lock CHRYSLER VOYAGER 2001 Service Manual

Schedule Condition Expected Operation
HotOil temperature at start-up above
80É F± Normal operation (upshift,
kickdowns, and coastdowns)
± Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
OverheatOil temperature above 240É F or
engine coolant temperature above
244É F± Delayed 2-3 upshift (25-32 mph)
± Delayed 3-4 upshift (41-48 mph)
± 3rd gear FEMCC from 30-48 mph
± 3rd gear PEMCC from 27-31 mph
Super OverheatOil temperature above 260É F ± All9Overheat9shift schedule
features apply
± 2nd gear PEMCC above 22 mph
± Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
STANDARD PROCEDURE - PINION FACTOR
SETTING
NOTE: This procedure must be performed if the
Transmission Control Module (TCM) has been
replaced with a NEW or replacement unit. Failure to
perform this procedure will result in an inoperative
or improperly calibrated speedometer.
The vehicle speed readings for the speedometer are
taken from the output speed sensor. The TCM must
be calibrated to the different combinations of equip-
ment (final drive and tires) available. Pinion Factor
allows the technician to set the Transmission Control
Module initial setting so that the speedometer read-
ings will be correct. To properly read and/or reset the
Pinion Factor, it is necessary to use a DRB scan tool.
(1) Plug the DRB scan tool into the diagnostic con-
nector located under the instrument panel.
(2) Select the Transmission menu.
(3) Select the Miscellaneous menu.
(4) Select Pinion Factor. Then follow the instruc-
tions on the DRB scan tool screen.
STANDARD PROCEDURE - QUICK LEARN
PROCEDURE
The quick learn procedure requires the use of the
DRB scan tool. This program allows the electronic
transaxle system to recalibrate itself. This will pro-
vide the best possible transaxle operation.NOTE: The quick learn procedure should be per-
formed if any of the following procedures are per-
formed:
²Transaxle Assembly Replacement
²Transmission Control Module Replacement
²Solenoid/Pressure Switch Assembly Replacement
²Clutch Plate and/or Seal Replacement
²Valve Body Replacement or Recondition
To perform the Quick Learn Procedure, the follow-
ing conditions must be met:
²The brakes must be applied
²The engine speed must be above 500 rpm
²The throttle angle (TPS) must be less than 3
degrees
²The shift lever position must stay until
prompted to shift to overdrive
²The shift lever position must stay in overdrive
after the Shift to Overdrive prompt until the DRB
indicates the procedure is complete
²The calculated oil temperature must be above
60É and below 200É
(1) Plug the DRB scan tool into the diagnostic con-
nector. The connector is located under the instrument
panel.
(2) Go to the Transmission screen.
(3) Go to the Miscellaneous screen.
(4) Select Quick Learn Procedure. Follow the
instructions of the DRB to perform the Quick Learn
Procedure.
RSELECTRONIC CONTROL MODULES8E-27
TRANSMISSION CONTROL MODULE (Continued)

(4) Allow the battery to stabilize to open-circuit
voltage. It may take up to five minutes for the bat-
tery voltage to stabilize.
(5) Rotate the load control knob to maintain a load
equal to 50% of the CCA rating of the battery (Fig.
14). After fifteen seconds, record the loaded voltage
reading, then return the load control knob to the Off
position.
(6) The voltage drop will vary with the battery
temperature at the time of the load test. The battery
temperature can be estimated by using the ambient
temperature during the past several hours. If the
battery has been charged, boosted, or loaded a few
minutes prior to the test, the battery will be some-
what warmer. See the Load Test Temperature Table
for the proper loaded voltage reading.
LOAD TEST TEMPERATURE TABLE
Minimum VoltageTemperature
ÉF ÉC
9.6 volts 70É and above 21É and above
9.5 volts 60É 16É
9.4 volts 50É 10É
9.3 volts 40É 4É
9.1 volts 30É -1É
8.9 volts 20É -7É
8.7 volts 10É -12É
8.5 volts 0É -18É
(7) If the voltmeter reading falls below 9.6 volts, at
a minimum battery temperature of 21É C (70É F), the
battery is faulty and must be replaced.
