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SPECIFICATIONS

FASTENER SPECIFICATIONS

ACCESSORIES & EQUIPMENT

Horns - Volt

Reusable Threaded Fastener Tightening Specifications

SCHEMATIC WIRING DIAGRAMS

HORN WIRING SCHEMATICS

Horns

.

Fig. 1: Horns

Courtesy of GENERAL MOTORS COMPANY

DIAGNOSTIC INFORMATION AND PROCEDURES

DTC B010E: PEDESTRIAN FRIENDLY ALERT AUDIO OUTPUT CIRCUIT

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check

- Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC B010E

Pedestrian Friendly Alert Audio Output Circuit Symptom Byte Information: Symptom Byte List Diagnostic Fault Information

Circuit/System Description

For an overview of the component/system, refer to:Pedestrian Alert Description and Operation

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Conditions for Running the DTC

Ignition - On / Vehicle - In Service Mode & Transmission in Drive

Conditions for Setting the DTC

B010E 1B - Control Circuit=Signal Cross Coupled B010E 04 - Control Circuit=Open/High Resistance

Actions Taken When the DTC Sets

Pedestrian Alert Sound System=Inoperative

Conditions for Clearing the DTC

A current DTC will clear when the diagnostic runs and passes.

A history DTC will clear after 50 consecutive malfunction-free ignition cycles.

Reference Information

Schematic Reference

Horn Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Component View Reference

Front of Vehicle/Engine Compartment Component Views

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

Scan Tool Reference

Control Module References

Circuit/System Verification

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1. Ignition - On / Vehicle - In Service Mode & Transmission in Drive

2. Verify the component is activated:P48 Pedestrian Alert Sound Speaker

If the component does not produce a sound

Refer to: Circuit/System Testing

If the component produces a sound

3. All OK.

Circuit/System Testing

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector:P48 Pedestrian Alert Sound Speaker

3. Test for less than 10 ohms between the test points:Low Reference terminal 1 & Ground

If 10 ohms or greater

1. Disconnect the electrical connector:K132 Pedestrian Alert Sound Control Module

2. Test for less than 2 ohms between the test points:Low Reference terminal 1 @Component harness & Terminal 2 @Control module harness

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Replace the component:K132 Pedestrian Alert Sound Control Module

If less than 10 ohms

4. Ignition - On / Vehicle - In Service Mode & Transmission in Drive

5. Test for 5 to 7 V between the test points:Control circuit terminal 2 & Ground

If less than 5 V

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector:K132 Pedestrian Alert Sound Control Module

3. Test for infinite resistance between the test points:Control circuit terminal 2 @Component harness & Ground

If less than infinite resistance - Repair the short to ground on the circuit. If infinite resistance

4. Test for less than 2 ohms between the test points:Control circuit terminal 9 @Component harness & Terminal 2 @Control module harness

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Replace the component:K132 Pedestrian Alert Sound Control Module

If greater than 7 V

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector:K132 Pedestrian Alert Sound Control Module

3. Ignition - On / Vehicle - In Service Mode

4. Test for less than 1 V between the test points:Control circuit terminal 2 @Component harness & Ground

If 1 V or greater - Repair the short to voltage on the circuit.

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If less than 1 V - Replace the component:K132 Pedestrian Alert Sound Control Module

If between 5 and 7 V

6. Test or replace the component:P48 Pedestrian Alert Sound Speaker

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair: Diagnostic Repair Verification

Pedestrian Sound Alert Speaker Replacement

For control module replacement, programming, and setup refer to: Control Module References

DTC B274E OR B274F: LOW NOTE HORN RELAY CONTROL CIRCUIT

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check

- Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

DTC Descriptor

DTC B274E

Low Note Horn Relay Control Circuit Symptom Byte Information: Symptom Byte List Diagnostic Fault Information

Circuit/System Description

For an overview of the component/system, refer to:Horns System Description and Operation

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Conditions for Running the DTC

KR3 Horn Relay - The component is commanded On.

