal switches.Once in this posi-
tion the switch is permanently adjusted (or
locked) and cannot be readjusted or released
even if the lever is moved back.
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH
NOTE: Before proceeding with this diagnostic test,
verify the adjustment lever on the back of the
switch is in the adjusted position. If the lever is in
the non-adjusted (diagonal) position it may have
never been adjusted (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - OPERATION). For adjustment, (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - INSTALLATION)
If the electrical circuit has been tested and the
brake lamp switch is suspected of being faulty, it can
be tested using the following method.
8L - 4 LAMPS/LIGHTING - EXTERIORRS
LAMPS/LIGHTING - EXTERIOR (Continued)
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(1) Remove the switch from the vehicle. (Refer to 8
- ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
BRAKE LAMP SWITCH - REMOVAL)
(2) With the switch in the released position (plung-
er extended), use an ohmmeter to test each of the
three internal switches as shown (Fig. 1). You should
achieve the results as listed in the figure.
(3) Gently push the plunger on the brake lamp
switch in until it stops.
(4) With the switch in this depressed position
(plunger pushed in), use an ohmmeter to test each of
the three internal switches as shown (Fig. 2). You
should achieve the results as listed in the figure.
If you do not achieve the results as listed in both
figures, the switch is faulty and must be replaced.
Refer to Removal And Installation in this section.If the switch is found to be operating properly, it
may be misadjusted. Do not reinstall the switch,
replace it. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/BRAKE LAMP SWITCH -
INSTALLATION)
CAUTION: The switch can only be adjusted once.
That is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for any reason, a new switch must be
installed and adjusted.
REMOVAL
(1) Disconnect and isolate the battery negative
cable from its post on the battery.
(2) Remove silencer panel below steering column
and knee blocker.
(3) Remove the brake lamp switch by rotating the
switch in a counterclockwise direction approximately
30 degrees and pulling it out of the bracket (Fig. 3).
(4) Release the locking tab and disconnect the wir-
ing connector from the switch.
(5) Discard the brake lamp switch. It must not be
reused.
Fig. 1 SWITCH TEST - RELEASED POSITION
Fig. 2 SWITCH TEST - DEPRESSED POSITION
Fig. 3 Pedal And Brake Lamp Switch
1 - SWITCH BRACKET
2 - BRAKE LAMP SWITCH
3 - WIRING CONNECTOR
4 - PEDAL AND BRACKET
RSLAMPS/LIGHTING - EXTERIOR8L-5
BRAKE LAMP SWITCH (Continued)
ProCarManuals.com

INSTALLATION
CAUTION: Do not reuse the original brake lamp
switch. The switch can only be adjusted once. That
is during initial installation of the switch. If the
switch is not adjusted properly or has been
removed for some service, a new switch must be
installed and adjusted.
(1) Mount and adjust the NEW brake lamp switch
using the following procedure:
(a) Connect the wiring connector to the switch
and latch the locking tab.
(b) Install the switch in its bracket by aligning
the index tab on the switch with the slot in the
mounting bracket.
(c) When the switch is fully seated in its
bracket, rotate the switch clockwise approximately
30É to lock the switch into place (Fig. 3).
(d) With the brake pedal in the fully released
position, move the lever on the back of the brake
lamp switch from the angled non-adjusted position
to the full vertical position as shown (Fig. 4). This
will adjust the brake lamp switch to the vehicle.
(2) Install silencer panel below steering column
knee blocker.
(3) Reconnect the battery negative terminal.
(4) Check the stop lamps to verify they are operat-
ing properly and not staying on when the pedal is in
the released position.
(5) Road test the vehicle to ensure proper opera-
tion of the brakes including ABS and speed control (if
equipped).
CENTER HIGH MOUNTED
STOP LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove two retaining screws (Fig. 5).
(3) Twist socket counter-clockwise and remove
from lamp.
(4) Pull bulb from socket (Fig. 6).
INSTALLATION
(1) Push bulb into socket.
(2) Install socket into the lamp unit.
(3) Install the retaining screws.
(4) Reconnect the battery negative cable.
CENTER HIGH MOUNTED
STOP LAMP UNIT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the two retaining screws (Fig. 5).
(3) Disconnect the rear window washer hose.
(4) Remove bulb socket from lamp unit (Fig. 6).
INSTALLATION
(1) Install bulb socket to lamp unit.
(2) Reconnect the rear window washer hose.
