Horn - Prevent Premature Failure
89audi09
Applies To: 5000S (non-turbo) 1984-1988
Subject: Horn relocation
Number: Group:
89-01
90
September 15, 1989
Electrical system
Horn failure may be the result of:
^ dirt and water ingress caused by environmental conditions
^ physical damage caused by road hazards
Relocate the horns using the following procedure to prevent premature horn failure caused by the above conditions.
Use this procedure only on vehicles out of the new vehicle warranty which have experienced prior horn failures.
^ loosen radiator fan shroud cover (arrows) and remove
CAUTION
Part numbers are for reference only. Always check with your Parts Department for latest parts information.
^ loosen front grill (arrows) and remove
^ disconnect wiring harness at horns
^ remove horns from brackets and save horns
^ remove horn brackets and discard
^ cut horn wiring harness where indicated (arrows) and separate connector terminal assembly 1 from supply wires 2
^ discard connector terminal assembly 1
^ strip 7 mm (1/4 in.) of insulation from ends of supply wires and properly crimp wire connector 1 P/N: N 017 491 8 onto each wire (two connectors necessary)
^ install white connector housing 2 P/N: 161 971 990 A over each new wire connector (two housings necessary) until tab on connector locks into housing
^ strip 7 mm (1/4 in.) of insulation from one end of new black 1.0 sq.mm (18 gauge) wire
^ strip 7 mm (1/4 in.) of insulation from one end of new brown 1.0 sq.mm (18 gauge) wire
^ properly crimp copper spade connector 3 P/N: N 017 461 4 onto stripped end of each wire (two connectors necessary)
^ install black connector housing 4 P/N: 161 971 976 A over each new spade connector (two housings necessary) until tab on connector locks into housing
^ tape brown and black wires together approximately every 20 cm (8.0 in.) with electrical tape
Note
Heat shrink tubing (available locally) cut in 2.5 cm (1.0 in.) strips and spaced every 20 cm (8.0 in.) can be used in place of electrical tape to secure the wires together.
^ connect new black and brown wires to existing horn wiring harness by inserting white connector housing into black for each wire.
Note
The new black and brown wires can be connected to either wire on the existing harness. Wire polarity will not affect horn operation.
^ route new horn wiring harness around front of radiator (right arrow) and across front apron (left arrow)
Note
When positioning new horn wiring across the front apron, follow the same routing as the alternator/headlight wiring harness.
^ secure horn wiring to alternator/headlight wiring harness (arrows) using plastic tie wraps (available locally)
^ continue routing wire up to top right of apron (upper left arrow)
^ position end of horn wiring harness so that it enters engine compartment behind right portion of grill (arrow)
^ temporarily set wires aside
^ position horns together so that horn openings lie next to each other and face in same direction
^ install crossover bracket P/N: 893 951 229 onto horns so that angled point on bracket (arrow) points away from horn openings
^ mount horn support bracket 1 P/N: 443 951 217 B to crossover bracket using bolt P/N: N 010 239 11, washer P/N: N 012 038 8, and nut P/N: N 011 008 18
^ 15 N-m (11 ft.lb.)
^ install horn and bracket assembly to front apron support with two bolts P/N: N 014 340 1 using holes (arrows) already in apron
^ 8 N-m (6.0 ft.lb.)
Note
Some vehicles may not have holes in the apron. In this case, mark apron using the horn bracket as a template and drill two holes (approximately 6 mm diameter). Prime and paint exposed metal before installing horns to prevent corrosion.
^ route new wiring harness (black and brown wires) to horns, trim off wire excess and save
CAUTION
DO NOT cut harness wires too short. Leave enough slack so that wires do not stretch when connected to horns.
^ strip 7 mm (1/4 in.) of insulation from end of black wire in wiring harness and from one end of excess piece of black wire
^ twist two ends of black wire together and properly crimp wire connector
PN: N 017 491 8 over both wires
^ install white connector housing P/N: 161 971 990 A over wire connector until tab on connector locks into housing
^ repeat three previous steps for brown wire, using same type of connector and housing
^ connect wires to left horn
^ route remaining brown and black wires to right horn and trim off wire excess
^ strip 7 mm (1/4 in.) of insulation from ends of both wires and properly crimp wire connector P/N: N 017 491 8 to each wire
^ install white connector housing P/N: 161 971 990 A over each wire connector until tab on connector locks into housing
^ connect wires to right horn
^ check operation of horns
^ re-install front grill and radiator fan housing