Conditions for Setting the DTC Control Circuit=Short to Voltage Actions Taken When the DTC Sets Horn Relay Command - Inoperative Conditions for Clearing the DTC

A current DTC will clear when the diagnostic runs and passes.

A history DTC will clear after 50 consecutive malfunction-free ignition cycles.

Reference Information

Schematic Reference

Horn Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Component View Reference

Front of Vehicle/Engine Compartment Component Views

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

Scan Tool Reference

Control Module References

Circuit/System Verification

1. Ignition - On / Vehicle - In Service Mode

2. Perform the scan tool control function:Horn Relay - On and Off Verify the component turns On and Off:P12 Horn

If the component does not turn On and Off

Refer to: Circuit/System Testing

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If the component turns On and Off

3. All OK.

Circuit/System Testing

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector:K9 Body Control Module

3. Ignition - On / Vehicle - In Service Mode

4. Momentarily connect a 3 A fused jumper wire between the test points:Control circuit terminal 19 X5 & Ground

Verify the component turns On and Off when connecting and disconnecting the jumper wire:P12 Horn

If the component does not turn On and Off

1. Ignition/Vehicle - Off & Remove - Jumper wire(s)

2. Disconnect the electrical connector: X2@X50A Fuse Block - Underhood

3. Ignition - On / Vehicle - In Service Mode

4. Test for less than 1 V between the test points:Control circuit terminal 19 X5 @Control module harness & Ground

If 1 V or greater - Repair the short to voltage on the circuit. If less than 1 V

5. Ignition/Vehicle - Off

6. Test for infinite resistance between the test points:Control circuit terminal 19 X5@Control module harness & Ground

If less than infinite resistance - Repair the short to ground on the circuit. If infinite resistance

7. Test for less than 2 ohms between the test points:Control circuit terminal 19 X5 @Control module harness & Control circuit terminal 51 X2@Fuse Block Harness

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Test or replace the component:X50A Fuse Block - Underhood

If the component turns On and Off

5. Replace the component:K9 Body Control Module

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair: Diagnostic Repair Verification

Fuse Block Replacement

For control module replacement, programming, and setup refer to: Control Module References

SYMPTOMS - HORNS

Important Preliminary Checks Before Starting:

1. Perform the Diagnostic System Check - Vehicle before using the symptom tables in order to verify that

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all of the following are true: There are no DTCs set.

The control modules can communicate via the serial data link.

2. Review the horn operation or pedestrian alert sound system operation in order to familiarize yourself with the system functions. Refer to the following:

Horns System Description and Operation

Pedestrian Alert Description and Operation

Visual/Physical Inspection

Inspect for aftermarket devices which could affect the operation of the rear window defogger. Refer to

Checking Aftermarket Accessories .

Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.

Intermittent

NOTE: Inspect for proper installation of electrical components if an intermittent condition exists. Inspect for aftermarket theft deterrent devices, lights, and cellular phones. Ensure that no aftermarket equipment is connected to the class 2 circuit. If you can not locate an intermittent condition, a cellular phone signal may cause the condition. Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections .

The problem may or may not turn ON the SERVICE VEHICLE SOON indicator or store a DTC. Do not use the symptom tables to diagnose intermittent conditions. The malfunction must be present in order to locate the problem.

Poor electrical connections or wiring cause most intermittent conditions. Perform a careful visual/physical check for the following conditions:

Poor mating of the connector halves or a terminal not fully seated in the connector body An improperly formed or damaged terminal

Reform or replace connector terminals in the problem circuit in order to ensure proper contact tension.

Poor terminal to wire connection requires removing the terminal from the connector body in order to perform the check.

Use a scan tool in order to help detect intermittent conditions. The scan tool has several features that can be used to locate an intermittent condition. The snapshot feature can capture and store data parameters within the scan tool when the malfunction occurs. This information can then be reviewed in order to see what caused the malfunction.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:

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Horns Malfunction

Pedestrian Alert System Malfunction

HORNS MALFUNCTION

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check

- Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

Diagnostic Fault Information

Circuit/System Description

For an overview of the component/system, refer to: Horns System Description and Operation

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Diagnostic Aids

Rotate the steering wheel while pressing the horn pad to identify intermittent and poor connections within the steering column.

