fuse CHRYSLER VOYAGER 1996 User Guide

CAUTION: Always disconnect the meter before
opening a door.
(3) Using an multimeter, that has least a milliam-
pere range of 200 mA. Set meter to the highest mA
range. Install meter between the battery negative
cable and battery negative post (Fig. 5). Carefully
remove the test lamp without disconnecting themeter. After all modules time-out the total vehicle
IOD should be less than 25 milliamperes. If ignition
off draw is more than 25 milliamperes go to Step 4.
(4) Each time the test lamp or milliampere meter
is disconnected and connected, all electronic timer
functions will be activated for approximately one
minute. The Body Control Module (BCM) ignition off
draw can reach 90 milliamperes.
(5) Remove the PDC fuses:
²Interior lamps
²Brake lamp
²IOD
(6) If there is any reading, with fuses removed
there is a short circuit in the wiring. Refer to Group
8W, wiring diagrams. If reading is less than 25 mA
go to Step 8.
(7) Install all fuses. After installing fuse, the cur-
rent can reach 90 mA. After time-out the reading
should not exceed 25 mA. If OK go to. If not, discon-
nect:
²Radio
BATTERY DIAGNOSIS AND TESTING
STEPS POSSIBLE CAUSE CORRECTION
VISUAL INSPECTION
Check for possible damage to
battery and clean battery.(1) Corroded post(s) or terminal(s)
(2) Loose terminal(s)
(3) Loose battery post, Cracked
battery cover or case, Leaks or Any
other physical
(4) Battery OK.(1) Clean post(s) or terminal(s)
(2) Clean and tighten
(3) Replace Battery
(4) Check state of charge. Refer to
Hydrometer Test
PERFORM BATTERY
HYDROMETER TEST(1) 1.285
(2) 1.235
(3) 1.175 or a variation between
cells of 0.050 or greater(1) Battery is charged. Perform
Battery 0pen Circuit Voltage Test
(2) Perform Battery Charging
procedure.
(3) Replace Battery.
BATTERY OPEN CIRCUIT
VOLTAGE TEST(1) Battery is above 12.40 Volts
(2) Battery is below 12.40 Volts.(1) Perform the Battery Load Test.
(2) Perform Battery Charging
procedure.
BATTERY CHARGING (1) Battery accepted Charge.
(2) Battery will not accept charge(1) Pass Hydrometer Test and
perform Battery 0pen Circuit Voltage
Test
(2) Perform Charging a Completely
Discharged Battery.
BATTERY LOAD TEST (1) Acceptable minimum voltage.
(2) Unacceptable minimum voltage(1) Battery is OK to put in use,
perform Battery Ignition Off Draw
Test.
(2) Replace Battery and perform
Battery Ignition Off Draw Test.
CHARGING A COMPLETELY
DISCHARGED BATTERY(1) Battery accepted charge.
(2) Battery will not accept charge.(1) Pass Hyrometer Test and
perform Battery 0pen Circuit Voltage
Test.
(2) Replace Battery.
IGNITION OFF DRAW TEST (1) IOD is 5-25 Milliamperes.
(2) IOD Exceeds 25 Milliamperes.(1) Vehicle is normal.
(2) Eliminate excess IOD draw.
Fig. 4 Disconnect Battery Negative Cable
8A - 4 BATTERYNS/GS
DIAGNOSIS AND TESTING (Continued)

²Body Control Module
²Remote Keyless Entry Module
(8) Disconnect one component at time, to see if any
component is at fault. If the high reading is not elim-
inated there is a short circuit in the wiring. Refer to
Group 8W, wiring diagrams.
(9) Remove interior and brake lamp fuses. Install
the fuses. The milliampere reading should be 2-4 mA.
If reading is higher than 4 mA:
(a) Disconnect PCM.
(b) If reading is OK, replace PCM.
(c) If reading does not change there is a short
circuit to the PCM. Refer to Group 8W, Wiring Dia-
grams.
