2004 CHRYSLER VOYAGER headlamp

BODY CONTROL MODULE
TABLE OF CONTENTS
page page
BODY CONTROL MODULE DESCRIPTION ..........................1
OPERATION ............................1 REMOVAL
.............................3
INSTALLATION ..........................3
BODY CONTROL MODULE
DESCRIPTION
The Body Control Module (BCM) is located in the
passenger compartment, attached to the bulkhead
underneath the left side of the instrument panel. The BCM utilizes integrated circuitry and informa-
tion carried on the Programmable Communications
Interface (PCI) data bus network along with many
hard wired inputs to monitor many sensor and
switch inputs throughout the vehicle. In response to
those inputs, the internal circuitry and programming
of the BCM allow it to control and integrate many
electronic functions and features of the vehicle
through both hard wired outputs and the transmis-
sion of electronic message outputs to other electronic
modules in the vehicle over the PCI data bus.
OPERATION
The Body Control Module (BCM) supplies vehicle
occupants with visual and audible information and
controls various vehicle functions. To provide and
receive information, the BCM is interfaced to the
vehicle's serial bus communications network, referred
to as the Programmable Communications Interface
(PCI) bus. This network consists of the;
² Powertrain Control Module (PCM)
² Transmission Control Module (TCM)
² Mechanical Instrument Cluster (MIC)
² Occupant Restraint Controller (ORC)
² Compass/Mini-Trip Computer (CMTC)
² Electronic Vehicle Information Center (EVIC)
² Controller Antilock Brake (CAB)
² HVAC Control Module
² Sliding Door Control Modules (driver and pas-
senger side doors) ² Power Liftgate Module (PLG) ²
Audio system equipped with RAZ, RBU, RBK,
and RBB radios. ² Sentry Key Remote Entry Module (SKREEM).
² Side Impact Airbag Control Module (SIACM)
² Memory Seat Module (MSM)
² Sentry Key Immobilizer Module (SKIM)
The BCM is operational when battery power is
supplied to the module. The BCM provides the following features:
² Power Door Locks
² Automatic Door Locks
² Battery Protection - The BCM will automatically
turn off all exterior lamps after 3 minutes, and all
interior lamps after 15 minutes after the ignition is
turned off, if they are not turned off by the driver. ² Chime Control
² Compass/Mini-Trip support.
² Interior Lighting (Courtesy/Reading Lamps)
² BCM Diagnostic Reporting
² Electronic Liftgate Release (with Power Door
Locks) ² Exterior Lighting
² Headlamp Time Delay (with/without Automatic
Headlamps) ² Illuminated Entry
² Fade to Off Interior Lamps - This feature dims
the interior lighting (courtesy lamps) gradually if the
BCM does not receive any new inputs that would
cause the interior lamps to remain on. ² Pulse Width Modulated Instrument Panel Dim-
ming ² Door Lock Inhibit - This feature disables the
door lock functions if the key is in the ignition and
either front door is ajar. Pressing the Remote Keyless
Entry (RKE) lock/unlock button under these condi-
tions result in normal lock/unlock activation. The BCM has the ability to LEARN additional fea-
tures in the vehicle, provided the appropriate switch
input and PCI data bus messages are received. Refer
to the LEARNED FEATURES table.
RS BODY CONTROL MODULE8Es-1