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 five
to thirty-five milliamperes (0.005 to 0.035 ampere)
with the ignition switch in the Off position, and all
non-ignition controlled circuits in proper working
order. Up to thirty-five milliamperes are needed to
enable the memory functions for the Powertrain Con-
trol Module (PCM), digital clock, electronically tuned
radio, and other modules which may vary with the
vehicle equipment.
A vehicle that has not been operated for approxi-
mately twenty days, may discharge the battery to an
inadequate level. When a vehicle will not be used for
twenty days or more (stored), remove the IOD fuse
from the Power Distribution Center (PDC). 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 thirty-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 three minutes. See the Electronic Module Igni-
tion-Off Draw Table for more information.
Fig. 14 Load 50% CCA Rating - Note Voltage -
Typical
8F - 14 BATTERY SYSTEMRS
BATTERY (Continued)

BATTERY CABLES
DESCRIPTION
The battery cables are large gauge, stranded cop-
per wires sheathed within a heavy plastic or syn-
thetic rubber insulating jacket. The wire used in the
battery cables combines excellent flexibility and reli-
ability with high electrical current carrying capacity.
Refer toWiring Diagramsin the index of this ser-
vice manual for the location of the proper battery
cable wire gauge information.
A clamping type female battery terminal made of
soft lead is die cast onto one end of the battery cable
wire. A square headed pinch-bolt and hex nut are
installed at the open end of the female battery termi-
nal clamp. Large eyelet type terminals are crimped
onto the opposite end of the battery cable wire and
then solder-dipped. The battery positive cable wires
have a red insulating jacket to provide visual identi-
fication and feature a larger female battery terminal
clamp to allow connection to the larger battery posi-
tive terminal post. The battery negative cable wires
have a black insulating jacket and a smaller female
battery terminal clamp.
The battery cables cannot be repaired and, if dam-
aged or faulty they must be replaced. Both the bat-
tery positive and negative cables are available for
service replacement only as a unit with the battery
wire harness, which may include portions of the wir-
ing circuits for the generator and other components
on some models. Refer toWiring Diagramsin the
index of this service manual for the location of more
information on the various wiring circuits included in
the battery wire harness for the vehicle being ser-
viced.
OPERATION
The battery cables connect the battery terminal
posts to the vehicle electrical system. These cables
also provide a path back to the battery for electrical
current generated by the charging system for restor-
ing the voltage potential of the battery. The female
battery terminal clamps on the ends of the battery
cable wires provide a strong and reliable connection
of the battery cable to the battery terminal posts.
The terminal pinch bolts allow the female terminal
clamps to be tightened around the male terminal
posts on the top of the battery. The eyelet terminals
secured to the opposite ends of the battery cable
wires from the female battery terminal clamps pro-
vide secure and reliable connection of the battery
cables to the vehicle electrical system.The battery positive cable terminal clamp is die
cast onto the ends of two wires. One wire has an eye-
let terminal that connects the battery positive cable
to the B(+) terminal stud of the Intelligent Power
Module (IPM), and the other wire has an eyelet ter-
minal that connects the battery positive cable to the
B(+) terminal stud of the engine starter motor sole-
noid. The battery negative cable terminal clamp is
also die cast onto the ends of two wires. One wire
has an eyelet terminal that connects the battery neg-
ative cable to the vehicle powertrain through a stud
on the left side of the engine cylinder block. The
other wire has an eyelet terminal that connects the
battery negative cable to the vehicle body through a
ground screw on the left front fender inner shield,
near the battery.
DIAGNOSIS AND TESTING - BATTERY CABLE
A voltage drop test will determine if there is exces-
sive resistance in the battery cable terminal connec-
tions or the battery cable. If excessive resistance is
found in the battery cable connections, the connec-
tion point should be disassembled, cleaned of all cor-
rosion or foreign material, then reassembled.
Following reassembly, check the voltage drop for the
battery cable connection and the battery cable again
to confirm repair.
When performing the voltage drop test, it is impor-
tant to remember that the voltage drop is giving an
indication of the resistance between the two points at
which the voltmeter probes are attached.EXAM-
PLE:When testing the resistance of the battery pos-
itive cable, touch the voltmeter leads to the battery
positive cable terminal clamp and to the battery pos-
itive cable eyelet terminal at the starter solenoid
B(+) terminal stud. If you probe the battery positive
terminal post and the battery positive cable eyelet
terminal at the starter solenoid B(+) terminal stud,
you are reading the combined voltage drop in the
battery positive cable terminal clamp-to-terminal
post connection and the battery positive cable.