BATTERY LOAD TEST
A fully charged battery must have cranking capac-
ity, to provide the starter motor and ignition system
enough power to start the engine over a broad range
of ambient temperatures. A battery load test will ver-
ify the actual cranking capability of the battery.
WARNING: IF BATTERY SHOWS SIGNS OF FREEZ-
ING, LEAKING, LOOSE POSTS, OR EXCESSIVELY
LOW ELECTROLYTE LEVEL, DO NOT TEST. ACID
BURNS OR AN EXPLOSIVE CONDITION MAY
RESULT.
(1) Remove both battery cables, negative cable
first. The battery top, cables and posts should be
clean. Test battery with a hydrometer. If battery
charge is low the charge battery. Refer to Battery
Charging Procedures.(2) Connect a Volt/Ammeter/Load tester to the bat-
tery posts (Fig. 6). Rotate the load control knob of the
Carbon pile rheostat to apply a 300 amp load. Apply
this load for 15 seconds to remove the surface charge
from the battery, and return the control knob to off
(Fig. 7).
(3) Allow the battery to stabilize for 2 minutes,
and then verify open circuit voltage.
(4) Rotate the load control knob on the tester to
maintain 50% of the battery cold crank rating for 15
seconds (Fig. 8). Record the loaded voltage reading
and return the load control to off. Refer to the Bat-
tery Specifications at the rear of this Group.
(5) Voltage drop will vary according to battery
temperature at the time of the load test. Battery
temperature can be estimated by the temperature of
exposure over the preceding several hours. If the bat-
tery has been charged or boosted a few minutes prior
to the test, the battery would be slightly warmer.
Refer to Load Test Voltage Chart for proper loaded
voltage reading.
Fig. 5 Milliampere Meter ConnectionFig. 6 Volt-Ammeter Load Tester Connections
Fig. 7 Remove Surface Charge From Battery
NS/GSBATTERY 8A - 5
DIAGNOSIS AND TESTING (Continued)

²Transmission range sensor, or Park/Neutral
Position switch with automatic transmissions
²Clutch Pedal Position Switch with manual
transmissions
²Ignition switch
²Battery
²All related wiring and connections
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
²To disable ignition and fuel systems, disconnect
the Automatic Shutdown Relay (ASD). The ASD relay
is located in the in the Power Distribution Center
(PDC). Refer to the PDC cover for the proper relay
location.
STARTER SOLENOID
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION WITH THE
PARKING BRAKE APPLIED
(1) Verify battery condition. Battery must be in
good condition with a full charge before performing
any starter tests. Refer to Battery Tests.
(2) Perform Starter Solenoid test BEFORE per-
forming the starter relay test.
(3) Raise the vehicle.
(4) Perform a visual inspection of the starter/
starter solenoid for corrosion, loose connections or
faulty wiring.
(5) Lower the vehicle.
(6) Locate and remove the starter relay from the
Power Distribution Center (PDC). Refer to the PDC
label for relay identification and location.
(7) Connect a remote starter switch or a jumper
wire between the remote battery positive post and
terminal 87 of the starter relay connector.
(a) If engine cranks, starter/starter solenoid is
good. Go to the Starter Relay Test.
(b) If engine does not or solenoid chatters, check
wiring and connectors from starter relay to starter
solenoid for loose or corroded connections. Particu-
larly at starter terminals.
(c) Repeat test. If engine still fails to crank prop-
erly, trouble is within starter or starter mounted
solenoid, and replace starter.
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK POSITION/NEUTRAL
WITH THE PARKING BRAKE APPLIED
RELAY TEST
The starter relay is located in the Power Distribu-
tion Center (PDC) in the engine compartment. Refer
to the PDC label for relay identification and location.
Remove the starter relay from the PDC as
described in this group to perform the following tests:
(1) A relay in the de-energized position should
have continuity between terminals 87A and 30, and
no continuity between terminals 87 and 30. If OK, go
to Step 2. If not OK, replace the faulty relay.
(2) Resistance between terminals 85 and 86 (elec-
tromagnet) should be 7565 ohms. If OK, go to Step
3. If not OK, replace the faulty relay.
(3) Connect a battery B+ lead to terminals 86 and
a ground lead to terminal 85 to energize the relay.