LEARNED FEATURES
FEATURE LEARNING KEY
REAR WIPER CONTROL ON HVAC CONTROL ON
INSTRUMENT PANEL PCI BUS MESSAGE RECEIVED FROM HVAC
CONTROL
AUTOMATIC HEADLAMPS PCI MESSAGE FROM OVERHEAD OR HEADLAMP SWITCH POSITION (AUTO)
REMOTE KEYLESS ENTRY SKREEM MESSAGE RECEIVED FROM MODULE
FRONT FOG LAMPS HEADLAMP SWITCH POSITION (PARK W/FRONT FOG LAMPS)
POWER SLIDING DOOR PCI IFR RECEIVED FROM MODULE
THE BCM HAS FOUR SWITCH INPUTS FOR THE POWER SLIDING DOOR FEATURE; LOCATED IN THE
OVERHEAD CONSOLE ARE THE LEFT AND RIGHT SIDE SLIDING DOOR SWITCHES TO ACTIVATE EITHER
OR BOTH SLIDING DOORS UNDER THE PROPER CONDITIONS. ALSO ARE B-PILLAR SWITCHES LOCATED
ON THE LEFT AND RIGHT B-PILLAR POSTS.
POWER LIFTGATE PCI IFR RECEIVED FROM MODULE
THE BCM HAS ONE LIFTGATE INPUT LOCATED IN THE OVERHEAD CONSOLE.
POWER LOCKOUT SWITCH INPUT
THE BCM HAS ONE LOCKOUT SWITCH INPUT THAT WHEN ENABLED WILL DISABLE THE B-PILLAR
SLIDING DOOR SWITCHES FROM ACTIVATING EITHER SLIDING DOOR WHEN DEPRESSED.
PCI AUDIO SYSTEM PCI MESSAGE RECEIVED FROM MODULE
REMOTE RADIO CONTROLS REMOTE RADIO SWITCHES PRESENT
VEHICLE THEFT SECURITY SKREEM MESSAGE RECEIVED, VALID KEY RECEIVED, & DIAGNOSTIC PID RECEIVED.
MEMORY SEAT AND MIRRORS MEMORY SEAT SWITCH PRESENT AND OR PCI MESSAGE RECEIVED FROM MEMORY MODULE
ABS W/TRACTION CONTROL PCI MESSAGE RECEIVED FROM CAB
SENTRY KEY IMMOBILIZER SYSTEM PCI MESSAGE RECEIVED FROM SKIM OR VTSS PRESENT
ADJUSTABLE PEDAL MODULE PCI MESSAGE RECEIVED FROM ADJUSTABLE PEDAL MODULE (APM)
8Es - 2 BODY CONTROL MODULERS
BODY CONTROL MODULE (Continued)

CONVENTIONAL BATTERY CHARGING TIME TABLE
Charging
Amperage5 Amps10
Amps20 Amps
Open Circuit
VoltageHours Charging @ 21É C
(70É F)
12.25 to 12.49 6 hours 3 hours 1.5
hours
12.00 to 12.24 10 hours 5 hours 2.5
hours
10.00 to 11.99 14 hours 7 hours 3.5
hours
Below 10.00 18 hours 9 hours 4.5
hours
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
This test can be used if no other battery tester is
available.
Before proceeding with this test, completely charge
the battery. Refer to Standard Procedures for the
proper battery charging procedures.
(1) Before measuring the open-circuit voltage, the
surface charge must be removed from the battery.
Turn on the headlamps for fifteen seconds, then
allow up to five minutes for the battery voltage to
stabilize.
(2) Disconnect and isolate both battery cables, neg-
ative cable first.
(3) Using a voltmeter connected to the battery
posts (see the instructions provided by the manufac-
turer of the voltmeter), measure the open-circuit volt-
age (Fig. 9).
See the Open-Circuit Voltage Table. This voltage
reading will indicate the battery state-of-charge, but
will not reveal its cranking capacity. If a battery has
an open-circuit voltage reading of 12.4 volts orgreater, it may be load tested to reveal its cranking
capacity. Refer to Standard Procedures for the proper
battery load test procedures.
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage
11.7 volts or less 0%
12.0 volts 25%
12.2 volts 50%
12.45 volts 75%
12.65 volts or more 100%
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term Ignition-Off Draw (IOD) identifies a nor-
mal condition where power is being drained from the
battery with the ignition switch in the Off position. A
normal vehicle electrical system will draw from fif-
teen to twenty-five milliamperes (0.015 to 0.025
ampere) with the ignition switch in the Off position,
and all non-ignition controlled circuits in proper
working order. Up to twenty-five milliamperes are
needed to enable the memory functions for the Pow-
ertrain Control Module (PCM), digital clock, electron-
ically tuned radio, and other modules which may
vary with the vehicle equipment.
A vehicle that has not been operated for approxi-
mately twenty-one days, may discharge the battery
to an inadequate level. When a vehicle will not be
used for twenty-one days or more (stored), remove
the IOD fuse from the Integrated Power Module
(IPM). This will reduce battery discharging.
Excessive IOD can be caused by:
²Electrical items left on.
²Faulty or improperly adjusted switches.
²Faulty or shorted electronic modules and compo-
nents.
²An internally shorted generator.
²Intermittent shorts in the wiring.
If the IOD is over twenty-five milliamperes, the
problem must be found and corrected before replac-
ing a battery. In most cases, the battery can be
charged and returned to service after the excessive
IOD condition has been corrected.
(1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
all doors. If the vehicle is equipped with an illumi-
nated entry system or an electronically tuned radio,
allow the electronic timer function of these systems
to automatically shut off (time out). This may take
up to twenty minutes.
(2) Disconnect the battery negative cable.
(3) Set an electronic digital multi-meter to its
highest amperage scale. Connect the multi-meter
Fig. 9 Testing Open-Circuit Voltage - Typical
RSBATTERY SYSTEM8F-13
BATTERY (Continued)