VOLTAGE DROP TEST
The following operation will require a voltmeter
accurate to 1/10 (0.10) volt. Before performing this
test, be certain that the following procedures are
accomplished:
²The battery is fully-charged and load tested.
Refer to Standard Procedures for the proper battery
charging and load test procedures.
²Fully engage the parking brake.
RSBATTERY SYSTEM8F-17

²If the vehicle is equipped with an automatic
transmission, place the gearshift selector lever in the
Park position. If the vehicle is equipped with a man-
ual transmission, place the gearshift selector lever in
the Neutral position and block the clutch pedal in the
fully depressed position.
²Verify that all lamps and accessories are turned
off.
²To prevent the engine from starting, remove the
Automatic Shut Down (ASD) relay. The ASD relay is
located in the Intelligent Power Module (IPM), in the
engine compartment. See the fuse and relay layout
label affixed to the underside of the IPM cover for
ASD relay identification and location.
(1) Connect the positive lead of the voltmeter to
the battery negative terminal post. Connect the neg-
ative lead of the voltmeter to the battery negative
cable terminal clamp (Fig. 16). Rotate and hold the
ignition switch in the Start position. Observe the
voltmeter. If voltage is detected, correct the poor con-
nection between the battery negative cable terminal
clamp and the battery negative terminal post.
(2) Connect the positive lead of the voltmeter to
the battery positive terminal post. Connect the nega-
tive lead of the voltmeter to the battery positive cable
terminal clamp (Fig. 17). Rotate and hold the ignition
switch in the Start position. Observe the voltmeter. If
voltage is detected, correct the poor connection
between the battery positive cable terminal clamp
and the battery positive terminal post.(3) Connect the voltmeter to measure between the
battery positive cable terminal clamp and the starter
solenoid B(+) terminal stud (Fig. 18). Rotate and hold
the ignition switch in the Start position. Observe the
voltmeter. If the reading is above 0.2 volt, clean and
tighten the battery positive cable eyelet terminal con-
nection at the starter solenoid B(+) terminal stud.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery positive cable.
Fig. 16 Test Battery Negative Connection
Resistance - Typical
1 - VOLTMETER
2 - BATTERY
Fig. 17 Test Battery Positive Connection Resistance
- Typical
1 - VOLTMETER
2 - BATTERY
Fig. 18 Test Battery Positive Cable Resistance -
Typical
1 - BATTERY
2 - VOLTMETER
3 - STARTER MOTOR
8F - 18 BATTERY SYSTEMRS
BATTERY CABLES (Continued)

(4) Connect the voltmeter to measure between the
battery negative cable terminal clamp and a good
clean ground on the engine block (Fig. 19). Rotate
and hold the ignition switch in the Start position.
Observe the voltmeter. If the reading is above 0.2
volt, clean and tighten the battery negative cable
eyelet terminal connection to the engine block.
Repeat the test. If the reading is still above 0.2 volt,
replace the faulty battery negative cable.
BATTERY TRAY
DESCRIPTION
The battery is mounted in a molded plastic battery
tray and support unit located in the left front corner
of the engine compartment. The battery tray and
support unit is secured with two nuts, one is located
directly under the battery and the other is located on
the right side of the tray which also serves as a cool-
ant bottle neck retaining bolt. An additional bolt is
located directly under the battery.
The battery tray and support unit also includes a
engine vacuum reservoir, located in the rear of the
unit (Fig. 20). And a drainage hose, located in the
front of the unit (Fig. 20).
OPERATION
The battery tray provides a secure mounting loca-
tion and supports the battery. The battery tray also
provides the anchor point for the battery holddown
hardware. The battery tray and the battery hold-
down hardware combine to secure and stabilize the
battery in the engine compartment, which prevents
battery movement during vehicle operation. Unre-
strained battery movement during vehicle operationcould result in damage to the vehicle, the battery, or
both.
The battery tray used on this model also includes a
engine vacuum reservoir and drainage hose. The vac-
uum reservoir provides a storage container for engine
vacuum. Refer to the engine section of the service
manual for more engine vacuum information. The
drainage hose provides means for any liquid that
might collect in the bottom of the battery tray to
drain under the vehicle.