If the horn produces only a weak noise, inspect the following: Debris or water in the horn.

Incorrect MountingRefer to: Fastener Specifications. Debris on the component.

Vehicle components that vibrate while the horn is sounding.

Reference Information

Schematic Reference

Horn Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Component View Reference

Front of Vehicle/Engine Compartment Component Views

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

Scan Tool Reference

Control Module References

Circuit/System Verification

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1. Verify the scan tool parameter:Horn Switch=Inactive

If not the specified state

Refer to: Circuit/System Testing - Test 1

If the specified state

2. Operate the component:S33 Horn Switch - Pressed Verify the scan tool parameter:Horn Switch=Active

If not the specified state

Refer to: Circuit/System Testing - Test 1

If the specified state

3. Perform the scan tool control function:Horn Relay Command - On and Off

Verify the component turns On and Off:P12 Horn & The horn should emit a clear and even tone.

If the component does not turn On and Off

Refer to: Circuit/System Testing - Test 2

If an abnormal noise is present

Refer to: Circuit/System Testing - Test 3

If the component turns On and Off & If no abnormal noise is present

4. All OK.

Circuit/System Testing

Test 1

NOTE: It may take up to 2 min for all vehicle systems to power down before an accurate ground or low reference circuit continuity test can be performed.

1. Ignition/Vehicle & All vehicle systems - Off

2. Disconnect the electrical connector: X1& X2@S33 Horn Switch

3. Test for less than 10 ohms between the test points:Ground circuit terminal X2 & Ground

If 10 ohms or greater

1. Ground Connection - Disconnect

2. Test for less than 2 ohms between the test points:Ground circuit terminal A X2 @Component harness & Ground Connection

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Repair the open/high resistance in the ground connection.

If less than 10 ohms

4. Ignition - On / Vehicle - In Service Mode

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5. Verify the scan tool parameter:Horn Switch=Inactive

If not the specified state

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector: X3 @K9 Body Control Module

3. Test for infinite resistance between the test points:Signal circuit terminal A X1@Component harness & Ground

If less than infinite resistance - Repair the short to ground on the circuit. If infinite resistance - Replace the component:K9 Body Control Module

If the specified state

6. Connect a 3 A fused jumper wire between the test points:Signal circuit terminal A X1 & Ground circuit terminal A X2

7. Verify the scan tool parameter:Horn Switch=Active

If not the specified state

1. Ignition/Vehicle - Off & Remove - Jumper wire(s)

2. Disconnect the electrical connector: X3 @K9 Body Control Module

3. Ignition - On / Vehicle - In Service Mode

4. Test for less than 1 V between the test points:Signal circuit terminal A X1 @Component harness & Ground

If 1 V or greater - Repair the short to voltage on the circuit. If less than 1 V

5. Ignition/Vehicle - Off

6. Test for less than 2 ohms between the test points:Signal circuit terminal A X1 @Component harness & Terminal 18 X3 @Control module harness

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Replace the component:K9 Body Control Module

If the specified state

8. Test or replace the component:S33 Horn Switch

Test 2

NOTE: It may take up to 2 min for all vehicle systems to power down before an accurate ground or low reference circuit continuity test can be performed.

1. Ignition/Vehicle & All vehicle systems - Off

2. Disconnect the electrical connector:P12 Horn

3. Test for less than 1 ohms between the test points:Ground circuit terminal 1 & Ground

If 1 ohms or greater

1. Ground Connection - Disconnect

2. Test for less than 1 ohms between the test points:Ground circuit terminal 1 & Ground Connection If 1 ohms or greater - Repair the open/high resistance in the circuit.