CONVENTIONAL BATTERY CHARGING TIME TABLECharging
Amperage 5 Amps10
Amps 20 Amps
Open Circuit Voltage Hours Charging @ 21É C (70É
F)
12.25 to 12.49 6 hours 3 hours 1.5 hours
12.00 to 12.24 10 hours 5 hours 2.5 hours
10.00 to 11.99 14 hours 7 hours 3.5 hours
Below 10.00 18 hours 9 hours 4.5 hours
STANDARD PROCEDURE - OPEN-CIRCUIT
VOLTAGE TEST
A battery open-circuit voltage (no load) test will
show the approximate state-of-charge of a battery.
This test can be used if no other battery tester is
available. Before proceeding with this test, completely charge
the battery. Refer to Standard Procedures for the
proper battery charging procedures. (1) Before measuring the open-circuit voltage, the
surface charge must be removed from the battery.
Turn on the headlamps for fifteen seconds, then
allow up to five minutes for the battery voltage to
stabilize. (2) Disconnect and isolate both battery cables, neg-
ative cable first. (3) Using a voltmeter connected to the battery
posts (see the instructions provided by the manufac-
turer of the voltmeter), measure the open-circuit volt-
age (Fig. 9).
See the Open-Circuit Voltage Table. This voltage
reading will indicate the battery state-of-charge, but
will not reveal its cranking capacity. If a battery has
an open-circuit voltage reading of 12.4 volts or greater, it may be load tested to reveal its cranking
capacity. Refer to Standard Procedures for the proper
battery load test procedures.
OPEN CIRCUIT VOLTAGE TABLE
Open Circuit Voltage Charge Percentage 11.7 volts or less 0% 12.0 volts 25%
12.2 volts 50%
12.45 volts 75%
12.65 volts or more 100%
STANDARD PROCEDURE - IGNITION-OFF
DRAW TEST
The term Ignition-Off Draw (IOD) identifies a nor-
mal condition where power is being drained from the
battery with the ignition switch in the Off position. A
normal vehicle electrical system will draw from fif-
teen to twenty-five milliamperes (0.015 to 0.025
ampere) with the ignition switch in the Off position,
and all non-ignition controlled circuits in proper
working order. Up to twenty-five milliamperes are
needed to enable the memory functions for the Pow-
ertrain Control Module (PCM), digital clock, electron-
ically tuned radio, and other modules which may
vary with the vehicle equipment. A vehicle that has not been operated for approxi-
mately twenty-one days, may discharge the battery
to an inadequate level. When a vehicle will not be
used for twenty-one days or more (stored), remove
the IOD fuse from the Integrated Power Module
(IPM). This will reduce battery discharging. Excessive IOD can be caused by:
² Electrical items left on.
² Faulty or improperly adjusted switches.
² Faulty or shorted electronic modules and compo-
nents. ² An internally shorted generator.
² Intermittent shorts in the wiring.
If the IOD is over twenty-five milliamperes, the
problem must be found and corrected before replac-
ing a battery. In most cases, the battery can be
charged and returned to service after the excessive
IOD condition has been corrected. (1) Verify that all electrical accessories are off.
Turn off all lamps, remove the ignition key, and close
all doors. If the vehicle is equipped with an illumi-
nated entry system or an electronically tuned radio,
allow the electronic timer function of these systems
to automatically shut off (time out). This may take
up to twenty minutes. (2) Disconnect the battery negative cable.
(3) Set an electronic digital multi-meter to its
highest amperage scale. Connect the multi-meter
Fig. 9 Testing Open-Circuit Voltage - Typical
RS BATTERY SYSTEM8Fs-13
BATTERY (Continued)