REMOVAL
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the battery from the vehicle. Refer to
the procedure in this section.
(3) Remove the battery tray retaining fasteners
(Fig. 21).
(4) Pull battery tray up far enough to disconnect
the engine vacuum harness hose from the battery
tray mounted, vacuum reservoir.
(5) Remove the battery tray from the vehicle.
INSTALLATION
(1) Position the battery tray in the vehicle.
(2) Connect the engine vacuum harness hose on
the battery tray mounted vacuum reservoir.
(3) Position drainage hose and install the battery
tray retaining fasteners (Fig. 21).
Fig. 19 Test Ground Circuit Resistance - Typical
1 - VOLTMETER
2 - BATTERY
3 - ENGINE GROUND
Fig. 20 BATTERY TRAY - TYPICAL
1 - ENGINE VACUUM RESERVOIR
2 - BATTERY TRAY ASSEMBLY
3 - DRAINAGE HOSE
RSBATTERY SYSTEM8F-19
BATTERY CABLES (Continued)

(5) The coil ground terminal (85) is connected to
the electromagnet in the relay. It is grounded
through the transmission range sensor only when the
gearshift selector lever is in the Park or Neutral
positions. Check for continuity to ground at the cav-
ity for relay terminal 85. If not OK with an auto-
matic transmission, check for an open or short circuit
to the transmission range sensor and repair.
SAFETY SWITCHES
For diagnostics of the Transmission Range Sensor,
refer to the Transaxle section for more information.
If equipped with Clutch Interlock/Upstop Switch,
refer to Diagnosis and Testing in the Clutch section.
IGNITION SWITCH
After testing starter solenoid and relay, test igni-
tion switch and wiring. Refer to the Ignition Section
or Wiring Diagrams for more information. Check all
wiring for opens or shorts, and all connectors for
being loose or corroded.
BATTERY
For battery diagnosis and testing, refer to the Bat-
tery section for procedures.
ALL RELATED WIRING AND CONNECTORS
Refer to Wiring Diagrams for more information.
FEED CIRCUIT RESISTANCE TEST
Before proceeding with this operation, review Diag-
nostic Preparation and Starter Feed Circuit Tests.
The following operation will require a voltmeter,
accurate to 1/10 of a volt.
CAUTION: Ignition and Fuel systems must be dis-
abled to prevent engine start while performing the
following tests.
(1) 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.
(2) Remove the air cleaner assembly for access to
battery terminals. Refer to the Fuel section for ser-
vice procedures.
(3) With all wiring harnesses and components
properly connected, perform the following:
(a) Connect the negative lead of the voltmeter to
the battery negative post, and positive lead to the
battery negative cable clamp. Rotate and hold the
ignition switch in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between cable clamp and post.(b) Connect positive lead of the voltmeter to the
battery positive post, and negative lead to the bat-
tery positive cable clamp. Rotate and hold the igni-
tion switch key in the START position. Observe the
voltmeter. If voltage is detected, correct poor con-
tact between the cable clamp and post.
(c) Connect negative lead of voltmeter to battery
negative terminal, and positive lead to engine
block near the battery cable attaching point.
Rotate and hold the ignition switch in the START
position. If voltage reads above 0.2 volt, correct
poor contact at ground cable attaching point. If
voltage reading is still above 0.2 volt after correct-
ing poor contacts, replace ground cable.
(4) Connect positive voltmeter lead to the starter
motor housing and the negative lead to the battery
negative terminal. Hold the ignition switch key in
the START position. If voltage reads above 0.2 volt,
correct poor starter to engine ground.
(a) Connect the positive voltmeter lead to the
battery positive terminal, and negative lead to bat-
tery cable terminal on starter solenoid. Rotate and
hold the ignition switch in the START position. If
voltage reads above 0.2 volt, correct poor contact at
battery cable to solenoid connection. If reading is
still above 0.2 volt after correcting poor contacts,
replace battery positive cable.
(b) If resistance tests do not detect feed circuit
failures, replace the starter motor.FEED CIRCUIT TEST
NOTE: The following results are based upon the
vehicle being at room temperature.
The following procedure will require a suitable
volt-ampere tester (Fig. 2).
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
Fig. 2 Volt Ampere Tester
RSSTARTING8F-31
STARTING (Continued)

²Remote Keyless Entry Module (RKE)- Refer
toRemote Keyless Entry Modulein Power Locks
for more information.
