horn CHRYSLER VOYAGER 2001 User Guide

Symptom:
HORN RELAY SHORTED TO BATTERY
When Monitored and Set Condition:
HORN RELAY SHORTED TO BATTERY
When Monitored: Continuously with the ignition on.
Set Condition: The FCM has detected a short to battery in the Horn Relay Control circuit.
POSSIBLE CAUSES
FUSE AND RELAY CENTER INTERNAL MALFUNCTION
HORN RELAY
INTERMITTENT CONDITION
FRONT CONTROL MODULE
TEST ACTION APPLICABILITY
1 Turn the ignition on.
With the DRBIIIt, erase the current Front Control Module DTC's.
Turn the ignition off, wait 10 seconds then turn the ignition on.
With the DRBIIIt, read the current Front Control Module DTC's.
Does the DRBIIItdisplay: HORN RELAY SHORTED TO BATTERY?All
Ye s®Go To 2
No®The condition that caused this symptom is currently not present.
Inspect the related wiring harness for a possible intermittent
condition.
Perform VTSS VERIFICATION TEST - 1A.
2 Turn the ignition off.
Disconnect the Horn Relay from the Fuse and Relay Center.
Substitute the original Horn Relay with a known good relay.
Turn the ignition on.
Attempt to operate the horn.
With the DRBIIIt, read the current Front Control Module DTC's.
Does the DRBIIItdisplay: HORN RELAY SHORTED TO BATTERY?All
Ye s®Go To 3
No®Replace the Horn Relay.
Perform VTSS VERIFICATION TEST - 1A.
925
VEHICLE THEFT/SECURITY

TEST ACTION APPLICABILITY
3 Turn the ignition off.
Disconnect the Front Control Module from the Fuse and Relay Center.
Disconnect the Horn Relay from the Fuse and Relay Center.
Measure the voltage of the Horn Relay Control circuit at the Fuse and Relay Center
side of the FCM connector.
Is the voltage above 10.0 volts?All
Ye s®Replace the Fuse and Relay Center.
Perform VTSS VERIFICATION TEST - 1A.
No®Replace the Front Control Module.
Perform VTSS VERIFICATION TEST - 1A.
926
VEHICLE THEFT/SECURITY
HORN RELAY SHORTED TO BATTERY ÐContinued

CD CHANGER-8WAYCAV CIRCUIT FUNCTION
1 X40 20GY/WT (EXCEPT
BUILT-UP-EXPORT)AUDIO OUT RIGHT
1 X40 24GY/WT (BUILT-UP-
EXPORT)AUDIO OUT RIGHT
2 E14 18OR/TN (EXCEPT
BUILT-UP-EXPORT)PANEL LAMPS DRIVER
2 E14 24OR/TN (BUILT-UP-
EXPORT)PANEL LAMPS DRIVER
3 D25 20WT/VT (EXCEPT
BUILT-UP-EXPORT)PCI BUS
3 D25 24VT/YL (BUILT-UP-
EXPORT)PCI BUS
4 X112 20RD (EXCEPT
BUILT-UP-EXPORT)IGNITION SWITCH OUTPUT
4 X112 24RD (BUILT-UP-
EXPORT)IGNITION SWITCH OUTPUT
5 X41 20DG/WT (EXCEPT
BUILT-UP-EXPORT)AUDIO OUT LEFT
5 X41 24DG/WT (BUILT-UP-
EXPORT)AUDIO OUT LEFT
6 Z140 24BK/OR (BUILT-UP-
EXPORT)GROUND
6 Z140 18BK/OR (EXCEPT
BUILT-UP-EXPORT)GROUND
7 Z141 18BK/TN (EXCEPT
BUILT-UP-EXPORT)GROUND
7 Z141 22BK/TN (BUILT-UP-
EXPORT)GROUND
8 X160 20GY/YL (EXCEPT
BUILT-UP-EXPORT)B(+)
8 X160 22GY/YL (BUILT-UP-
EXPORT)B(+)
CENTER DOME LAMP (BASE/HIGH LINE) - GRAY 3 WAYCAV CIRCUIT FUNCTION
1 M22 20YL/OR COURTESY LAMPS DRIVER
2 Z327 20BK/OR GROUND
3 M27 20YL/LB READING LAMPS DRIVER
CLOCKSPRING C1 - WHITE 6 WAYCAV CIRCUIT FUNCTION
1 X920 20GY/OR RADIO CONTROL MUX RETURN
2 X20 20GY/WT RADIO CONTROL MUX
3 X3 20DG/VT HORN SWITCH SENSE
4 V37 20VT SPEED CONTROL SWITCH SIGNAL
5 Z23 20BK/LB SPEED CONTROL SWITCH GROUND
6- -
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CONNECTOR PINOUTS