If less than 1 ohms

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4. Connect a test lamp between the test points:Control circuit terminal 2 & Ground circuit terminal 1

5. Ignition - On / Vehicle - In Service Mode

6. Perform the scan tool control function:Horn Relay Command - On and Off Verify the test lamp does not turn On and Off.

If the test lamp turns On and Off

Test or replace the component:P12 Horn

If the test lamp does not turn On and Off

7. Ignition/Vehicle - Off

8. Connect the electrical connector:P12 Horn

9. Disconnect the electrical connector: X1@X50A Fuse Block - Underhood

10. Ignition - On / Vehicle - In Service Mode

11. Momentarily connect a 15 A fused jumper wire between the test points:Control circuit terminal 59 X1 & B+

Verify the component turns On and Off when connecting and disconnecting the jumper wire:P12 Horn

If the component does not turn On and Off

1. Ignition/Vehicle - Off & Remove - Jumper wire(s)

2. Disconnect the electrical connector:P12 Horn

3. Ignition - On / Vehicle - In Service Mode

4. Test for less than 1 V between the test points:Control circuit terminal 2 @Component harness & Ground

If 1 V or greater - Repair the short to voltage on the circuit. If less than 1 V

5. Ignition/Vehicle - Off

6. Test for infinite resistance between the test points:Control circuit terminal 2 @Component harness & Ground

If less than infinite resistance - Repair the short to ground on the circuit. If infinite resistance

7. Test for less than 2 ohms between the test points:Control circuit terminal 2 @Component harness & Control circuit terminal 59 X1 @Fuse Block Harness

If 2 ohms or greater - Repair the open/high resistance in the circuit. If less than 2 ohms - Test or replace the component:P12 Horn

If the component turns On and Off

12. Connect the electrical connector: X1 @X50A Fuse Block - Underhood

13. Disconnect the electrical connector: X5 @K9 Body Control Module

14. Ignition - On / Vehicle - In Service Mode

15. Momentarily connect a 3 A fused jumper wire between the test points:Control circuit terminal 19 X5&

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B+

Verify the component turns On and Off when connecting and disconnecting the jumper wire:P12 Horn

If the component does not turn On and Off

1. Ignition/Vehicle - Off & Remove - Jumper wire(s)

2. Disconnect the electrical connector:X2@X50A Fuse Block - Underhood

3. Ignition - On / Vehicle - In Service Mode

4. Test for less than 1 V between the test points:Control circuit terminal 19 X5 @Control module harness & Ground

If 1 V or greater - Repair the short to voltage on the circuit. If less than 1 V

5. Ignition/Vehicle - Off

6. Test for infinite resistance between the test points:Control circuit terminal 19 X5 @Control module harness & Ground

If less than infinite resistance - Repair the short to ground on the circuit. If infinite resistance

7. Test for less than 2 ohms between the test points:Control circuit terminal 19 X5 @Control module harness & Terminal 51 X2 @Fuse Block Harness

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Test or replace the component:X50A Fuse Block - Underhood

If the component turns On and Off

16. Replace the component:K9 Body Control Module

Test 3

NOTE: It may take up to 2 min for all vehicle systems to power down before an accurate ground or low reference circuit continuity test can be performed.

1. Ignition/Vehicle & All vehicle systems - Off

2. Disconnect the electrical connector:P12 Horn

3. Test for less than 1 ohms between the test points:Ground circuit terminal 1 & Ground

If 1 ohms or greater

1. Ground Connection - Disconnect

2. Test for less than 1 ohms between the test points:Ground circuit terminal 1 & Ground Connection If 1 ohms or greater - Repair the open/high resistance in the circuit.

If less than 1 ohms

4. Disconnect the electrical connector: X1 @X50A Fuse Block - Underhood

5. Test for less than 1 ohms between the test points:Control circuit terminal 2 @Component harness & Control circuit terminal 59 X1 @Fuse Block Harness

If 1 ohms or greater - Repair the open/high resistance in the circuit.

