1996 CHRYSLER VOYAGER fuse diagram

ANTILOCK BRAKE SYSTEM ± TEVES MARK-20
INDEX
page page
DESCRIPTION AND OPERATION
ABS BRAKE SYSTEM COMPONENTS........ 87
ABS BRAKES COMPONENT
ABBREVIATION LIST.................... 85
ABS BRAKES OPERATION AND VEHICLE
PERFORMANCE....................... 86
ABS FUSES............................ 89
ABS MASTER CYLINDER AND POWER
BRAKE BOOSTER..................... 87
ABS RELAYS........................... 89
ABS WARNING LAMP (YELLOW)............ 91
ANTILOCK BRAKES OPERATION
DESCRIPTION........................ 85
ASR VALVE (ABS WITH TRACTION
CONTROL ONLY)...................... 88
CONTROLLER ANTILOCK BRAKES (CAB)..... 90
HCU BRAKE FLUID ACCUMULATORS AND
NOISE DAMPING CHAMBER............. 88
HCU PUMP/MOTOR..................... 89
HYDRAULIC CIRCUITS AND VALVE
OPERATION.......................... 92
INLET VALVES AND SOLENOIDS............ 88
INTEGRATED CONTROL UNIT (ICU)......... 87
OUTLET VALVES AND SOLENOIDS.......... 88
PROPORTIONING VALVES................ 89
WHEEL SPEED SENSORS................. 89
DIAGNOSIS AND TESTING
ABS BRAKE DIAGNOSTIC TOOL
CONNECTOR......................... 96
ABS DIAGNOSTIC TROUBLE CODES........ 97
ABS DIAGNOSTICS MANUAL.............. 96ABS GENERAL DIAGNOSTICS
INFORMATION........................ 95
ABS SERVICE PRECAUTIONS.............. 99
ABS SYSTEM SELF DIAGNOSTICS.......... 96
ABS WIRING DIAGRAM INFORMATION....... 95
BRAKE FLUID CONTAMINATION............ 98
DRB DIAGNOSTIC SCAN TOOL USAGE...... 96
INTERMITTENT DIAGNOSTIC TROUBLE
CODES.............................. 97
PROPORTIONING VALVE................. 98
TEST DRIVING ABS COMPLAINT VEHICLE.... 98
TONEWHEEL INSPECTION................ 98
SERVICE PROCEDURES
BLEEDING TEVES MARK 20 HYDRAULIC
SYSTEM............................. 99
BRAKE FLUID LEVEL INSPECTION.......... 99
REMOVAL AND INSTALLATION
ABS GENERAL SERVICE PRECAUTIONS.... 100
CONTROLLER ANTILOCK BRAKES (CAB).... 103
HYDRAULIC CONTROL UNIT.............. 100
TONE WHEEL (REAR AWD)............... 111
TONE WHEEL (REAR FWD)............... 110
WHEEL SPEED SENSOR (FRONT)......... 105
WHEEL SPEED SENSOR (REAR AWD)...... 108
WHEEL SPEED SENSOR (REAR FWD)...... 106
SPECIFICATIONS
BRAKE FASTENER TORQUE
SPECIFICATIONS..................... 112
SPEED SENSOR TONE WHEEL RUNOUT.... 112
WHEEL SPEED SENSOR TO TONE
WHEEL CLEARANCE.................. 112
DESCRIPTION AND OPERATION
ANTILOCK BRAKES OPERATION DESCRIPTION
The purpose of an Antilock Brake System (ABS) is to
prevent wheel lock-up under braking conditions on virtu-
ally any type of road surface. Antilock Braking is desirable
because a vehicle which is stopped without locking the
wheels will retain directional stability and some steering
capability. This allows the driver to retain greater control
of the vehicle during braking.
This section of the service manual covers the description
and on car service for the ITT Teves Mark 20 ABS Brake
System and the ITT Teves Mark 20 ABS Brake System
with Traction Control. If other service is required on the
non ABS related components of the brake system, refer to
the appropriate section in this group of the service manual
for the specific service procedure required.
ABS BRAKES COMPONENT ABBREVIATION LIST
In this section of the service manual, several
abbreviations are used for the components of the
Teves Mark 20 ABS Brake System and the Teves
Mark 20 ABS Brake System with Traction Control.
They are listed below for your reference.
²CAB±Controller Antilock Brake
²ICU±Integrated Control Unit
²HCU±Hydraulic Control Unit
²TCS±Traction Control
²ABS±Antilock Brake System
²PSI±Pounds Per Square Inch (pressure)
²WSS±Wheel Speed Sensor
²FWD±Front Wheel Drive
²AWD±All Wheel Drive
²DTC±Diagnostic Trouble Code
NSBRAKES 5 - 85