Fig. 4 Adjustment Lever MovementFig. 5 CHMSL
1 - CHMSL UNIT
2 - LIFTGATE
8L - 6 LAMPS/LIGHTING - EXTERIORRS
BRAKE LAMP SWITCH (Continued)
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INSTALLATION
(1) Install bulb to bulb socket.
(2) Install bulb socket to headlamp unit.
(3) Install headlamp unit.
(4) Connect battery negative cable.
REAR FOG LAMP - EXPORT
DESCRIPTION
The rear fog lamps are incorporated into the tail
lamp unit. (Refer to 8 - ELECTRICAL/LAMPS/
LIGHTING - EXTERIOR/TAIL LAMP - REMOVAL)
for service procedures.
REPEATER LAMP - EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Push the side repeater lamp to one side and
release retaining tab.
(3) Pull side repeater lamp out and disengage bulb
socket from lamp.
(4) Depress, then rotate and pull bulb from socket.
INSTALLATION
(1) Install bulb to socket.
(2) Push lamp socket into the 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) Connect battery negative cable.
TAIL LAMP
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on the bulb socket and
remove from tail lamp unit (Fig. 28).
(4) Pull bulb from lamp socket.
INSTALLATION
(1) Push bulb into the lamp socket.
(2) Install bulb socket into the tail lamp unit.
Ensure that both retaining tabs engage with an audi-
ble click.
(3) Install the tail lamp unit. (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - INSTALLATION).(4) Reconnect the battery negative cable.
TAIL LAMP - EXPORT
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the tail lamp unit (Refer to 8 - ELEC-
TRICAL/LAMPS/LIGHTING - EXTERIOR/TAIL
LAMP UNIT - REMOVAL).
(3) Squeeze the tabs on housing retaining the
bulbs and remove from the tail lamp unit (Fig. 29).
(4) Remove bulbs by depressing, then turning
counter-clockwise.
Fig. 28 TAIL LAMP SOCKET
1 - LAMP SOCKET
2 - TAIL LAMP UNIT
Fig. 29 TAIL LAMP BULBS
1 - TAIL LAMP UNIT
2 - BRAKE/PARK LAMP
3 - TURN SIGNAL LAMP
4 - BACK UP LAMP
5 - REAR FOG LAMP
RSLAMPS/LIGHTING - EXTERIOR8L-23
PARK/TURN SIGNAL LAMP - EXPORT (Continued)
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LAMPS/LIGHTING - INTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS.....................25
CENTER CONSOLE LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................26
CLUSTER ILLUMINATION LAMPS
REMOVAL.............................26
INSTALLATION.........................26
COURTESY LAMP
REMOVAL.............................26
INSTALLATION.........................26
DOME LAMP
REMOVAL.............................26INSTALLATION.........................26
GLOVE BOX LAMP SWITCH
REMOVAL.............................26
INSTALLATION.........................27
LIFTGATE LAMP
REMOVAL.............................27
INSTALLATION.........................27
READING LAMP
REMOVAL.............................27
INSTALLATION.........................28
VANITY LAMP
REMOVAL.............................28
INSTALLATION.........................28
LAMPS/LIGHTING - INTERIOR
SPECIFICATIONS
INTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
ABS LED
AIRBAG LED
ALARM SET PC74
AUTOSTICK VFD*
BRAKE SYSTEM WARNING LED
CONSOLE 194
CRUISE INDICATOR VFD*
DOME/RAIL LAMPS 578
DOOR AJAR INDICATOR LED
DOOR COURTESY LAMP 578
FRONT DOOR COURTESY 567
GLOVE BOX 194
HIGH BEAM INDICATOR (BASE
CLUSTER)LED
HIGH BEAM INDICATOR PC74
CLUSTER ILLUMINATION PC74
LAMP BULB
LIFTGATE 578
LIFTGATE AJAR LED
LOW FUEL INDICATOR LED
LOW WASHER FLUID
INDICATORLED
MIL (BASE CLUSTER) LED
MIL PC74
OIL INDICATOR (BASE
CLUSTER)LED
OIL INDICATOR PC74
OVERHEAD CONSOLE READING PC579
OVERDRIVE OFF INDICATOR VFD*
READING 578
SEAT BELT INDICATOR LED
TEMPERATURE INDICATOR LED
TRAC OFF INDICATOR VFD*
TURN SIGNAL INDICATOR
(BASE CLUSTER)LED
TURN SIGNAL INDICATOR PC74
VISOR VANITY 6501966
VOLTAGE INDICATOR LED
* VFD = VACUUM FLUORESCENT DISPLAY
RSLAMPS/LIGHTING - INTERIOR8L-25
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The mirror switch allows the driver a manual con-
trol of whether the automatic dimming feature is
operational. When AUTO is selected a small Light-
Emitting Diode (LED), to the right of the mirror
switch, is illuminated. The automatic dimming fea-
ture will only operate when the ignition switch is in
the On position. The mirror also senses the backup
lamp circuit, and will automatically disable its self-
dimming feature whenever the transmission gear
selector is in the Reverse position.