INTELLIGENT POWER MODULE C2 - GREEN/BLUE 10 WAYCAV CIRCUIT FUNCTION
1 N173 18DB/VT (EXCEPT
BUILT-UP-EXPORT/GAS)RADIATOR FAN RELAY CONTROL
1 N173 16DB/VT (BUILT-UP-
EXPORT/GAS)RADIATOR FAN RELAY CONTROL
2 V53 12BR/OR (BUILT-UP-
EXPORT)HEADLAMP WASHER RELAY OUTPUT
3 L60 18WT/TN (EXCEPT
BUILT-UP-EXPORT)RIGHT FRONT TURN SIGNAL DRIVER
3 L60 16WT/TN (BUILT-UP-
EXPORT)RIGHT FRONT TURN SIGNAL DRIVER
4 L13 18WT/YL (BUILT-UP-
EXPORT)HEADLAMP ADJUST SIGNAL
5 X2 18DG/OR HORN RELAY OUTPUT
6 L90 18WT/OR (FOG
LAMPS)FRONT FOG LAMP RELAY OUTPUT
7 L61 18WT/LG (EXCEPT
BUILT-UP-EXPORT)LEFT FRONT TURN SIGNAL DRIVER
7 L61 16WT/LG (BUILT-UP-
EXPORT)LEFT FRONT TURN SIGNAL DRIVER
8- -
9 A112 12OR/RD FUSED B(+)
10 L89 18WT/YL (FOG
LAMPS)FRONT FOG LAMP RELAY OUTPUT
INTELLIGENT POWER MODULE C3 (DIESEL) - YELLOW/RED 20 WAYCAV CIRCUIT FUNCTION
1 N21 20DB/TN LIFT PUMP RELAY CONTROL
2- -
3 T751 20YL IGNITION SWITCH OUTPUT (START)
4 T2 18DG/WT TRS REVERSE SENSE
5 N2 18DB/YL LIFT PUMP RELAY OUTPUT
6 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
7 C3 18DB/YL A/C COMPRESSOR CLUTCH RELAY OUTPUT
8 Z114 18BK/LG GROUND
9 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
10 A119 16RD/OR FUSED B(+)
11 C41 20LB/DG CABIN HEATER ASSIST CONTROL
12 T753 20DG/YL IGNITION SWITCH OUTPUT (START)
13 - -
14 T752 20DG/OR ENGINE STARTER MOTOR RELAY CONTROL
15 Z116 18BK/VT GROUND
16 K51 20BR/WT ECM/PCM RELAY CONTROL
17 F202 18PK/GY IGNITION SWITCH OUTPUT (RUN-START)
18 - -
19 K342 16BR/WT ECM/PCM RELAY OUTPUT
20 - -
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CONNECTOR PINOUTS

INTELLIGENT POWER MODULE C6 - NATURAL 10 WAYCAV CIRCUIT FUNCTION
1 A101 12VT/RD FUSED B(+)
2 Z117 16BK/WT GROUND
3 Z118 16BK/YL GROUND
4 A110 12OR/RD (POWER
SEAT)FUSED B(+)
5- -
6- -
7 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT
8 F307 16LB/PK (BATTERY
POSITION)FUSED B(+)
8 F307 16LB/PK (ACCESSO-
RY RELAY POSITION)FUSED ACCESORY RELAY OUTPUT
9 A113 12WT/RD (POWER
SLIDING DOOR)FUSED B(+)
10 - -
INTELLIGENT POWER MODULE C7 - BLACK/RED 20 WAYCAV CIRCUIT FUNCTION
1 C16 20DB/GY (EXCEPT
BUILT-UP-EXPORT)FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
1 C16 18DB/GY (BUILT-UP-
EXPORT)FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
2 T751 20YL (EXCEPT
BUILT-UP-EXPORT)IGNITION SWITCH OUTPUT (START)
2 T141 20YL/OR (BUILT-UP-
EXPORT)IGNITION SWITCH OUTPUT (START)
3 D25 20WT/VT PCI BUS
4 L13 20WT/YL (BUILT-UP-
EXPORT)HEADLAMP ADJUST SIGNAL
5 K32 18DB/YL (GAS) BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL
6- -
7 W7 20BR/GY FRONT WIPER PARK SWITCH SENSE
8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
9 F201 18PK/OR FCM OUTPUT (RUN-START)
10 F214 18PK/LG FCM OUTPUT (RUN-START)
11 A106 20LB/RD FUSED B(+)
12 - -
13 F2 18PK/WT (GAS) FCM OUTPUT (UNLOCK-RUN-START)
14 - -
15 A114 16GY/RD FUSED B(+) (I.O.D.)
16 D23 20WT/BR FLASH PROGRAM ENABLE
17 L50 18WT/TN PRIMARY BRAKE SWITCH SIGNAL
18 X1 16DG/BR (PREMIUM 8
SPEAKER)NAME BRAND SPEAKER RELAY OUTPUT
19 X3 20DG/VT HORN SWITCH SENSE
20 F100 18PK/VT FCM OUTPUT (RUN)
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CONNECTOR PINOUTS