If less than 1 ohms

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6. Test or replace the component:P12 Horn

Component Testing

P12 Horn

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector:P12 Horn

3. Connect a jumper wire between the test points:Ground terminal 1 & Ground

4. Momentarily connect a 15 A fused jumper wire between the test points:Control terminal 2 & 12 V Verify the component turns On and Off when connecting and disconnecting the jumper wire:P12 Horn

If the component does not turn On and Off

Replace the component:P12 Horn

If the component turns On and Off

5. All OK.

S33 Horn Switch

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector: X1 & X2 @S33 Horn Switch

3. Test for infinite resistance between the test points:Signal terminal X1 & Ground terminal A X2 - Switch Not Pressed

If less than infinite resistance

Replace the component:S33 Horn Switch

If infinite resistance

4. Test for less than 3 ohms between the test points:Signal terminal A X1 & Ground terminal A X2 - Switch

- Pressed

If 3 ohms or greater

Replace the component:S33 Horn Switch

If less than 3 ohms

5. All OK.

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair: Diagnostic Repair Verification

Engine Wiring Harness Junction Block Replacement Steering Wheel Horn Contact Replacement

Horn Replacement

For control module replacement, programming, and setup refer to: Control Module References

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PEDESTRIAN ALERT SYSTEM MALFUNCTION

Diagnostic Instructions

Perform the Diagnostic System Check prior to using this diagnostic procedure: Diagnostic System Check

- Vehicle

Review the description of Strategy Based Diagnosis: Strategy Based Diagnosis

An overview of each diagnostic category can be found here: Diagnostic Procedure Instructions

Diagnostic Fault Information

.

Circuit/System Description

For an overview of the component/system, refer to:Pedestrian Alert Description and Operation

Reference Information

Schematic Reference

Horn Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

.

Component View Reference

Front of Vehicle/Engine Compartment Component Views

Electrical Information Reference

Circuit Testing

Connector Repairs

Testing for Intermittent Conditions and Poor Connections Wiring Repairs

Scan Tool Reference

Control Module References

Circuit/System Verification

1. Ignition - On / Vehicle - In Service Mode & Transmission in Drive

2. Verify the component is activated:P48 Pedestrian Alert Sound Speaker

If the component does not produce a sound

Refer to: Circuit/System Testing

If the component produces a sound

3. All OK.

Circuit/System Testing

NOTE: It may take up to 2 min for all vehicle systems to power down before an accurate ground or low reference circuit continuity test can be performed.

1. Ignition/Vehicle & All vehicle systems - Off

2. Disconnect the electrical connector:K132 Pedestrian Alert Sound Control Module

3. Test for less than 10 ohms between the test points:Ground circuit terminal 3 & Ground

If 10 ohms or greater

1. Disconnect the ground connection: G302

2. Test for less than 2 ohms between the test points:Ground circuit terminal 3 & Terminal G302 If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Repair the open/high resistance in the ground connection.

If less than 10 ohms

4. Ignition - On / Vehicle - In Service Mode

5. Verify a test lamp turns On between the test points:B+ circuit terminal 10 & Ground

If the test lamp does not turn On and the circuit fuse is OK

1. Ignition/Vehicle - Off & Remove - Test lamp

2. Test for less than 2 ohms between the test points: B+ circuit terminal 10 & Output terminal @

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F9UA Fuse

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Verify the fuse is OK and there is voltage at the fuse.

If the test lamp does not turn On and the circuit fuse is open

1. Ignition/Vehicle - Off & Remove - Test lamp

2. Test for infinite resistance between the test points: B+ circuit terminal 10 & Ground If less than infinite resistance - Repair the short to ground on the circuit.

If infinite resistance - Replace the component:K132 Pedestrian Alert Sound Control Module

If the test lamp turns On

6. Ignition/Vehicle - Off

7. Connect the electrical connector:K132 Pedestrian Alert Sound Control Module

8. Disconnect the electrical connector:P48 Pedestrian Alert Sound Speaker

9. Test for less than 10 ohms between the test points:Low Reference terminal 2 & Ground

If 10 ohms or greater

1. Disconnect the electrical connector:K132 Pedestrian Alert Sound Control Module

2. Test for less than 2 ohms between the test points:Low Reference terminal 2 @Component harness & Terminal 8 @Control module harness

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Replace the component:K132 Pedestrian Alert Sound Control Module

If less than 10 ohms

10. Ignition - On / Vehicle - In Service Mode & Transmission in Drive

11. Test for 5 to 7 V between the test points:Control circuit terminal 1 & Ground

If less than 5 V

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector:K132 Pedestrian Alert Sound Control Module

3. Test for infinite resistance between the test points:Control circuit terminal 1 @Component harness & Ground

If less than infinite resistance - Repair the short to ground on the circuit. If infinite resistance

4. Test for less than 2 ohms between the test points:Control circuit terminal 1 @Component harness & Terminal 9 @Control module harness

If 2 ohms or greater - Repair the open/high resistance in the circuit.