The relay should click. Also test for continuity
between terminals 30 and 87, and no continuity
between terminals 87A and 30. If OK, refer to Relay
Circuit Test procedure. If not OK, replace the faulty
relay.
RELAY CIRCUIT TEST
(1) The relay common feed terminal cavity (30) is
connected to battery voltage and should be hot at all
times. If OK, go to Step 2. If not OK, repair the open
circuit to the PDC fuse as required.
(2) The relay normally closed terminal (87A) is
connected to terminal 30 in the de-energized position,
but is not used for this application. Go to Step 3.
(3) The relay normally open terminal (87) is con-
nected to the common feed terminal (30) in the ener-
gized position. This terminal supplies battery voltage
to the starter solenoid field coils. There should be
continuity between the cavity for relay terminal 87
and the starter solenoid terminal at all times. If OK,
go to Step 4. If not OK, repair the open circuit to the
starter solenoid as required.
(4) The coil battery terminal (86) is connected to
the electromagnet in the relay. It is energized when
the ignition switch is held in the Start position. On
Starter Relay
8B - 2 STARTERNS
DIAGNOSIS AND TESTING (Continued)

GENERATOR
The generator is belt-driven by the engine. It is
serviced only as a complete assembly. If the genera-
tor fails for any reason, the entire assembly must be
replaced.
As the energized rotor begins to rotate within the
generator, the spinning magnetic field induces a cur-
rent into the windings of the stator coil. Once the
generator begins producing sufficient current, it also
provides the current needed to energize the rotor.
The Y type stator winding connections deliver the
induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC
current is delivered to the vehicle electrical system
through the generator, battery, and ground terminals.
Noise emitting from the generator may be caused
by:
²Worn, loose or defective bearings
²Loose or defective drive pulley
²Incorrect, worn, damaged or misadjusted drive
belt
²Loose mounting bolts
²Misaligned drive pulley
²Defective stator or diode
BATTERY TEMPERATURE SENSOR
The temperature sensor, in the PCM, is used to
determine the battery temperature. This temperature
data, along with data from monitored line voltage, is
used by the PCM to vary the battery charging rate.
System voltage will be higher at colder temperatures
and is gradually reduced at warmer temperatures.
ELECTRONIC VOLTAGE REGULATOR
The Electronic Voltage Regulator (EVR) is not a
separate component. It is actually a voltage regulat-
ing circuit located within the Powertrain Control
Module (PCM). The EVR is not serviced separately. If
replacement is necessary, the PCM must be replaced.
Operation:The amount of DC current produced
by the generator is controlled by EVR circuitry con-
tained within the PCM. This circuitry is connected in
series with the generators second rotor field terminal
and its ground.
Voltage is regulated by cycling the ground path to
control the strength of the rotor magnetic field. The
EVR circuitry monitors system line voltage and bat-
tery temperature (refer to Battery Temperature Sen-
sor for more information). It then compensates and
regulates generator current output accordingly. Also
refer to Charging System Operation for additional
information.
DIAGNOSIS AND TESTING
CHARGING SYSTEM
When the ignition switch is turned to the ON posi-
tion, battery potential will register on the voltmeter.
During engine cranking a lower voltage will appear
on the meter. With the engine running, a voltage
reading higher than the first reading (ignition in ON)
should register.
The following are possible symptoms of a charging
system fault:
²The voltmeter does not operate properly
²An undercharged or overcharged battery condi-
tion occurs.
Remember that an undercharged battery is often
caused by:
²Accessories being left on with the engine not
running
²A faulty or improperly adjusted switch that
allows a lamp to stay on. See Ignition-Off Draw Test
in Group 8A, Battery for more information.
The following procedures may be used to correct a
problem diagnosed as a charging system fault.
INSPECTION
(1) Inspect condition of battery cable terminals,
battery posts, connections at engine block, starter
solenoid and relay. They should be clean and tight.
Repair as required.
(2) Inspect all fuses in the fuseblock module and
Power Distribution Center (PDC) for tightness in
receptacles. They should be properly installed and
tight. Repair or replace as required.