NOTE: The mirror always defaults to an ON state
upon ignition.
The driver side automatic dimming mirror is stan-
dard with the automatic dimming inside mirror. The
signal to control the dimming of that mirror is gen-
erated by the automatic day/night inside rear view
mirror circuitry. That signal is then delivered to the
driver side outside rear view mirror on a hard wired
circuit.
The automatic day/night mirror cannot be
repaired. If faulty or damaged, the entire inside rear
view mirror assembly must be replaced.
DIAGNOSIS AND TESTING - AUTOMATIC DAY /
NIGHT MIRROR
For circuit descriptions and diagrams, refer to the
appropriate wiring information. The wiring informa-
tion includes wiring diagrams, proper wire and con-
nector repair procedures, details of wire harness
routing and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
(1) Check the fuse in the intelligent power module.
If OK, go to Step 2. If not OK, repair the shorted cir-
cuit or component as required and replace the faulty
fuse.
(2) Turn the ignition switch to the On position.
Check for battery voltage at the fuse in the intelli-
gent power module. If OK, go to Step 3. If not OK,
repair the open circuit to the ignition switch as
required.
(3) Unplug the wire harness connector from the
automatic day/night mirror. Check for battery voltage
at the fused ignition switch output circuit cavity of
the automatic day/night mirror wire harness connec-
tor. If OK, go to Step 4. If not OK, repair the open
circuit to the junction block as required.
(4) Turn the ignition switch to the Off position.
Check for continuity between the ground circuit cav-
ity of the automatic day/night mirror wire harness
connector and a good ground. There should be conti-
nuity. If OK, go to Step 5. If not OK, repair the cir-
cuit to ground as required.(5) Turn the ignition switch to the On position. Set
the parking brake. Place the transmission gear selec-
tor lever in the Reverse position. Check for battery
voltage at the backup lamp switch output circuit cav-
ity of the automatic day/night mirror wire harness
connector. If voltage is present, reinstall the auto-
matic day/night mirror wire harness connector and
go to Step 6. If not OK, repair the open circuit as
required.
(6) Place the transmission gear selector lever in
the Neutral position. Place the automatic day/night
mirror switch in the On (LED in the switch is
lighted) position. Cover the forward facing ambient
photocell sensor to keep out any ambient light.
NOTE: The ambient photocell sensor must be cov-
ered completely, so that no light reaches the sen-
sor. Use a finger pressed tightly against the sensor,
or cover the sensor completely with electrical tape.
(7) Shine a light into the rearward facing head-
lamp photocell sensor. The automatic day/night mir-
ror should darken. The automatic day/night mirror
should darken within 2 minutes if testing for the
first time. For immediate response, turn the vehicle
OFF and back ON with the forward-facing light sen-
sor still covered. This defeats the day-detect logic. If
OK, go to Step 8. If not OK, replace the faulty mirror
unit.
(8) With the mirror darkened, place the transmis-
sion gear selector lever in the Reverse position. The
automatic day/night mirror should return to its nor-
mal reflectance. If not OK, replace the faulty mirror
unit.
Bench testing both mirrors can be done, of care is
exercised. For an inside mirror, the pin closest to he
mount is 12V (+), the next is 12V (-). The third is
reverse override. The fourth is outside mirror (+),
and the fifth is outside mirror (-).Do not apply 12
volts to the fourth and fifth pins.With 12 volts
on pins 1 and 2, the mirror can be tested by blocking
the rear sensor and shining a light into the forward
sensor. For an outside mirror, there is a 2±pin con-
nector. Applying 1.2 volts will cause the mirror to
dim. If the mirror does not dim, the entire glass
assembly can be replaced just as it is when the glass
is broken.
WARNING: Do not apply 12 volts to the outside mir-
ror. Damage to the mirror will result.
8N - 48 POWER MIRRORSRS
AUTOMATIC DAY / NIGHT MIRROR (Continued)
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