2002 CHRYSLER VOYAGER Service Manual

jump cable spare wheel lug pattern dimensions power steering fluid coolant level

Page 497 of 2399

CHRYSLER VOYAGER 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
ERRATIC DISPLAY 1. INTERNAL CLUSTER
FAILURE.1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
AND CHECK FOR FAULT CODES.
²IF ODOMETER PASSES THE SEGMENT TEST,
FAILURE MAY N

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CHRYSLER VOYAGER 2002 Service Manual CONDITION POSSIBLE CAUSES CORRECTION
ALL SEGMENTS ARE ON. 1. NO PCI BUS
MESSAGE FROM THE
TCM.1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)
PASSES TEST GO TO STE

CONDITION POSSIBLE CAUSES CORRECTION
ALL SEGMENTS ARE ON. 1. NO PCI BUS
MESSAGE FROM THE
TCM.1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)
PASSES TEST GO TO STEP 1.B. IF PRND3L
(PRND1234 IF AUTOSTICK EQUIPPED) FAILS TEST,
REPLACE CLUSTER ASSEMBLY.
1.B. CHECK THE TCM USING A DRB IIITSCAN
TOOL. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.
MECHANICAL TRANSMISSION RANGE INDICATOR (PRND21) DIAGNOSIS
CONDITION POSSIBLE CAUSES CORRECTION
INDICATOR DOES NOT
SHOW PROPER GEAR
OR NO INDICATION.MIS-ADJUSTED. 1.A. VERIFY TRANSMISSION SHIFT SYSTEM IS
CORRECTLY ADJUSTED.
1.B. VERIFY CORRECT ROUTING AND
ATTACHMENT OF PRNDL CABLE AND GUIDE TUBE.
1.C. RE-ADJUST PRNDL INDICATOR IN NEUTRAL
USING ADJUSTER WHEEL BELOW STEERING
COLUMN.
INDICATOR DOES NOT
FOLLOW GEAR SHIFT
LEVER.NOT ATTACHED. 1.A. VERIFY INDICATOR CABLE CONNECTED TO
SHIFT LEVER PIN IN THE GROOVE.
1.B. VERIFY THAT THE INDICATOR CLIP IS SECURE,
AND ATTACHED TO THE MOUNTING BRACKET.
MAKE SURE THAT THE CLIP IS NOT BROKEN. IF
THE CLIP IS BROKEN, REPLACE CLIP ON
INDICATOR.
INDICATOR DOES NOT
MAKE FULL TRAVEL (ªPº
< > ª1º).1. CABLE DISLODGED
FROM ITS PATH ON THE
INDICATOR BASE.1. VERIFY CORRECT ATTACHMENT OF INDICATOR
CABLE TO SHIFT LEVER PIN (UNDER HOOP OF
TRANS. SHIFT CABLE) AND CLIP ONTO THE
MOUNTING BRACKET.
2. INCORRECT
ATTACHMENT OF CABLE
TO SHIFT LEVER PIN.2. VERIFY INDICATOR TRAVEL BY PULLING ON
CABLE GENTLY OVER FULL TRAVEL RANGE. IF
THERE IS STILL A PROBLEM, REMOVE CLUSTER
TO ACCESS INDICATOR BASE AND CONFIRM
CABLE PATH.
REMOVAL
WITH ELECTRONIC TRANSMISSION RANGE
INDICATOR
(1) Disconnect and isolate the battery negative
cable.
(2) Remove Over Steering Column Bezel by lifting
it straight up with a firm pull.
(3) Remove the four cluster bezel attaching screws.
(4) Tilt the steering column in the full down posi-
tion.
(5) Pull rearward on the cluster bezel and remove.
(6) Remove the four screws holding instrument
cluster to instrument panel.(7) Rotate top of cluster outward.
(8) Disconnect the cluster harness connector.
(9) Remove instrument cluster from instrument
panel.WITH MECHANICAL TRANSMISSION RANGE
INDICATOR
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the lower steering column cover. Refer
to Body, Instrument Panel, Lower Steering Column
Cover, Removal.
RSINSTRUMENT CLUSTER8J-11
INSTRUMENT CLUSTER (Continued)
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CHRYSLER VOYAGER 2002 Service Manual (3) Remove the plastic knee blocker reinforcement.
Refer to Body, Instrument Panel, Knee Blocker Rein-
forcement, Removal.
(4) Disconnect the transmission range indicator
cable end from shift lever by