(3) Inspect the electrolyte level in the battery.
Replace battery if electrolyte level is low.
(4) Inspect generator mounting bolts for tightness.
Replace or tighten bolts if required. Refer to the Gen-
erator Removal/Installation section of this group for
torque specifications.
(5) Inspect generator drive belt condition and ten-
sion. Tighten or replace belt as required. Refer to
Belt Tension Specifications in Group 7, Cooling Sys-
tem.
(6) Inspect automatic belt tensioner (if equipped).
Refer to Group 7, Cooling System for information.
(7) Inspect connections at generator field, battery
output, and ground terminals. Also check ground con-
nection at engine. They should all be clean and tight.
Repair as required.
8C - 2 CHARGING SYSTEMNS
DESCRIPTION AND OPERATION (Continued)

Clean Spark Plug cables with a cloth moistened
with a non-flammable solvent. Wipe the cables dry.
Check for brittle or cracked insulation.
SPARK PLUG CABLESÐ3.3/3.8L
The spark plug cables and spark plug boots are
made from high temperature silicone materials. The
spark plug boots utilize metal heat shields for ther-
mal protection from the exhaust manifold. The heat
shields slide over the spark plug boots. The notches
on the heat shields ensure the spark plug boot and
shield twist together during spark plug boot removal.
They also identify proper heat shield installation on
the boot for service.Refer to 3.3/3.8L Spark Plug
Cable removal and installation.All spark plug
cable leads are properly identified with cylinder num-
bers. The inside of the spark plug boot is coated with
a special high temperature silicone grease for greater
sealing and to minimize boot bonding to the spark
plug insulator. The convoluted tubing on the rear
plug cables are made of a high temperature plastic
material. Under normal driving conditions, the spark
plug cables have a recommended service life of a
100,000 miles. The spark plugs have a recommended
service life of 75,000 miles for severe driving condi-
tions per schedule B in this manual.
The spark plug heat shield can be reused if an
ignition cable is replaced due to failure. Never reuse
heat shield's that have heat shield anti-twist, side or
spark plug attachment tabs bent or missing. Ensure
that the heat shield is properly attached to the spark
plug to avoid RFI problems. The bottom of the spark
plug heat shield must make contact with the spark
plug hex.
The front ignition cables must not make contact
with the oil dip stick tube and #5 cable must not
touch the coil mounting bolt to avoid abrasion/dielec-
tric failures.
IGNITION COIL
WARNING: THE DIRECT IGNITION SYSTEM GEN-
ERATES APPROXIMATELY 40,000 VOLTS. PER-
SONAL INJURY COULD RESULT FROM CONTACT
WITH THIS SYSTEM.
The ignition coil assembly consists of 3 indepen-
dent coils molded together (Fig. 4). The coil assembly
is mounted on the intake manifold. Spark plug cables
route to each cylinder from the coil. The coil fires two
spark plugs every power stroke. One plug is the cyl-
inder under compression, the other cylinder fires on
the exhaust stroke. The Powertrain Control Module
(PCM) determines which of the coils to charge and
fire at the correct time.
Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders
2 and 5, coil 3 fires cylinders 3 and 6.The Auto Shutdown (ASD) relay provides battery
voltage to the ignition coil. The PCM provides a
ground contact (circuit) for energizing the coil. When
the PCM breaks the contact, the energy in the coil
primary transfers to the secondary causing the
spark. The PCM will de-energize the ASD relay if it
does not receive the crankshaft position sensor and
camshaft position sensor inputs. Refer to Auto Shut-
down (ASD) RelayÐPCM Output, in this section for
relay operation.
AUTOMATIC SHUTDOWN (ASD) RELAY
The Powertrain Control Module (PCM) operates
the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The ASD relay supplies battery voltage to the fuel
injectors, electronic ignition coil and the heating ele-
ments in the oxygen sensors.