FRONT CONTROL MODULE - BLACK 49 WAYCAV CIRCUIT FUNCTION
1 A1 B(+)
2 A1 B(+)
3 L43 LEFT LOW BEAM DRIVER
4 L34 RIGHT HIGH BEAM DRIVER
5 L33 LEFT HIGH BEAM DRIVER
6 L44 RIGHT LOW BEAM DRIVER
7 - NOT USED
8 Z117, Z118, Z343, Z344 GROUND
9 A1 B(+)
10 FCM 10 HORN RELAY CONTROL
11 FCM 11 NAME BRAND SPEAKER RELAY CONTROL
12 - SPARE
13 FCM 13 PARK LAMP RELAY CONTROL
14 FCM 14 FRONT WIPER ON/OFF RELAY CONTROL
15 C41 (DIESEL) CABIN HEATER ASSIST CONTROL
16 W7 FRONT WIPER PARK SWITCH SENSE
17 X3 HORN SWITCH SENSE
18 W1 WASHER FLUID LEVEL SWITCH SENSE
19 FCM 19 (GAS) IGNITION SWITCH OUTPUT (START)
20 A114 FUSED B(+) (I.O.D.)
21 L78 FUSED PARK LAMP RELAY OUTPUT (RIGHT)
22 D25 PCI BUS
23 G931 AMBIENT TEMPERATURE SENSOR RETURN
24 - SPARE
25 G31 AMBIENT TEMPERATURE SENSOR SIGNAL
26 L13 (RG) HEADLAMP ADJUST SIGNAL
27 F1, F2 FCM OUTPUT (UNLOCK-RUN-START)
28 F214 FCM OUTPUT (RUN-START) (SIACM)
29 F100 FCM OUTPUT (RUN) (ORC)
30 FCM 30 FRONT/REAR BLOWER MOTOR RELAY CONTROL
31 FCM 31 REAR WINDOW DEFOGGER RELAY CONTROL
32 FCM 32 (BUILT-UP-
EXPORT))HEADLAMP WASHER RELAY CONTROL
33 FCM 33 FRONT FOG LAMP RELAY CONTROL
34 FCM 34 FRONT WIPER HIGH/LOW RELAY CONTROL
35 FCM 35 ACCESSORY RELAY CONTROL (RUN-ACC)
36 B20 BRAKE FLUID LEVEL SWITCH SENSE
37 F20 IGNITION SWITCH OUTPUT (RUN-START)
38 A1 B(+)
39 T2 TRS REVERSE SENSE
40 T753 (DIESEL) IGNITION SWITCH OUTPUT (START)
41 L77 FUSED PARK LAMP RELAY OUTPUT (LEFT)
42 D23 FLASH PROGRAM ENABLE
43 Z116 GROUND
44 L50 PRIMARY BRAKE SWITCH SIGNAL
45 W10 FRONT WASHER PUMP MOTOR CONTROL
46 W20 REAR WASHER PUMP MOTOR CONTROL
47 K32 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID CONTROL
48 F201 FCM OUTPUT (RUN-START) (ORC)
49 - NOT USED
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CONNECTOR PINOUTS

GROUP TAB LOCATOR
INIntroduction
INaIntroduction
0Lubrication & Maintenance
0aLubrication & Maintenance
2Suspension
2aSuspension
3Differential & Driveline
5Brakes
5aBrakes
6aClutch
7Cooling
7aCooling
8AAudio
8AaAudio
8BChime/Buzzer
8BaChime/Buzzer
8EElectronic Control Modules
8FEngine Systems
8FaEngine Systems
8GHeated Systems
8HHorn
8IIgnition Control
8JInstrument Cluster
8JaInstrument Cluster
8LLamps
8LaLamps
8MMessage Systems
8NPower Systems
8NaPower Systems
8ORestraints
8PSpeed Control
8QVehicle Theft Security
8RWipers/Washers
8WaWiring
9Engine
9aEngine
11Exhaust System
11aExhaust System
13Frame & Bumpers
14Fuel System
14aFuel System
19Steering
19aSteering
21Transmission/Transaxle
21aTransmission/Transaxle
22Tires/Wheels
23Body
24Heating & Air Conditioning
24aHeating & Air Conditioning
25Emissions Control
25aEmissions Control
Service Manual Comment Forms