If less than 2 ohms - Replace the component:K132 Pedestrian Alert Sound Control Module

If greater than 7 V

1. Ignition/Vehicle - Off

2. Disconnect the electrical connector:K132 Pedestrian Alert Sound Control Module

3. Ignition - On / Vehicle - In Service Mode

4. Test for less than 1 V between the test points:Control circuit terminal 1 @Component harness & Ground

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If 1 V or greater - Repair the short to voltage on the circuit.

If less than 1 V - Replace the component:K132 Pedestrian Alert Sound Control Module

If between 5 and 7 V

12. Test or replace the component:P48 Pedestrian Alert Sound Speaker

Repair Instructions

Perform the Diagnostic Repair Verification after completing the repair: Diagnostic Repair Verification

Pedestrian Sound Alert Speaker Replacement

For control module replacement, programming, and setup refer to: Control Module References

REPAIR INSTRUCTIONS

WIRE TO WIRE REPAIR - HORNS

Special Tools

EL-38125-10 Splice Sleeve Crimping Tool (non GMNA)

J-38125-5A Ultra Torch Special Tool

J-38125-8 Splice Sleeve Crimping Tool (GMNA)

For equivalent regional tools, refer to Special Tools .

WARNING: In order to reduce the risk of personal injury, loss of high voltage isolation to ground and higher system impedance, do not attempt to repair any HV wiring, connector, or terminal that is damaged. High voltage coaxial type cables are not repairable. Never attempt to repair a coaxial type cable. The entire cable/harness or component must be replaced. In order to maintain system integrity and personal safety, never attempt to repair any high voltage wiring, cables, or terminals. Performing this procedure on high voltage circuits may result in serious injury or death.

NOTE: If the wiring harness internal to the transmission is damaged, the wiring harness must be replaced. The use of splice sleeves in an attempt to repair the internal transmission wires, connectors, or terminals could result in performance issues.

NOTE: Do not splice wires in Door Harness Grommets.

NOTE: The DuraSeal splice sleeves have the following 2 critical features:

A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside.

A cross hatched (knurled) core crimp provides the necessary low resistance contact integrity for these sensitive, low energy circuits.

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Use only DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except high voltage and specialty cables. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing.

Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves.

Splice Sleeve Selection

NOTE: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact.

1. Open the harness by removing any tape:

Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.

Use the DuraSeal splice sleeves on all types of insulation except Tefzel and coaxial.

Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together.

2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice.

Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.

3. Strip the insulation:

When adding a length of wire to the existing harness, use the same size wire as the original wire. Perform one of the following items in order to find the correct wire size:

Find the wire on the schematic and convert to regional wiring gauge size.

If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation.

Strip approximately 5.0 mm (0.20 in) of insulation from each wire to be spliced.

Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. If the wire is damaged, repeat this procedure after removing the damaged section.

4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure.

5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests.

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Fig. 2: Splice Sleeve Crimping Tool With 4 Crimp Nests Courtesy of GENERAL MOTORS COMPANY

6. The EL-38125-10 splice sleeve crimping tool has four crimp nests. The largest crimp nest (4) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (3) is used for crimping 14 and 16 gauge wires. The third largest crimp nest (2) is used for crimping 18 and 20 gauge wires. The smallest crimp nest (1) is used for crimping 22 to 26 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

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Fig. 3: Splice Sleeve Crimping Tool With 3 Crimp Nests Courtesy of GENERAL MOTORS COMPANY

7. The J-38125-8 splice sleeve crimping tool has three crimp nests. The largest crimp nest (3) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (2) is used for crimping 14 and 16 gauge wires. The smallest crimp nest (1) is used for crimping 18 to 20 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

8. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. For the four crimp nest tool, use the three largest crimp nests to crimp the splice sleeves. For the three crimp nest tool, use all three crimp nests to crimp the splice sleeves. Use the four and three crimp tool diagrams (above) and the table (farther above) to match the splice sleeve with the correct crimp nest. The crimp tool diagram callout numbers match the numbers in the table (under crimp tool nest color).