The PCM controls the relay by switching the
ground path for the solenoid side of the relay on and
off. The PCM turns the ground path off when the
ignition switch is in the Off position unless the 02
Heater Monitor test is being run. Refer to Group 25,
On-Board Diagnostics. When the ignition switch is in
the On or Crank position, the PCM monitors the
crankshaft position sensor and camshaft position sen-
sor signals to determine engine speed and ignition
timing (coil dwell). If the PCM does not receive the
crankshaft position sensor and camshaft position sen-
sor signals when the ignition switch is in the Run
position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution
Center (PDC). The PDC is located on the driver's
side inner fender well (Fig. 5). A label on the under-
side of the PDC cover identifies the relays and fuses
in the PDC.
Fig. 4 Ignition Coil Pack
8D - 4 IGNITION SYSTEMNS
GENERAL INFORMATION (Continued)

AUDIO SYSTEMS
CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION......................... 1
DESCRIPTION AND OPERATION
ANTENNA.............................. 1
CHOKEÐINFINITY SPEAKERS.............. 2
INTERFERENCE ELIMINATION.............. 1
NAME BRAND SPEAKER RELAY............ 3
RADIO IGNITION INTERFERENCE........... 2
RADIOS................................ 1
REMOTE RADIO SWITCHES................ 3
DIAGNOSIS AND TESTING
ANTENNA.............................. 3AUDIO SYSTEM......................... 4
RADIO................................. 4
REMOTE RADIO SWITCHES................ 6
REMOVAL AND INSTALLATION
ANTENNA EXTENSION CABLE.............. 7
ANTENNA MAST AND CABLE LEAD......... 7
D±PILLAR SPEAKER.................... 10
FRONT DOOR SPEAKER................... 9
INSTRUMENT PANEL SPEAKER............. 8
QUARTER PANEL SPEAKER............... 10
RADIO/TAPE/CD PLAYER.................. 8
REMOTE RADIO SWITCHES................ 9
GENERAL INFORMATION
INTRODUCTION
Operating instructions for the factory installed
audio systems can be found in the Owner's Manual
provided with the vehicle.
NS vehicles are equipped with an Ignition Off
Draw (IOD) fuse in the power distribution center
located in the engine compartment. After the IOD
fuse or battery has been disconnected, the radio sta-
tion sets and clock will require resetting.
DESCRIPTION AND OPERATION
ANTENNA
All models use a fixed-length stainless steel rod-
type antenna mast, installed at the right front fender
of the vehicle. The antenna mast is connected to the
center wire of the coaxial antenna cable, and is not
grounded to any part of the vehicle.
To eliminate static, the antenna base must have a
good ground. The coaxial antenna cable shield (the
outer wire mesh of the cable) is grounded to the
antenna base and the radio chassis.
The antenna coaxial cable has an additional dis-
connect, located near the right end of the instrument
panel. This additional disconnect allows the instru-
ment panel assembly to be removed and installed
without removing the radio.
The factory-installed Electronically Tuned Radios
(ETRs) automatically compensate for radio antenna
trim. Therefore, no antenna trimmer adjustment isrequired or possible when replacing the receiver or
the antenna.
INTERFERENCE ELIMINATION
Some components used on the vehicles are
equipped with a capacitor to suppress radio fre-
quency interference/static.
Capacitors are mounted in various locations inter-
nal to the generator, instrument cluster and wind-
shield wiper motor.
To eliminate radio interference, ground straps are
used in different areas of the vehicle. These ground
circuits should be securely tightened to assure good
metal to metal contact. The ground straps conduct
very small high frequency electrical signals to ground
and require clean surface contact area. The radio
ground is supplied from the instrument panel har-
ness and is attached to the rear of the radio. Some
engines have other ground straps to eliminate fur-
ther radio interference:
²Radio chassis to instrument panel structure
²Engine to dash panel
²Engine to chassis
²A/C h valve to dash panel
Radio resistance type spark plug cables in the high
tension circuit of the ignition system complete the
interference suppression. Faulty or deteriorated
spark plug wires should be replaced.