START-UP CYCLE
The self diagnostic ABS start up cycle begins when
the ignition switch is turned to the on position. Elec-
trical checks are completed on ABS components, such
as the Controller, solenoid continuity, and the system
relay operation. During this check the Amber ABS
Warning Light is turned on for approximately 4 sec-
onds and the brake pedal may emit a popping sound
and move slightly when the solenoid valves are
checked.
DRIVE-OFF CYCLE
Further Functional testing is accomplished once
the vehicle is set in motion and reaches a speed of
about 20 kph (12 mph.). This cycle is performed only
once after each ignition on/off cycle.
²The pump/motor is activated briefly to verify
function. When the pump/motor is activated a whirl-
ing or buzzing sound may be heard by the driver,
which is normal when the pump/motor is running.
²The wheel speed sensor output is verified to be
within the correct operating range.
ONGOING TESTS
Other tests are performed on a continuous basis.
These include checks for solenoid continuity, wheel
speed sensor continuity and wheel speed sensor out-
put.
ABS DIAGNOSTIC TROUBLE CODES
Diagnostic trouble codes (DTC) are kept in the con-
troller's memory until either erased by the technician
using the DRB or erased automatically after 3500
miles. DTC's are retained by the controller even if
the ignition is turned off or the battery is discon-
nected. More than one DTC can be stored at a time.
The mileage of the most recent occurrence, number of
occurrences and the DTC that was stored is also dis-
played. Most functions of the CAB and the ABS sys-
tem can be accessed by the technician for testing and
diagnostic purposes by using the DRB.
LATCHING VERSUS NON-LATCHING
DIAGNOSTIC TROUBLE CODES
Some DTC's detected by the CAB are latching; the
DTC is latched and ABS braking is disabled until the
ignition switch is reset. Thus ABS braking is non
operational even if the original DTC has disappeared.
Other DTC's are non-latching; any warning lights
that are turned on, are only turned on as long as the
DTC condition exists. As soon as the condition goes
away, the ABS Warning Light is turned off, although
a DTC will be set in most cases.
INTERMITTENT DIAGNOSTIC TROUBLE CODES
As with virtually any electronic system, intermit-
tent electrical problems in the ABS system may be
difficult to accurately diagnose.
Most intermittent electrical problems are caused
by faulty electrical connections or wiring. When an
intermittent fault is encountered, check suspect cir-
cuits for:
A visual inspection for loose, disconnected, or mis-
routed wires should be done before attempting to
diagnose or service the ITT Teves Mark 20 antilock
brake system. A visual inspection will eliminate
unnecessary testing and diagnostics time. A thorough
visual inspection will include the following compo-
nents and areas of the vehicle.
(1) Inspect fuses in the power distribution center
(PDC) and the wiring junction block. Verify that all
fuses are fully inserted into the PDC and wring junc-
tion block. A label on the underside of the PDC cover
identifies the locations of the ABS fuses in the PDC.
(2) Inspect the 25-way electrical connector at the
CAB for damage, spread or backed-out wiring termi-
nals. Verify that the 25-way connector is fully
inserted in the socket on the CAB. Be sure that wires
are not stretched tight or pulled out of the connector.
(3) Verify that all the wheel speed sensor connec-
tions are secure.
(4) Poor mating of connector halves or terminals
not fully seated in the connector body.
(5) Improperly formed or damaged terminals. All
connector terminals in a suspect circuit should be
carefully reformed to increase contact tension.
(6) Poor terminal to wire connection. This requires
removing the terminal from the connector body to
inspect.
(7) Pin presence in the connector assembly
(8) Proper ground connections. Check all ground
connections for signs of corrosion, tight fasteners, or
other potential defects. Refer to wiring diagram man-
ual for ground locations.
(9) Problems with main power sources of the vehi-
cle. Inspect battery, generator, ignition circuits and
other related relays and fuses.
(10) If a visual check does not find the cause of the
problem, operate the car in an attempt to duplicate
the condition and record the trouble code.
(11) Most failures of the ABS system will disable
ABS function for the entire ignition cycle even if the
fault clears before key-off. There are some failure
conditions, however, which will allow ABS operation
to resume during the ignition cycle in which a failure
occurred if the failure conditions are no longer
present. The following conditions may result in inter-
mittent illumination of the ABS Warning Lamp. All
other failures will cause the lamp to remain on until
the ignition switch is turned off. Circuits involving
NSBRAKES 5 - 97
DIAGNOSIS AND TESTING (Continued)