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Fig. 4: Identifying Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

9. Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.

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Fig. 5: Crimped Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

10. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

11. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Repeat steps 4 and 6 for the opposite end of the splice.

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Fig. 6: Crimped Duraseal Splice Sleeve Courtesy of GENERAL MOTORS COMPANY

12. Using the heat torch, apply heat to the crimped area of the barrel.

13. Start in the middle and gradually move the heat barrel to the open ends of the tubing: The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

Weatherpack™ Wiring Repair

NOTE: Some replacement pigtail connectors may be delivered without the terminated leads installed into the connector. For Weatherpack™ connectors, all terminated leads included in the package should to be installed into the connector. If the connector end view shows that a terminal is not occupied, the extra terminated lead(s) need to be installed and the end(s) sealed using a DuraSeal splice sleeve and taped back into the harness.

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1. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. Refer to Folded-Over Wire Repair for splicing wires of 0.35 mm or less (22, 24, 26 gauge sizes) and for splicing wires of different gauges.

Fig. 7: Tightly Close Handles Of Crimp Tool Courtesy of GENERAL MOTORS COMPANY

2. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until you apply the proper amount of pressure to the DuraSeal splice sleeve. Holding the DuraSEAL with one hand gently tug on the wire to ensure it is crimped in the DuraSeal.

3. Using the heat torch, apply heat to the crimped area of the barrel.

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Fig. 8: Heat To Crimped Area Of Barrel Courtesy of GENERAL MOTORS COMPANY

4. Start in the middle and gradually move the heat barrel to the open ends of the tubing: The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

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Fig. 9: Taping Extra Terminated Leads Back Into Harness Courtesy of GENERAL MOTORS COMPANY

5. Tape the extra terminated lead(s) back into the harness.

High Temperature Wiring Repairs

Use the following procedures to perform high temperature wiring repairs:

1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve.

2. Using the heat torch, apply heat to the high temperature heat shrink tubing.

3. Gradually move the heat from the center to the open end of the tubing:

The tubing will shrink completely as the heat is moved along the insulation.

A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

4. Replace any reflective tape and clips that may have been removed during the repair.

CONNECTOR RECONNECTION - HORNS

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Special Tools

EL-35616 Terminal Test Probe Kit

For equivalent regional tools, refer to Special Tools .

When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition.

Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items:

Loose, corroded, or painted terminal stud/fastener Wiring broken inside the insulation

Poor connection between the male and female terminal at a connector A terminal not seated all the way into the connector body

Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc.

Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits.

Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle.

Wiring that comes in contact with hot or exhaust components

Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern.

Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions.

Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation.

Testing for Terminal Fretting

Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 microns can cause fretting. To put this in perspective, a sheet of paper is about 100 microns thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface.

To correct a fretting condition disconnect the suspect connector and add dielectric grease / lubricant (Nyogel

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760G or equivalent, meeting GM specification 9986087) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion.

Testing for Proper Terminal Contact

It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation.

Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter. Always use the EL-35616 kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Testing for Proper Terminal Contact in Bussed Electrical Centers

It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use the EL-35616 kit to test for proper terminal contact. Failure to use the EL-35616 kit can result in improper diagnosis of the bussed electrical center.

Follow the procedure below in order to test terminal contact:

1. Separate the connector halves.

2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.

3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question.

Flat Wire Connectors

There are no serviceable parts for flat wire connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact:

1. Remove the component in question.

2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well.

3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.

4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question.

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Control Module/Component Voltage and Grounds

Poor voltage or ground connections can cause widely varying symptoms.

Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current.

Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing

, and Power Distribution Schematics .

Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested.

