Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2002 Chrysler Voyager ECFACTORY OEM SERVICE PROCEDURE
Headlight Switch Open
NOTE:
After making any repairs, perform BODY VERIFICATION TEST under VERIFICATION TESTS.
- Turn ignition on. Using scan tool, clear all Body Control Module (BCM) DTCs. Turn headlights on. Recheck for DTCs. If HEADLAMP SWITCH OPEN resets, go to next step. If HEADLAMP SWITCH OPEN does not reset, conditions necessary to set this DTC are not present at this time. Check for intermittent poor connections or faulty circuits and repair as necessary.
- Turn ignition off. Disconnect headlight switch connector. For removal and installation procedures, see ANALOG INSTRUMENT PANELS article. Connect a fused jumper between headlight switch connector terminals No. 6 (White/Yellow wire) and No. 11 (White/Brown wire). See Figure. Turn ignition on. Using scan tool, select BODY then BODY CONTROL MODULE and monitor HEADLAMP SWITCH voltage. If HEADLAMP SWITCH voltage is greater than 0.5 volt, go to next step. If HEADLAMP SWITCH voltage is less than 0.5 volt, replace headlight switch.
- Turn ignition off and to LOCK position. Locate and disconnect Body Control Module (BCM) connector C5. See COMPONENT LOCATIONS . See Figure and Figure . Check condition of connectors and repair as necessary. Using DVOM, measure resistance of White/Brown wire between BCM connector C5 terminal No. 18 and headlight switch connector terminal No. 11. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open in White/Brown wire.
- Using DVOM, measure resistance of White/Yellow wire between BCM connector C5 terminal No. 17 and headlight switch connector terminal No. 6. If resistance is 5 ohms or less, replace BCM. See BODY CONTROL MODULE under REMOVAL & INSTALLATION. If resistance is greater than 5 ohms, repair open in White/Yellow wire.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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