HORN SYSTEMS

CONTENTS
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
BODY CONTROL MODULE . . . . . . . . . . . . . . . . . 1
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DIAGNOSIS AND TESTING
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
HORN RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GENERAL INFORMATION
INTRODUCTION
Fol l owi ng are general descri pti ons of the major
components i n the factory-i nstal l ed horn systems.
Refer to 8W-41 - Horns/Ci gar Li ghter i n Group 8W -
Wi ri ng Di agrams for compl ete ci rcui t descri pti ons
and di agrams.
DESCRIPTION AND OPERATION
HORN RELAY
The horn rel ay i s a I nternati onal Standards Orga-
ni zati on (I SO) mi cro-rel ay. The termi nal desi gnati ons
and functi ons are the same as a conventi onal I SO
rel ay. However, the mi cro-rel ay termi nal ori entati on
(or footpri nt) i s di fferent, current capaci ty i s l ower,
and the rel ay case di mensi ons are smal l er than those
of the conventi onal I SO rel ay.
The horn rel ay i s a el ectromechani cal devi ce that
swi tches battery current to the horn when the horn
swi tch grounds the rel ay coi l . See the Di agnosi s and
Testi ng secti on of thi s group for more i nformati on on
the operati on of the horn rel ay.
The horn rel ay i s l ocated i n the Power Di stri buti on
Center (PDC), i n the engi ne compartment. Refer to
the PDC l abel for rel ay i denti fi cati on and l ocati on.
I f a probl em i s encountered wi th a conti nuousl y
soundi ng horn, i t can usual l y be qui ckl y resol ved by
removi ng the horn rel ay from the PDC unti l further
di agnosi s i s compl eted.
The horn rel ay cannot be repai red and, i f faul ty or
damaged, i t must be repl aced.
HORN SWITCH
A center-bl ow, resi sti ve membrane-type horn
swi tch i s i nstal l ed on the back si de of the dri ver si de
ai rbag modul e tri m cover i n the center of the steer-
i ng wheel . When the center area of the ai rbag tri m
cover i s depressed, the horn swi tch compl etes a ci r-
cui t to ground for the coi l si de of the horn rel ay. The
steeri ng wheel and steeri ng col umn must be properl y
grounded for the horn swi tch to functi on.
The horn swi tch i s onl y servi ced as a part of the
ai rbag modul e tri m cover. I f the horn swi tch shoul d
fai l , or i f the ai rbag i s depl oyed, the ai rbag modul e
tri m cover and horn swi tch must be repl aced as a
uni t.
HORN
Dual -note, el ectromagneti c di aphragm-type horns
are standard equi pment on thi s model . The horns are
secured next to each other on a bracket beneath the
ri ght radi ator cl osure extensi on panel and forward of
the ri ght front i nner wheel house.
The horns are connected i n paral l el . Both horns
are grounded through thei r wi re harness connector
and ci rcui t to an eyel et bol ted to the ri ght i nner
fender shi el d near the Power Di stri buti on Center
(PDC), and they recei ve battery feed through the
cl osed contacts of the horn rel ay.
The horns cannot be repai red or adjusted and, i f
faul ty or damaged, they must be repl aced.
BODY CONTROL MODULE
A Body Control Modul e (BCM) i s used on thi s
model to control and i ntegrate many of the el ectroni c
functi ons and features i ncl uded on the vehi cl e. The
BCM contai ns a central processi ng uni t and i nter-
faces wi th other modul es i n the vehi cl e on the
Chrysl er Col l i si on Detecti on (CCD) data bus network.
ZJ HORN SYSTEMS 8G - 1
The CCD data bus network al l ows the shari ng of
sensor i nformati on. Thi s hel ps to reduce wi re har-
ness compl exi ty, reduce i nternal control l er hardware,
and reduce component sensor current l oads. At the
same ti me, thi s system provi des i ncreased rel i abi l i ty,
enhanced di agnosti cs, and al l ows the addi ti on of
many new feature capabi l i ti es.
The horn system i s one of the outputs of the BCM.
The BCM i s programmed to energi ze or de-energi ze
the horn rel ay i n response to certai n i nputs from the
Vehi cl e Theft Securi ty System (VTSS) and the
Remote Keyl ess Entry (RKE) system. Refer to Group
8P - Power Lock Systems for more i nformati on on the
RKE system. Refer to Group 8Q - Vehi cl e Theft/Secu-
ri ty Systems for more i nformati on on the VTSS.
The BCM i s mounted under the dri ver si de out-
board end of the i nstrument panel , behi nd the i nstru-
ment panel support armature and bel ow the
outboard swi tch pod. Refer to Group 8E - I nstrument
Panel Systems for the removal and i nstal l ati on pro-
cedures. For di agnosi s of the BCM or the CCD data
bus, the use of a DRB scan tool and the proper Di ag-
nosti c Procedures manual are recommended. The
BCM can onl y be servi ced by an authori zed el ectroni c
repai r stati on. Refer to the l atest Warranty Pol i ci es
and Procedures manual for a current l i sti ng of autho-
ri zed el ectroni c repai r stati ons.