FASTENER IDENTIFICATION
DESCRIPTION
The SAE bolt strength grades range from grade 2
to grade 8. The higher the grade number, the greater
the bolt strength. Identification is determined by the
line marks on the top of each bolt head. The actual
bolt strength grade corresponds to the number of line
marks plus 2. The most commonly used metric bolt
strength classes are 9.8 and 10.9. The metric
strength class identification number is imprinted on
the head of the bolt. The higher the class number,
the greater the bolt strength. Some metric nuts are
imprinted with a single-digit strength class on the
nut face. Refer to the Fastener Identification and
Fastener Strength Charts.
FASTENER USAGE
DESCRIPTION - FASTENER USAGE
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
International Symbols
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RSINTRODUCTION5
INTERNATIONAL SYMBOLS (Continued)

FASTENER USAGE
DESCRIPTION
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER-
SONAL INJURY.
Figure art, specifications and torque references in
this Service Manual are identified in metric and SAE
format.
During any maintenance or repair procedures, it is
important to salvage all fasteners (nuts, bolts, etc.)
for reassembly. If the fastener is not salvageable, a
fastener of equivalent specification must be used.
THREADED HOLE REPAIR
DESCRIPTION
Most stripped threaded holes can be repaired using
a Helicoilt. Follow the vehicle or Helicoiltrecommen-
dations for application and repair procedures.
INTERNATIONAL VEHICLE
CONTROL & DISPLAY
SYMBOLS
DESCRIPTION
The graphic symbols illustrated in the following
International Control and Display Symbols Chart
(Fig. 4) are used to identify various instrument con-
trols. The symbols correspond to the controls and dis-
plays that are located on the instrument panel.
Fig. 4 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Windscreen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
RGINTRODUCTION5a

²Front Fog Lamp Relay Actuation
²Front and Rear Blower Motor Relay Actuation
²Accessory Relay Actuation
²Electronic Back Light (EBL) Rear Defogger
²Horn Relay Actuation
²Park Lamp Relay Actuation
²Name Brand Speaker (NBS) Relay Actuation
²Headlamp Washer Relay Actuation
²Diesel Cabin Heater (Diesel Engine Vehicles)
The following inputs areReceived/Monitoredby
the Front Control Module:
²B+ Connection Detection
²Ambient Temperature Sensing
²Right/Left Park Lamp Outage
²Ignition Switch Start Only
²Ignition Switch Run and Start Only
²Washer Fluid Level
²Windshield Wiper Park
²Brake Fluid Level
²Back-Up switch
²Stop Lamp Sense
²Engine Crank Signal (Diesel Engine Vehicles)
²Horn Input
DIAGNOSIS AND TESTING - FRONT CONTROL
MODULE
The front control module is a printed circuit board
based module with a on-board micro-processor. The
front control module interfaces with other electronic
modules in the vehicle via the Programmable Com-
munications Interface (PCI) data bus (J1850). In
order to obtain conclusive testing the Programmable
Communications Interface (PCI) data bus network
and all of the electronic modules that provide inputs
to, or receive outputs from the front control module
must be checked. All PCI (J1850) communication
faults must be resolved prior to further diagnosing
any front control module related issues.
The front control module was designed to be diag-
nosed with an appropriate diagnostic scan tool, such
as the DRB IIIt. The most reliable, efficient, and
accurate means to diagnose the front control module
requires the use of a DRB IIItscan tool and the
proper Body Diagnostic Procedures manual.
Before any testing of the front control module is
attempted, the battery should be fully charged and
all wire harness and ground connections inspected
around the affected areas on the vehicle.
REMOVAL
(1) Disconnect the positive and negative battery
cables from the battery.
(2) Remove the battery from the vehicle. Refer to
the procedure in Battery Systems.(3) Using a long flat-pladed screwdriver, gently
twist the Intelligent Power Module (IPM) retaining
clip outboard to free the intelligent power module
from its mounting bracket (Fig. 6). Rotate intelligent
power module upward to access the Front Control
Module (FCM) retaining screws.
(4) Remove the front control module retaining
screws.
(5) Using both hands, pull the front control module
straight from the intelligent power module assembly
to disconnect the 49-way electrical connector (Fig. 7)
and remove the front control module from the vehi-
cle.
INSTALLATION
(1) Install the front control module in the intelli-
gent power module assembly by pushing the 49-way
electrical connector straight in (Fig. 7).
(2) Install the front control module retaining
screws. Torque the screws to 7 in. lbs.
(3) Rotate the intelligent power module assembly
downward to secure in mounting bracket.
(4) Install the battery in the vehicle. Refer to the
procedure in Battery Systems.
(5) Connect the positive and negative battery
cables.
NOTE: If the vehicle is not equipped with Name
Brand Speakers (NBS, Infinity) or Headlamp Wash-
ers the DRB IIITmust be used to Disable the appro-
priate relays in the Intelligent Power Module
Assembly.
Fig. 6 REMOVING INTELLIGENT POWER MODULE
8E - 6 ELECTRONIC CONTROL MODULESRS
FRONT CONTROL MODULE (Continued)