²Electronic Vehicle Information Center
(EVIC)- Refer toElectronic Vehicle Information
Centerin Overhead Console for more information.
²Heated Seat Module (HSM)- Refer toHeated
Seat Modulein Electronic Control Modules for more
information.
²Memory Heated Seat Module (MHSM)-If
the vehicle is equipped with the Memory System,
refer toMemory Seat Mirror Module (MSMM)in
Electronic Control Modules for more information.
Refer toWiring Diagramsfor complete circuit
diagrams. Following are general descriptions of the
major components in the heated seat system.
OPERATION
The heated seat system will only operate when the
ignition switch is in the On position, and the surface
temperature at the front seat heating element sen-
sors is below the designed temperature set points of
the system. The heated seat system will not operate
in ambient temperatures greater than about 41É C
(105É F). The front seat heating elements and sensors
are hard wired to the Heated Seat Module (HSM) or
the Memory Heated Seat Module (MHSM).
The heated seat switches are hard wired to the
Body Control Module (BCM). The BCM monitors the
heated seat switch inputs, then sends heated seat
switch status messages to the HSM or MHSM over
the Programmable Communications Interface J1850
(PCI) data bus. The HSM or MHSM contains the con-
trol logic for the heated seat system. The HSM or
MHSM responds to the heated seat switch status
messages, ignition switch status messages, and the
front seat heating element sensor inputs by control-
ling the output to the front seat heating elements
through integral solid-state relays.
When a seat heater is turned on, the sensor
located on the seat cushion electric heater element
provides the HSM or MHSM with an input indicating
the surface temperature of the seat cushion. If the
surface temperature input is below the temperature
set point for the selected Low or High heated seat
switch position, the HSM or MHSM energizes the
integral solid-state relay, which supplies battery cur-
rent to the heating elements in the seat cushion and
back. When the sensor input indicates the correct
temperature set point has been achieved, the HSM or
MHSM de-energizes the solid-state relay. The HSM
or MHSM will continue to cycle the solid-state relay
as needed to maintain the temperature set point.
The HSM or MHSM and the seat heater elements
operate on non-switched battery current supplied
through the power seat fuse in the intelligent powermodule. However, the HSM or MHSM will automati-
cally turn off the heating elements if it detects an
open in the sensor circuit, a short in the heating ele-
ment circuit causing an excessive current draw, or
when the ignition switch is turned to the Off posi-
tion.
See the owner's manual in the vehicle glove box for
more information on the features, use and operation
of the heated seat system.
DRIVER HEATED SEAT
SWITCH
DESCRIPTION
The heated seat switches are mounted in the
instrument panel center bezel (Fig. 2). The two three-
position rocker-type switches, one switch for each
front seat, are incorporated into one large switch
assembly that also includes the hazzard, rear window
wiper and washer switches. The heated seat switches
provide a resistor multiplexed signal to the Body
Control Module (BCM) through separate hard wired
circuits. Each switch has an Off, Low, and High posi-
tion so that both the driver and the front seat pas-
senger can select a preferred seat heating mode.
Each switch has two Light-Emitting Diodes (LED)
which light to indicate that the heater for the seat is
turned on.
The heated seat switches and their LEDs cannot
be repaired. If either switch or LED is faulty or dam-
aged, the entire switch assembly must be replaced.
Fig. 2 HEATED SEAT SWITCHES
8G - 8 HEATED SEAT SYSTEMRS
HEATED SEAT SYSTEM (Continued)

HORN
TABLE OF CONTENTS
page page
HORN
DESCRIPTION............................1
OPERATION.............................1
DIAGNOSIS AND TESTING..................1
HORN
DIAGNOSIS AND TESTING..................3
REMOVAL...............................4INSTALLATION............................5
HORN RELAY
DIAGNOSIS AND TESTING..................5
REMOVAL...............................5
INSTALLATION............................5
HORN SWITCH
DESCRIPTION............................5
HORN
DESCRIPTION
HORN SYSTEM
WARNING:
ON VEHICLES EQUIPPED WITH AIRBAG, REFER TO
ELECTRICAL, RESTRAINTS FOR SAFETY PRECAU-
TIONS. DISCONNECT THE NEGATIVE CABLE FROM
THE BATTERY BEFORE SERVICING COMPONENTS
INVOLVING THE AIRBAG SYSTEM. ACCIDENTAL
DEPLOYMENT OF AIRBAG AND PERSONAL INJURY
CAN RESULT.