DIAGNOSIS AND TESTING
HORN RELAY
For ci rcui t descri pti ons and di agrams, refer to
8W-41 - Horns/Ci gar Li ghter i n Group 8W - Wi ri ng
Di agrams.
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.
RELAY TEST
The horn rel ay (Fi g. 1) i s l ocated i n the Power Di s-
tri buti on Center (PDC) i n the engi ne compartment.
Refer to the PDC l abel for horn rel ay i denti fi cati on
and l ocati on.
Remove the horn rel ay from the PDC as descri bed
i n thi s group to perform the fol l owi ng tests:
(1) A rel ay i n the de-energi zed posi ti on shoul d
have conti nui ty between termi nal s 87A and 30, and
no conti nui ty between termi nal s 87 and 30. I f OK, go
to Step 2. I f not OK, repl ace the faul ty rel ay.
(2) Resi stance between termi nal s 85 and 86 (el ec-
tromagnet) shoul d be 75 5 ohms. I f OK, go to Step
3. I f not OK, repl ace the faul ty rel ay.
(3) Connect a battery to termi nal s 85 and 86.
There shoul d now be conti nui ty between termi nal s
30 and 87, and no conti nui ty between termi nal s 87A
and 30. I f OK, see the Rel ay Ci rcui t Test i n thi s
group. I f not OK, repl ace the faul ty rel ay.
RELAY CIRCUIT TEST
(1) The rel ay common feed termi nal cavi ty (30) i s
connected to battery vol tage and shoul d be hot at al l
ti mes. I f OK, go to Step 2. I f not OK, repai r the open
ci rcui t to the PDC fuse as requi red.
(2) The rel ay normal l y cl osed termi nal (87A) i s
connected to termi nal 30 i n the de-energi zed posi ti on,
but i s not used for thi s appl i cati on. Go to Step 3.
(3) The rel ay normal l y open termi nal (87) i s con-
nected to the common feed termi nal (30) i n the ener-
gi zed posi ti on. Thi s termi nal suppl i es battery vol tage
to the horn(s). There shoul d be conti nui ty between
the cavi ty for rel ay termi nal 87 and the horn rel ay
output ci rcui t cavi ty of each horn wi re harness con-
nector at al l ti mes. I f OK, go to Step 4. I f not OK,
repai r the open ci rcui t to the horn(s) as requi red.
(4) The coi l battery termi nal (86) i s connected to
the el ectromagnet i n the rel ay. I t i s connected to bat-
tery vol tage and shoul d be hot at al l ti mes. Check for
battery vol tage at the cavi ty for rel ay termi nal 86. I f
OK, go to Step 5. I f not OK, repai r the open ci rcui t to
the PDC fuse as requi red.
(5) The coi l ground termi nal (85) i s connected to
the el ectromagnet i n the rel ay. I t i s grounded
through the horn swi tch when the horn swi tch i s
depressed. I t can al so be grounded by the Body Con-
trol Modul e (BCM) i n response to i nputs from the
Vehi cl e Theft Securi ty System (VTSS) or the Remote
Keyl ess Entry (RKE) system. Check for conti nui ty to
Fig 1. Horn Relay
8G - 2 HORN SYSTEMS ZJ
DESCRIPTION AND OPERATION (Continued)
ground at the cavi ty for rel ay termi nal 85. There
shoul d be conti nui ty wi th the horn swi tch depressed,
and no conti nui ty wi th the horn swi tch rel eased. I f
not OK, see the di agnosi s for the Horn Swi tch i n thi s
group.
HORN SWITCH
For ci rcui t descri pti ons and di agrams, refer to
8W-41 - Horns/Ci gar Li ghter i n Group 8W - Wi ri ng
Di agrams.
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) Di sconnect and i sol ate the battery negati ve
cabl e. Remove the steeri ng col umn openi ng cover/
knee bl ocker from the i nstrument panel . Refer to
Steeri ng Col umn Openi ng Cover and Knee Bl ocker i n
Group 8E - I nstrument Panel Systems for the proce-
dures.
(2) Check for conti nui ty between the metal steer-
i ng col umn jacket and a good ground. There shoul d
be conti nui ty. I f OK, go to Step 3. I f not OK, refer to
Steeri ng Col umn i n Group 19 - Steeri ng for the
proper i nstal l ati on of the steeri ng col umn mounti ng
hardware.
(3) Remove the dri ver si de ai rbag modul e from the
steeri ng wheel . Refer to Ai rbag Modul e i n Group 8M
- Passi ve Restrai nt Systems for the procedures.