Inspect grounds for clean and tight connections at the grounding point (screw or stud). Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing , and Ground Distribution Schematics .

Temperature Sensitivity

An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot.

Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable.

If the intermittent is related to heat, review the data for a relationship with the following: High ambient temperatures

Underhood/engine generated heat

Circuit generated heat due to a poor connection, or high electrical load Higher than normal load conditions, towing, etc.

If the intermittent is related to cold, review the data for the following:

Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion.

The condition only occurs on a cold start.

The condition goes away when the vehicle warms up.

Information from the customer may help to determine if the trouble follows a pattern that is temperature related.

If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition.

Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required.

Electromagnetic Interference and Electrical Noise

Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions:

A mis-routed harness that is too close to high voltage/high current devices such as secondary ignition

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components, motors, generator etc. - These components may induce electrical noise on a circuit that could interfere with normal circuit operation.

Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch - These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating.

Installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc. - These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories .

Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode.

The generator may be allowing AC noise into the electrical system.

Incorrect Control Module

There are only a few situations where reprogramming a control module is appropriate: A new service control module is installed.

A control module from another vehicle is installed.

Revised software/calibration files have been released for this vehicle.

NOTE: DO NOT re-program the control module with the SAME software/calibration files that are already present in the control module. This is not an effective repair for any type of concern.

Verify that the control module contains the correct software/calibration. If incorrect programming is found, reprogram the control module with the most current software/calibration. Refer to Control Module References for replacement, setup, and programming.

HORN REPLACEMENT

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Fig. 10: Horn

Courtesy of GENERAL MOTORS COMPANY

STEERING WHEEL HORN CONTACT REPLACEMENT

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Fig. 11: Steering Wheel Horn Contact Courtesy of GENERAL MOTORS COMPANY

PEDESTRIAN SOUND ALERT MODULE REPLACEMENT

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Fig. 12: Pedestrian Sound Alert Module Courtesy of GENERAL MOTORS COMPANY

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PEDESTRIAN SOUND ALERT SPEAKER REPLACEMENT

Fig. 13: Pedestrian Sound Alert Speaker Courtesy of GENERAL MOTORS COMPANY

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DESCRIPTION AND OPERATION

HORNS SYSTEM DESCRIPTION AND OPERATION

System Description

The horn system consists of the following components: HORN fuse

Underhood fuse block (contains PCB horn relay) Horn switch

Horn-low note Horn-high note

Body control module (BCM)

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Fig. 14: Horns System Block Diagram Courtesy of GENERAL MOTORS COMPANY

System Operation

The vehicle horn system is activated under the following conditions: When the horn switch is depressed

The BCM commands the horns ON under any of the following conditions:

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When the content theft deterrent system detects a vehicle intrusion - For further information refer to

Theft Systems Description and Operation .

When the panic button is depressed on the remote control door lock transmitter - For further information refer to Keyless Entry System Description and Operation .

When the keyless entry system is used to lock the vehicle, a horn chirp may sound to notify the driver that the vehicle has been locked. The notification feature may be enabled or disabled through personalization. For further information refer to Keyless Entry System Description and Operation .

When the OnStar® system is used to sound the horns if equipped - For further information, refer to OnStar Description and Operation .

Circuit Operation

Battery positive voltage is applied at all times to the horn relay coil and the horn relay switch. Pressing either of the horn switches applies ground to the horn relay control circuit. The BCM may also apply ground to the horn relay control circuit as described above. When the horn relay control circuit is grounded, the horn relay is energized and battery positive voltage is applied to the horns through the horn control circuit. The horns sound as long as ground is applied to the horn relay control circuit.

PEDESTRIAN ALERT DESCRIPTION AND OPERATION

Electric vehicles present a situation for visually impaired pedestrians who cannot hear an approaching electric vehicle, the pedestrian alert module creates sounds from a dedicated speaker to alert a visually impaired pedestrian, in a non-startling manner.

Operation of the Pedestrian Alert

Emit sound from 0 to 12 MPH (20 KM/H)

Fade in and out control for the sound ON and OFF

Change the pitch of the sound dependent of vehicle speed

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