The horn circuit consists of a horn switch, clock-
spring, horn relay, horns and intelligent power mod-
ule. The horn switch is a membrane switch located in
the airbag trim cover. The horns are located forward
of the left front wheel behind the bumper fascia.
OPERATION
The horn relay plugs into the intelligent power
module which is located in the engine compartment.
For circuit information and component locations,
refer to the appropriate wiring information. The wir-
ing information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
The horns will not function if the switch is
ªCLOSEDº for more than 30 seconds. Once the
switch is ªOPENº, a 20±30 second delay will occur
before the horns are functional again.
DIAGNOSIS AND TESTING
Refer to Horn System Test below. If the horn does
not sound, check horn fuse located in the intelligent
power module. If the fuse is blown, replace with the
correct fuse. If the horns fail to sound and the new
fuse blows when depressing the horn switch, a short
circuit in the horn or the horn wiring between the
fuse terminal and the horn is responsible, or a defec-
tive horn switch allowed the horn to burn out is
responsible.
If the fuse is OK, test horn relay (Refer to 8 -
ELECTRICAL/HORN/HORN RELAY - DIAGNOSIS
AND TESTING).
If the relay is OK, test horn. Refer to Horn System
Test.
CAUTION:
Continuous sounding of horn may cause horn relay
to fail.
Should the horn sound continuously:
²Unplug the horn relay from intelligent power
module.
²Refer to (Refer to 8 - ELECTRICAL/HORN/
HORN RELAY - DIAGNOSIS AND TESTING).
Refer to the appropriate wiring information. The
wiring information includes wiring diagrams, proper
wire and connector repair procedures, details of wire
harness routing and retention, connector pin-out
information and location views for the various wire
harness connectors, splices and grounds.
RSHORN8H-1

HORN SYSTEM TEST
CONDITION POSSIBLE CAUSE CORRECTION
HORN SOUNDS CONTINUOUSLY.
NOTE: IMMEDIATELY UNPLUG
HORN RELAY IN THE
INTELLIGENT POWER MODULE.(1) FAULTY HORN RELAY. (1) REFER TO HORN RELAY
TEST.
(2) HORN CONTROL CIRCUIT TO
RELAY SHORTED TO GROUND.(2) CHECK TERMINAL 85 IN
INTELLIGENT POWER MODULE
FOR CONTINUITY TO GROUND.
IF CONTINUITY TO GROUND
INDICATES:
(A) STEERING WHEEL HORN
SWITCH/LEAD SHORTED TO
GROUND.
(B) WIRING HARNESS SHORTED
TO GROUND. FIND THE SHORT
AND REPAIR AS NECESSARY.
(3) PINCHED HORN SWITCH
WIRE UNDER DRIVER AIRBAG
MODULE.(3) REPLACE DRIVER AIRBAG
MODULE TRIM.
(4) FAULTY HORN SWITCH. (4) REPLACE DRIVER AIRBAG
MODULE TRIM.
(5) FAULTY CLOCKSPRING. (5) REPLACE CLOCKSPRING.
HORN SOUND INTERMITTENTLY
AS THE STEERING WHEEL IS
TURNED.(1) HORN RELAY CONTROL
CIRCUIT X3 IS SHORTED TO
GROUND INSIDE STEERING
COLUMN OR WHEEL.(1) REMOVE DRIVER AIRBAG
MODULE AND/OR WHEEL.
CHECK FOR RUBBING OR
LOOSE WIRE/CONNECTOR,
REPAIR AS NECESSARY.
(2) PINCHED HORN SWITCH
WIRE UNDER DRIVER AIRBAG
MODULE.(2) REPLACE DRIVER AIRBAG
MODULE TRIM.
(3) FAULTY HORN SWITCH. (3) REPLACE DRIVER AIRBAG
MODULE TRIM.
(4) FAULTY CLOCKSPRING. (4) REPLACE CLOCKSPRING.
HORN DOES NOT SOUND (1) CHECK FUSE 8 IN
INTELLIGENT POWER MODULE.(1) REPLACE FUSE IF BLOWN
REPAIR AS NECESSARY.