RADIOS
Available factory-installed radio receivers for this
model include an AM/FM/cassette (RAS sales code),
an AM/FM/cassette/5-band graphic equalizer with CD
changer control feature (RBN sales code), an AM/FM/
NSAUDIO SYSTEMS 8F - 1

CONDITION POSSIBLE CAUSE CORRECTION
NO AUDIO. 1. FUSE FAULTY.
2. RADIO CONNECTOR
FAULTY.
3. WIRING FAULTY.
4. GROUND FAULTY.
5. RADIO FAULTY.
6. SPEAKERS FAULTY.1. CHECK RADIO FUSES IN FUSEBLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. CHECK FOR LOOSE OR CORRODED RADIO
CONNECTOR. REPAIR, IF REQUIRED.
3. CHECK FOR BATTERY VOLTAGE AT RADIO
CONNECTOR. REPAIR WIRING, IF REQUIRED.
4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS
AND A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
6. SEE SPEAKER DIAGNOSIS, IN THIS GROUP.
NO DISPLAY. 1. FUSE FAULTY.
2. RADIO CONNECTOR
FAULTY.
3. WIRING FAULTY.
4. GROUND FAULTY.
5. RADIO FAULTY.1. CHECK RADIO FUSES IN FUSEBLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. CHECK FOR LOOSE OR CORRODED RADIO
CONNECTOR. REPAIR, IF REQUIRED.
3. CHECK FOR BATTERY VOLTAGE AT RADIO
CONNECTOR. REPAIR WIRING, IF REQUIRED.
4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS
AND A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO MEMORY. 1. FUSE FAULTY.
2. RADIO CONNECTOR
FAULTY.
3. WIRING FAULTY.
4. GROUND FAULTY.
5. RADIO FAULTY.1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE,
IF REQUIRED.
2. CHECK FOR LOOSE OR CORRODED RADIO
CONNECTOR. REPAIR, IF REQUIRED.
3. CHECK FOR BATTERY VOLTAGE AT RADIO
CONNECTOR. REPAIR WIRING, IF REQUIRED.
4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS
AND A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
POOR RADIO
RECEPTION.1. ANTENNA FAULTY.
2. GROUND FAULTY.
3. RADIO FAULTY.1. SEE ANTENNA DIAGNOSIS, IN THIS GROUP. REPAIR
OR REPLACE ANTENNA, IF REQUIRED.
2. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS
AND A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED..
3. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO/POOR TAPE
OPERATION.1. FAULTY TAPE.
2. FOREIGN OBJECTS
BEHIND TAPE DOOR.
3. DIRTY CASSETTE TAPE
HEAD.
4. FAULTY TAPE DECK.1. INSERT KNOWN GOOD TAPE AND TEST OPERATION.
2. REMOVE FOREIGN OBJECTS AND TEST OPERATION.
3. CLEAN HEAD WITH MOPAR CASSETTE HEAD
CLEANER.
4. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
NO COMPACT
DISC
OPERATION1. FAULTY CD.
2. FOREIGN MATERIAL ON
CD.
3. CONDENSATION ON CD
OR OPTICS.
4. FAULTY CD PLAYER.1. INSERT KNOWN GOOD CD AND TEST OPERATION.
2. CLEAN CD AND TEST OPERATION.
3. ALLOW TEMPERATURE OF VEHICLE INTERIOR TO
STABILIZE AND TEST OPERATION.
4. EXCHANGE OR REPLACE RADIO, IF REQUIRED.
AUDIO SYSTEM DIAGNOSIS
NSAUDIO SYSTEMS 8F - 5
DIAGNOSIS AND TESTING (Continued)

(1) Check the fuse(s) in the junction block and the
Power Distribution Center (PDC). If OK, go to Step
2. If not OK, repair the shorted circuit or component
as required and replace the faulty fuse(s).
(2) Check for battery voltage at the fuse in the
PDC. If OK, go to Step 3. If not OK, repair the open
circuit to the battery as required.
(3) Turn the ignition switch to the ON position.
Check for battery voltage at the fuse in the junction
block. If OK, go to Step 4. If not OK, repair the open
circuit to the ignition switch as required.
(4) Turn the ignition switch to the OFF position.