use. Refer to Causes of Battery Discharging in this
Group for more information.
NOTE: CLEAR COLOR = Replace Battery
WARNING: DO NOT CHARGE, ASSIST BOOST,
LOAD TEST, OR ADD WATER TO THE BATTERY
WHEN CLEAR COLOR DOT IS VISIBLE. PERSONAL
INJURY MAY OCCUR.
A clear color dot shows electrolyte level in battery
is below the test indicator (Fig. 1). Water cannot be
added to a maintenance free battery. The battery
must be replaced. A low electrolyte level may be
caused by an over charging condition. Refer to Gen-
erator Test Procedures on Vehicle.
CAUSES OF BATTERY DISCHARGING
It is normal to have a small 5 to 25 milliamperes
continuous electrical draw from the battery. This
draw will take place with the ignition in the OFF
position, and the courtesy, dome, storage compart-
ments, and engine compartment lights OFF. The con-
tinuous draw is due to various electronic features or
accessories that require electrical current with the
ignition OFF to function properly. When a vehicle is
not used over an extended period of approximately 20
days the IOD fuse should be pulled. The fuse is
located in the power distribution center. Disconnec-
tion of this fuse will reduce the level of battery dis-
charge. Refer to Battery Diagnosis and Testing table
and to the proper procedures.
ABNORMAL BATTERY DISCHARGING
²Corroded battery posts, cables or terminals.
²Loose or worn generator drive belt.
²Electrical loads that exceed the output of the
charging system due to equipment or accessories
installed after delivery.
²Slow driving speeds in heavy traffic conditions
or prolonged idling with high-amperage electrical
systems in use.²Defective electrical circuit or component causing
excess Ignition Off Draw (IOD). Refer to Battery
Ignition Off Draw (IOD).
²Defective charging system.
²Defective battery.
BATTERY IGNITION OFF DRAW (IOD)
High current draw on the battery with the ignition
OFF will discharge a battery. After a dead battery is
serviced the vehicle Ignition Off Draw (IOD) should
be checked. Determine if a high current draw condi-
tion exists first check the vehicle with a test lamp.
(1) Verify that all electrical accessories are OFF.
²Remove key from ignition switch
²Turn off all lights
²Liftgate and glove box door is closed
²Sun visor vanity lights are OFF
²All doors are closed
²Allow the Illuminated Entry System to time out
in approximately 30 seconds, if equipped.
²During Transmission Control Module (TCM)
power down there will be 500 milliamperes present
for 20 minutes. Afterwards less than 1.0 milliampere.
(2) Disconnect battery negative cable (Fig. 4).
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 the
meter. 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
²Body Control Module
²Remote Keyless Entry Module
Fig. 3 Test Indicator
NSBATTERY 8A - 3
DIAGNOSIS AND TESTING (Continued)

(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, disconnect the
TCM.
(d) If reading is OK, replace TCM.
(e) If reading stays, there is a short circuit to
one of the modules. Refer to Group 8W, Wiring
Diagrams.
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
BATTERY DIAGNOSIS AND TESTING
STEPS POSSIBLE CAUSE CORRECTION
VISUAL INSPECTION
Check for possible damage to
battery and clean battery.(1) Loose battery post, Cracked
battery cover or case, Leaks or Any
other physical
(2) Battery OK.(1) Replace Battery
(2) Check state of charge. Refer to
Test Indicator.
TEST INDICATOR
Check Charge Eye Color(1) GREEN
(2) BLACK
(3) CLEAR(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) Ensure that the indicator eye is
GREEN 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) Ensure that the indicator eye is
GREEN 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
DIAGNOSIS AND TESTING (Continued)

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)

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)