(3) Remove the plastic knee blocker reinforcement.
Refer to Body, Instrument Panel, Knee Blocker Rein-
forcement, Removal.
(4) Disconnect the transmission range indicator
cable end from shift lever by flexing the HOOP on
the transmission shift cable rearward and slip the
indicator cable loop off the lever pin.
(5) Disconnect the clip holding the indicator cable
to the mounting bracket.
(6) Remove Over Steering Column Bezel by lifting
it straight up with a firm pull.
(7) Remove the four bezel attaching screws.
(8) Tilt the steering column in the full down posi-
tion.
(9) Pull rearward on the cluster bezel and remove.
(10) Remove the four cluster attaching screws.
(11) Rotate top of the cluster rearward.
(12) Disconnect the cluster harness connector.
(13) Remove the instrument cluster carefully while
guiding the range indicator cable and guide tube
through the opening to avoid any damage.
INSTALLATION
WITH ELECTRONIC TRANSMISSION RANGE
INDICATOR
(1) Connect the instrument cluster wire connector.
(2) Rotate top of cluster inward as placing into
instrument panel opening.
(3) Install the four screws holding instrument clus-
ter to instrument panel.
(4) Position cluster bezel into place.
(5) Install the four bezel attaching screws.
(6) Install the Over Steering Column Bezel by
firmly snapping into place.
(7) Connect the battery negative cable.
WITH MECHANICAL TRANSMISSION RANGE
INDICATOR
(1) Guide the range indicator cable and guide tube
through the opening of instrument panel.
(2) Connect the instrument cluster wire connector.
(3) Rotate top of cluster inward as placing into
instrument panel opening.
(4) Install the four screws holding instrument clus-
ter to instrument panel.
(5) Position cluster bezel into place.
(6) Install the four bezel attaching screws.
(7) Install the Over Steering Column Bezel by
firmly snapping into place.
(8) Connect the clip holding the indicator cable to
the mounting bracket.(9) Connect the transmission range indicator cable
end to the shift lever by flexing the HOOP on the
transmission shift cable forward and slip the indica-
tor cable loop on the lever pin.
(10) Install the plastic knee blocker reinforcement.
Refer to Body, Instrument Panel, Knee Blocker Rein-
forcement, Installation.
(11) Install the lower steering column cover. Refer
to Body, Instrument Panel, Lower Steering Column
Cover, Installation.
(12) Connect the battery negative cable.
CLUSTER LENS
REMOVAL
(1) Remove the instrument cluster. Refer to Elec-
trical, Instrument Cluster, Removal.
(2) Remove the screws holding the lens to the
instrument cluster.
(3) Press down on the snap features of the lens
and remove the lens from the cluster.
INSTALLATION
(1) Insert the lens snap features into the cluster.
(2) Install the screws holding the lens to the
instrument cluster.
(3) Install the instrument cluster. Refer to Electri-
cal, Instrument Cluster, Installation.
MECHANICAL TRANSMISSION
RANGE INDICATOR
REMOVAL
(1) Remove the instrument cluster and disconnect
the range indicator cable at both attaching points.
Refer to Electrical, Instrument Cluster, Removal.
(2) From the backside of the cluster, remove two
screws holding the mechanical transmission range
indicator and then remove it fromt instrument clus-
ter.
INSTALLATION
(1) Insert the mechanical transmission range indi-
cator into the backside of the instrument cluster and
install the two screws.
(2) Install the instrument cluster. Refer to Electri-
cal, Instrument Cluster, Installation.
8J - 12 INSTRUMENT CLUSTERRS
INSTRUMENT CLUSTER (Continued)
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CHRYSLER VOYAGER 2002 Service Manual RED BRAKE WARNING
INDICATOR
DESCRIPTION
The red BRAKE warning indicator (lamp) is
located in the instrument panel cluster and is used to
indicate a low brake fluid condition or that the park-
ing brak

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CHRYSLER VOYAGER 2002 Service Manual ProCarManuals.com