Disconnect and isolate the battery negative cable.
Remove the instrument cluster center bezel. Remove
the radio, but do not unplug the wire harness connec-
tors. Check for continuity between the radio chassis
and a good ground. There should be continuity. If
OK, go to Step 5. If not OK, repair the open radio
chassis ground circuit as required.
(5) Connect the battery negative cable. Turn the
ignition switch to the ON position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the left (gray) radio wire harness connector.
If OK, go to Step 6. If not OK, repair the open circuit
as required.
(6) Turn the ignition switch to the OFF position.
Check for battery voltage at the fused B(+) circuit
cavity of the left (gray) radio wire harness connector.
If OK, replace the faulty radio. If not OK, repair the
open circuit to the Ignition-Off Draw (IOD) fuse as
required.
REMOTE RADIO SWITCHES
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable. Wait two minutes for the airbag system capac-
itor to discharge before further service.
(2) Remove the remote radio switch(es) from the
steering wheel.
(3) Use an ohmmeter to check the switch resis-
tance as shown in the Remote Radio Switch Test
table (Fig. 8).
NOTE: The right remote radio switch back is white
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat.(4) If the switch resistance checks OK, go to Step
5. If not OK, replace the faulty switch.
(5) Check for continuity between the ground cir-
cuit cavity of the switch wire harness connector and
a good ground. There should be continuity. If OK, go
to Step 6. If not OK, repair the open circuit as
required.
(6) Unplug the 24-way white wire harness connec-
tor from the Body Control Module (BCM). Check for
continuity between the radio control circuit cavity of
the remote radio switch wire harness connector and a
good ground. There should be no continuity. If OK, go
to Step 7. If not OK, repair the short circuit as
required.
(7) Check for continuity between the radio control
circuit cavities of the remote radio switch wire har-
ness connector and the BCM wire harness connector.
There should be continuity. If OK, refer to the proper
Diagnostic Procedures manual to test the BCM and
the CCD data bus. If not OK, repair the open circuit
as required.
Fig. 8 Remote Radio Switches
REMOTE RADIO SWITCH TEST
SWITCH POSITION RESISTANCE
VOLUME UP 7320 OHMS
VOLUME DOWN 1210 OHMS
SEEK UP 4530 OHMS
SEEK DOWN 2050 OHMS
PRE-SET STATION ADVANCE 10 OHMS
8F - 6 AUDIO SYSTEMSNS
DIAGNOSIS AND TESTING (Continued)

HORNS
CONTENTS
page page
DESCRIPTION AND OPERATION
INTRODUCTION......................... 1
DIAGNOSIS AND TESTING
HORN RELAY........................... 1
HORN SYSTEM.......................... 3
HORN SYSTEM TEST..................... 3HORN................................. 1
HORNS SOUND CONTINUOUSLY............ 3
HORNS WILL NOT SOUND................ 2
REMOVAL AND INSTALLATION
HORN SWITCH.......................... 4
HORNS................................ 4
DESCRIPTION AND OPERATION
INTRODUCTION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, SEE GROUP 8M, RESTRAINT SYSTEMS FOR
SAFETY PRECAUTIONS. DISCONNECT THE NEGA-
TIVE CABLE FROM THE BATTERY BEFORE SER-
VICING 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 Body Control Module
(Fig. 1). The horn switch is a membrane switch
located in the airbag cover. The horns are located for-
ward of the left front wheel behind the bumper fas-
cia. The horn relay plugs into the junction block. For
circuit information and component locations refer to
Group 8W, Wiring Diagrams.
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. 3).
(3) Depress the horn switch, battery voltage
should be present.
(4) If no voltage, refer to Horn 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.
HORN RELAY
(1) Remove horn relay.
(2) Using ohmmeter, test between relay connector
terminals 85 to 86 for 70 to 75 ohms resistance (Fig.
2). If resistance not OK, replace relay.
(3) Test for continuity between ground and termi-
nal 85 of horn relay.
(a) When the horn switch is not depressed, no
continuity should be present.
(b) Continuity to ground when horn switch is
depressed.