(2) NO VOLTAGE AT HORN
RELAY TERMINALS 30 & 86, AND
FUSE IS OK.(2) NO VOLTAGE, REPAIR THE
CIRCUIT AS NECESSARY.
(3) OPEN CIRCUIT FROM
TERMINAL 85 OF THE HORN
RELAY TO HORN SWITCH, X3
CIRCUIT.(3) REPAIR CIRCUIT AS
NECESSARY.
(4) FAULTY OR DAMAGED HORN. (4) VOLTAGE AT HORN WHEN
HORN SWITCH IS PRESSED,
REPLACE HORN.
(5) FAULTY HORN SWITCH. (5) REPLACE DRIVER AIRBAG
MODULE TRIM.
(6) FAULTY CLOCKSPRING. (6) REPLACE CLOCKSPRING.
8H - 2 HORNRS
HORN (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
FUSE BLOWS WHEN HORN
SOUNDS(1) SHORT CIRCUIT IN HORN OR
HORN WIRING.(1) REMOVE HORN RELAY,
CHECK FOR SHORTED HORN OR
HORN WIRING. DISCONNECT
HORN WIRE HARNESS TO
ISOLATE SHORT AND REPAIR AS
NECESSARY.
(2) FAULTY CLOCKSPRING. (2) REPLACE CLOCKSPRING.
FUSE BLOWS WITHOUT
BLOWING HORN(1) SHORT CIRCUIT. (1) REMOVE RELAY, INSTALL
NEW FUSE, IF FUSE DOES NOT
BLOW REPLACE HORN RELAY. IF
FUSE BLOWS WITH RELAY
REMOVED, CHECK FOR SHORT
TO GROUND WITH OHMMETER
ON CIRCUIT BETWEEN
TERMINALS 30 & 86 AND THE
FUSE TERMINAL. REPAIR AS
NECESSARY.
(2) FAULTY CLOCKSPRING. (2) REPLACE CLOCKSPRING.
HORN
DIAGNOSIS AND TESTING
HORN
(1) Disconnect wire connector at horn.
(2) Using a voltmeter, connect one lead to ground
terminal and the other lead to the positive wire ter-
minal (Fig. 1).
(3) Depress the horn switch, battery voltage
should be present.
(4) If no voltage, refer toHORNS WILL NOT
SOUND. If voltage is OK, go to step Step 5.
(5) Using ohmmeter, test ground wire for continu-
ity to ground.
(6) If no ground repair as necessary.
(7) If wires test OK and horn does not sound,
replace horn.
HORNS SOUND CONTINUOUSLY
CAUTION:
Continuous sounding of horns may cause relay to
fail.
The horn switch (membrane) sometimes can be the
cause without the switch being depressed.
(1) Remove the horn relay from the intelligent
power module.
(2) Using a continuity tester, test continuity from
the X3 cavity of the horn relay to ground. Refer to
the appropriate wiring information. The wiring infor-
mation includes wiring diagrams, proper wire and
connector repair procedures, details of wire harnessrouting and retention, connector pin-out information
and location views for the various wire harness con-
nectors, splices and grounds.
(a) If continuity is detected, proceed to step Step
3.
(b) If NO continuity, replace the horn relay.
(3) Remove the airbag trim cover from the steering
wheel and disengage horn connector.
(4) Install horn relay into intelligent power mod-
ule.
(a) If horn does not sound, replace airbag trim
cover.
(b) If horn sounds, repair grounded X3 circuit
from intelligent power module to clockspring in the
steering column. Refer to the appropriate wiring
information. The wiring information includes wir-
ing diagrams, proper wire and connector repair
procedures, details of wire harness routing and
retention, connector pin-out information and loca-
tion views for the various wire harness connectors,
splices and grounds.HORNS WILL NOT SOUND
Check horn fuse#8intheintelligent power mod-
ule. If fuse is blown, check for a shorted switch in the
airbag module. and refer to FUSE BLOWN section. If
fuse is OK, refer to FUSE OK section.
FUSE BLOWN
(1) Verify condition of battery terminals and volt-
age, (Refer to 8 - ELECTRICAL/BATTERY SYSTEM
- DIAGNOSIS AND TESTING). If battery connec-
tions and battery charge is OK proceed to Step 2.
RSHORN8H-3
HORN (Continued)