LAMPS
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR............... 1LAMPS/LIGHTING - INTERIOR............... 20
LAMPS/LIGHTING - EXTERIOR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR
DESCRIPTION..........................2
OPERATION............................2
WARNING.............................3
SPECIFICATIONS
EXTERIOR LAMPS.....................3
BRAKE LAMP SWITCH
DESCRIPTION..........................4
OPERATION............................4
DIAGNOSIS AND TESTING - BRAKE LAMP
SWITCH.............................4
REMOVAL.............................5
INSTALLATION..........................5
CENTER HIGH MOUNTED STOP LAMP
REMOVAL.............................6
INSTALLATION..........................6
CENTER HIGH MOUNTED STOP LAMP UNIT
REMOVAL.............................6
INSTALLATION..........................6
FRONT FOG LAMP
DIAGNOSIS AND TESTING - FRONT FOG
LAMP...............................7
REMOVAL.............................8
INSTALLATION..........................8
FRONT FOG LAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - FRONT FOG
LAMP UNIT ALIGNMENT.................9
STANDARD PROCEDURE - FRONT FOG
LAMP UNIT ALIGNMENT - EXPORT........9
REMOVAL.............................9
INSTALLATION.........................10
HEADLAMP
DIAGNOSIS AND TESTING - HEADLAMP.....10
REMOVAL.............................12
INSTALLATION.........................12HEADLAMP SWITCH
DIAGNOSIS AND TESTING - HEADLAMP
SWITCH............................12
REMOVAL.............................13
INSTALLATION.........................13
HEADLAMP UNIT
STANDARD PROCEDURE
STANDARD PROCEDURE - HEADLAMP
UNIT ALIGNMENT.....................13
STANDARD PROCEDURE - HEADLAMP
UNIT ALIGNMENT - EXPORT.............14
REMOVAL.............................15
INSTALLATION.........................17
HEADLAMP UNIT - EXPORT
REMOVAL.............................17
INSTALLATION.........................17
LICENSE LAMP
REMOVAL.............................17
INSTALLATION.........................17
MULTI-FUNCTION SWITCH
DESCRIPTION - TURN SIGNAL SYSTEM.....17
OPERATION - TURN SIGNAL SYSTEM.......18
DIAGNOSIS AND TESTING - MULTI-
FUNCTION SWITCH...................18
REMOVAL.............................18
INSTALLATION.........................18
PARK/TURN SIGNAL LAMP
REMOVAL.............................18
INSTALLATION.........................18
TAIL LAMP
REMOVAL.............................18
INSTALLATION.........................19
TAIL LAMP UNIT
REMOVAL.............................19
INSTALLATION.........................19
RSLAMPS8L-1

LAMPS/LIGHTING - EXTERIOR
DESCRIPTION
LAMP SYSTEMS
Lighting circuits are protected by fuses. Lighting
circuits require an overload protected power and high
side drivers source, ON/OFF device, lamps and body
grounds to operate properly. Plastic lamps require a
wire in the harness to supply body ground to the
lamp socket. Replace sockets and bulbs that are cor-
roded.
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. Daytime run-
ning lamps are functional when 450 rpm's are
reached.
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-
sage transmitted by the BCM to the FCM to turn off
the headlamps.
OPERATION
AUTOMATIC HEADLAMP SYSTEM
Automatic headlamps are controlled by the Body
Control Module (BCM). With the headlamp switch in
the AUTO position, the BCM will control the head-
lamp, parking, 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 Electrochromatic Mirror (ECM)
present from the Compass Mini Trip (CMTC) located
on the front windshield in front of the rear view mir-
ror ECM. Ambient light readings are averaged to
limit cycling the lamps ON and OFF when passing
through areas with varying light levels. The auto-
matic 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.
8L - 2 LAMPS/LIGHTING - EXTERIORRS

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. Daytime running lamps are
functional when 450 rpm's are reached.
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 or PCI data bus communication between
the BCM and the FCM fails. The system will return
to normal operation 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.
NOTE: For RG - Export vehicles, the low beams and
front fog lamps will remain ON when high beams
are activated.
WARNING
WARNING: EYE PROTECTION SHOULD BE USED
WHEN SERVICING GLASS COMPONENTS. PER-
SONAL INJURY OR DEATH 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.
SPECIFICATIONS
EXTERIOR LAMPS
BULB APPLICATION TABLE
LAMP BULB
BACK-UP 3057
CHMSL 921
FRONT SIDE MARKER/PARK/
TURN3157A
RSLAMPS/LIGHTING - EXTERIOR8L-3
LAMPS/LIGHTING - EXTERIOR (Continued)

LAMP BULB
FRONT FOG 9040
HEADLAMP 9007
LICENSE 168
TAIL, STOP 3057
TURN SIGNAL 3057
BULB APPLICATION TABLE - EXPORT
LAMP BULB
HEADLAMP LOW/HIGH BEAM H7
FRONT FOG H3
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 via a brake switch
input to the BCM. The BCM will then activate the
stop lamps. Other functions include speed control
deactivation, brake sense for the antilock brake sys-
tem 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 closedcompleting 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.
(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
(plunger 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.
8L - 4 LAMPS/LIGHTING - EXTERIORRS
LAMPS/LIGHTING - EXTERIOR (Continued)