(c) If continuity is not correct repair horn
switch or wiring as necessary, refer to Group 8W,
Wiring Diagrams Group 8M Restraint System for
Driver's Airbag Module removal procedures.
(4) Using voltmeter, test voltage at:
(a) Terminals 30 and 86 of the horn relay to
body ground.
(b) If NO voltage check fuse 7 of the BCM.
(c) If incorrect voltage repair as necessary. Refer
to Group 8W, Wiring Diagrams.
(5) Insert a jumper wire between terminal 30 and
87 of the power distribution center.
(a) If horn sounds replace relay.
Fig. 1 Horn System
NSHORNS 8G - 1

(b) If the horn does not sound, install horn relay
and refer to Horn Test.
HORNS WILL NOT SOUND
Check horn fuse 6 in the Power Distribution Cen-
ter and fuse 7 in the Junction Block. If fuse is blown
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 Group 8A, Battery. If battery connec-
tions and battery charge is OK proceed to Step 2.
(2) Using a voltmeter, test for battery voltage at
both sides of horn fuse 7. If voltage is OK, on both
sides of fuse, proceed to Fuse OK. If voltage is OK,
on one side of fuse, the fuse is blown, proceed to Step
3.
(3) Using a suitable ammeter in place of the fuse,
test amperage draw of the horn circuit. If amperage
draw is greater than 20 amps without the horn
switch depressed, a grounded circuit exists between
the fuse and the horn relay. Proceed to Step 4. If
amperage draw is greater than 20 amps with the
horn switch depressed, a grounded circuit exists
between the horn relay and the horn. Proceed to step
Step 5.
(4) Remove the horn relay from the Junction
Block. If the amperage draw drops to 0 amps, the
horn switch or circuit is shorted. Refer to group 8W,
Wiring Diagrams for circuit information. If the
amperage draw does not drop to 0 amps, repair short
at the Junction Block.
(5) Disengage a wire connector from one of the
horns. If amperage drops and the connected horn
sounds, replace the faulty horn. If amperage does not
drop with both horns disconnected and the horn
switch depressed, proceed to Step 6.
(6) Using a continuity tester, with the horns dis-
connected test continuity of the X2 cavity of the horn
relay to ground. Refer to Group 8W, Wiring Diagrams
for circuit information. If continuity is detected, the
circuit is grounded between the Junction Block and
the horns. Locate and repair pinched harness.
FUSE OK
(1) Remove the horn relay from the Junction
Block.
(2) Using a continuity tester, Depress horn switch
and test continuity from the X3 cavity of the horn
relay to ground. Refer to Group 8W, Wiring Diagrams
for circuit information.
(a) If continuity is detected, proceed to Step 3.
(b) If NO continuity, proceed to Step 4.
(3) Using a suitable jumper wire, jump across the
fuse F62 cavity and the X2 cavity of the horn relay in
the Junction Block.
(a) If the horn sounds, replace the horn relay.
(b) If the horn does not sound, proceed to Step 4.
(4) Remove airbag/horn pad from steering wheel.
Refer to Group 8M, Restraint Systems for proper pro-
cedures.
(5) Test continuity across horn switch connectors
with horn switch depressed.
(a) If continuity is detected, repair open circuit
between the relay and the horn switch.
(b) If NO continuity, replace airbag cover.
(6) Install horn relay into Junction Block.
(7) Disengage wire connectors from horns.
(8) Using a voltmeter, with the horn switch
depressed test voltage across horn connector termi-
nals of the wire harness (Fig. 3).
(a) If voltage is detected, replace horns.
(b) If NO voltage, proceed to step Step 9.
(9) With the horn switch depressed, test for volt-
age between the X2 circuit and ground.
(a) If voltage OK, repair system ground at right
cowl area. Refer to Group 8W, Wiring Diagrams.
(b) If NO voltage, repair open X2 circuit between
the relay and the horns.
Fig. 2 Horn Relay
Fig. 3 Horn and Connector
8G - 2 HORNSNS
DIAGNOSIS AND TESTING (Continued)