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CHRYSLER VOYAGER 2002 Service Manual LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR............... 1LAMPS/LIGHTING - INTERIOR............... 25
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR

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
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CHRYSLER VOYAGER 2002 Service Manual OPERATION - TURN SIGNAL SYSTEM.......21
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH...................22
REMOVAL.............................22
INSTALLATION.........................22
PARK/TURN SIG

OPERATION - TURN SIGNAL SYSTEM.......21
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH...................22
REMOVAL.............................22
INSTALLATION.........................22
PARK/TURN SIGNAL LAMP
REMOVAL.............................22
INSTALLATION.........................22
PARK/TURN SIGNAL LAMP - EXPORT
REMOVAL.............................22
INSTALLATION.........................23
REAR FOG LAMP - EXPORT
DESCRIPTION.........................23REPEATER LAMP - EXPORT
REMOVAL.............................23
INSTALLATION.........................23
TAIL LAMP
REMOVAL.............................23
INSTALLATION.........................23
TAIL LAMP - EXPORT
REMOVAL.............................23
INSTALLATION.........................24
TAIL LAMP UNIT
REMOVAL.............................24
INSTALLATION.........................24
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power source,
on/off device, lamps and body ground to operate prop-
erly. Plastic lamps require a wire in the harness to
supply body ground to the lamp socket. Replace sock-
ets and bulbs that are corroded.
Some of the interior and exterior lighting functions
are governed by the Body Control Module (BCM).
The headlamp, dome, and the door ajar switches pro-
vide signals to the BCM. The BCM in turn sends a
Programmable Communication Interface (PCI) bus
message to the Front Control Module (FCM) to
enable the necessary drivers to set the required illu-
mination configuration.
Wire connectors can make intermittent contact or
become corroded. Before coupling wire connectors,
inspect the terminals inside the connector. Male ter-
minals should not be bent or disengaged from the
insulator. Female terminals should not be sprung
open or disengaged from the insulator. Bent and
sprung terminals can be repaired using needle nose
pliers and pick tool. Corroded terminals appear
chalky or green. Corroded terminals should be
replaced to avoid recurrence of the problem symp-
toms.
Begin electrical system failure diagnosis by testing
related fuses in the fuse block and intelligent power
module. Verify that bulbs are in good condition and
test continuity of the circuit ground. Refer to the
appropriate wiring information.
AUTOMATIC HEADLAMP SYSTEM
The Automatic Headlamp system turns the instru-
mentation and exterior illumination lamps ON when
the ambient light levels are Night and the engine
RPM is 450 or above, and OFF when light levels are
Day.
DAYTIME RUNNING LAMPS
Operating the high-beam headlamps at reduced
power provides daytime running lamps, which are
required on all new Canadian vehicles.
HEADLAMPS ON WITH WINDSHIELD WIPERS
For vehicles equipped with the Automatic Head-
lamp System, the instrumentation and exterior illu-
mination lamps will be turned ON when the
headlamp switch is in the AUTO position, RPM >
450 and the windshield wipers have been in the
intermittent, low or high mode of operation for more
than ten seconds. When the windshield wipers are
turned OFF the Body Control Module will determine
if the instrumentation and exterior illumination
lamps should remain ON base upon the current
ambient light level.
HEADLAMP SYSTEM
The configuration of the headlamp system of head-
lamps, park lamps and fog lamps is determined by
the BCM. The BCM determines the lighting configu-
ration as a result of the inputs from the ignition
switch, headlamp switch and multi-function switch. A
PCI bus is transmitted from the BCM to the FCM to
enable the necessary drivers to set the illumination
configuration. Four wires are connected between the
headlamp switch and the BCM. The first wire con-
tains information regarding the position of the head-
lamp switch (Off, Automatic Headlamps, Automatic
Headlamp switch fog, Park with Fog, Head, or Head
with Fog Lamps). The second wire contains informa-
tion regarding the position of the dimmer switch
(Dome Lamp, Daytime Brightness, Dimming Level or
Off). The third wire is a dedicated signal return
(ground) wire. The fourth wire provides power to the
front fog lamp indicator.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is controlled by
the Body Control Module (BCM) via a PCI bus mes-
8L - 2 LAMPS/LIGHTING - EXTERIORRS
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CHRYSLER VOYAGER 2002 Service Manual sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body Con-
trol Module (BCM). With the headlamp switch in

sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body Con-
trol Module (BCM). With the headlamp switch in the
AUTO position, the BCM will control the headlamp, park-
ing, side marker, tail and instrumentation lamps based on
ambient light levels. Ambient light levels are monitored
by the BCM using the Day/Night signal and Electrochro-
matic Mirror (ECM) present from the Compass Mini Trip
(CMTC) located on the front windshield in front of the
rear view mirror ECM. Ambient light readings are aver-
aged to limit cycling the lamps ON and OFF when pass-
ing through areas with varying light levels. The
automatic headlamps will only function when the engine
is running with RPM > 450. When the headlamp switch is
in the AUTO position (Automatic mode), the Headlamp
Time Delay system will function when the ignition switch
is placed in any position other than run/start.
DAYTIME RUNNING LAMPS
Power is reduced using pulse-width modulation to
the high beams, where by the power is switched on
and off rapidly instead of remaining on continuously.
The duration and interval of the power pulses is pro-
grammed into the FCM.
HEADLAMP SYSTEM
The headlamp system will default to headlamps
ON position when ignition switch is ON and when an
open or short circuit failure occurs on the headlamp
switch input. The system will return to normal oper-
ation when the open or short is repaired. A fault will
be reported by the BCM when a failure occurs on the
dimmer or headlamp switch input.
If the exterior lamps are ON and the headlamp
switch is in any position other than OFF or AUTO
and with the ignition switch OFF (LOCK) after 3
minutes the BCM sends a message via PCI bus to
the FCM informing the FCM to turn off the head-
lamps, park lamps and fog lamps. This feature pre-
vents the vehicle battery from being discharged when
the vehicle lights have been left ON.
HEADLAMP TIME DELAY SYSTEM
The headlamp time delay system is activated by
turning the headlamps ON (high or low beam) while
the engine is running, turning the ignition switch
OFF, and then turning the headlamp switch OFF
within 45 seconds. The system will not activate if
more than 45 seconds elapse between ignition switch
OFF and headlamp switch OFF. The BCM will allow
the headlamps to remain ON for 90 seconds (config-urable) before they automatically turn off (If the key
is in the ignition during the headlamp time delay
mode, then both the headlamps and park lamps
(including panel dimming) will be ON). Refer to the
Owner's Manual for more information.
If the headlamp switch is in the Auto Headlamp
Position, the headlamps are ON due to the night sig-
nal from the CMTC and the ignition switch is in any
position other than run/start, the BCM shall enter a
90 second (configurable) Auto Headlamps time delay
mode. If the key is in the ignition during the head-
lamp time delay mode, then both the headlamps and
park lamps (including panel dimming) will be ON. If
the key is not in the ignition, then only the head-
lamps will be ON. The BCM will allow the head-
lamps to remain ON for 90 seconds before they
automatically turn OFF. Refer to the Owner's Man-
ual for more information.
OPTICAL HORN/HIGH BEAMS
When the multi-function switch is pulled to the
first detent (optical horn) signal, the headlamps are
ON, key-in the ignition the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers to illuminate all four filaments (Low
and High beams). When the multi-function switch is
pulled to the second detent (high beam) signal and
the headlamps are ON, the BCM shall send a mes-
sage via PCI bus to the FCM to turn on the head-
lamps drivers. The High Beams are illuminated and
the Low Beams and Fog Lamps (if ON) are extin-
guished. If the headlamps were in the high beam
configuration when power was removed from the
headlamps, the headlamps will be configured as low
beam the next time they are activated.
WARNING
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY CAN RESULT.
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result. Do not use bulbs other than
those indicated in the Bulb Application table. Dam-
age to lamp and/or Daytime Running Lamp Module
can result. Do not use fuses, circuit breakers or
relays having greater amperage value than indi-
cated on the fuse panel or in the Owners Manual.
CAUTION: Do not use bulbs other than those listed
in the Bulb Application Table. Damage to lamp can
result. Do not touch halogen bulbs with fingers or
other oily surfaces. Bulb life will be reduced.
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)
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