Unpl ug the horn swi tch wi re harness connectors
from the ai rbag modul e.
(4) Unpl ug the Body Control Modul e (BCM) wi re
harness connector B (whi te). Unpl ug the horn rel ay
from the Power Di stri buti on Center (PDC). Check for
conti nui ty between the steeri ng col umn hal f of the
horn swi tch feed wi re harness connector and a good
ground. There shoul d be no conti nui ty. I f OK, go to
Step 5. I f not OK, repai r the short ci rcui t as
requi red.
(5) Check for conti nui ty between the steeri ng col -
umn hal f of the horn swi tch feed wi re harness con-
nector and the horn rel ay control ci rcui t cavi ty for
the horn rel ay i n the PDC. There shoul d be conti nu-
i ty. I f OK, go to Step 6. I f not OK, repai r the open
ci rcui t as requi red.
(6) Check for conti nui ty between the horn swi tch
feed wi re and the horn swi tch ground wi re on the
ai rbag modul e. There shoul d be no conti nui ty. I f OK,
go to Step 7. I f not OK, repl ace the faul ty horn
swi tch.
(7) Depress the center of the ai rbag modul e tri m
cover and check for conti nui ty between the horn
swi tch feed wi re and the horn swi tch ground wi re on
the ai rbag modul e. There shoul d now be conti nui ty. I f
not OK, repl ace the faul ty horn swi tch.
HORN
For ci rcui t descri pti ons and di agrams, refer to
8W-41 - Horns/Ci gar Li ghter i n Group 8W - Wi ri ng
Di agrams.
(1) Unpl ug the horn wi re harness connectors. Mea-
sure the resi stance between the ground ci rcui t cavi ty
of the horn wi re harness connectors and a good
ground. There shoul d be no measurabl e resi stance. I f
OK, go to Step 2. I f not OK, repai r the ci rcui t to
ground as requi red.
(2) Wi th the horn wi re harness connectors sti l l
unpl ugged, depress the horn swi tch. There shoul d be
battery vol tage at the horn rel ay output ci rcui t cavi ty
of the horn wi re harness connectors. I f OK, repl ace
the faul ty horn(s). I f not OK, repai r the open ci rcui t
to the horn rel ay as requi red.
REMOVAL AND INSTALLATION
HORN RELAY
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Remove the cover from the Power Di stri buti on
Center (PDC) (Fi g. 2).
(3) Refer to the l abel on the PDC for horn rel ay
i denti fi cati on and l ocati on.
(4) Unpl ug the horn rel ay from the PDC.
(5) I nstal l the horn rel ay by al i gni ng the rel ay ter-
mi nal s wi th the cavi ti es i n the PDC and pushi ng the
rel ay fi rml y i nto pl ace.
(6) I nstal l the PDC cover.
(7) Connect the battery negati ve cabl e.
Fig. 2 Power Distribution Center
ZJ HORN SYSTEMS 8G - 3
DIAGNOSIS AND TESTING (Continued)
(8) Test the rel ay operati on.
HORN SWITCH
WARNING: ON VEHICLES EQUIPPED WITH A
DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTE-
GRAL TO THE AIRBAG MODULE TRIM COVER.
SERVICE OF THIS COMPONENT SHOULD BE PER-
FORMED ONLY BY CHRYSLER-TRAINED AND
AUTHORIZED DEALER SERVICE TECHNICIANS.
FAILURE TO TAKE THE PROPER PRECAUTIONS
OR TO FOLLOW THE PROPER PROCEDURES
COULD RESULT IN ACCIDENTAL, INCOMPLETE, OR
IMPROPER AIRBAG DEPLOYMENT AND POSSIBLE
PERSONAL INJURY. REFER TO DRIVER SIDE AIR-
BAG TRIM COVER AND HORN SWITCH IN GROUP
8M - PASSIVE RESTRAINT SYSTEMS FOR THE
SERVICE PROCEDURES.
HORN
(1) Di sconnect and i sol ate the battery negati ve
cabl e.
(2) Rai se and support the vehi cl e.
(3) Remove the radi ator l ower ai r defl ector. Refer
to Group 7 - Cool i ng System for the procedures.
(4) Unpl ug the wi re harness connectors from the
horns (Fi g. 3).
(5) Remove the screw that secures the horn
mounti ng bracket to the radi ator cl osure extensi on
panel .
(6) Remove the horns and mounti ng bracket from
the vehi cl e.
(7) Reverse the removal procedures to i nstal l .
Ti ghten the horn mounti ng bracket screw to 28 Nm
(250 i n. l bs.).
Fig. 3 Horns Remove/Install
8G - 4 HORN SYSTEMS ZJ
REMOVAL AND INSTALLATION (Continued)