Lighting - Condensation in Headlamps
NUMBER: 08-002-05GROUP: Electrical
DATE: January 13, 2005
THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL JANUARY 17, 2005.
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-043-04 DATED DECEMBER 18, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES AN ADDITIONAL NOTE.
SUBJECT:
Headlamp Condensation
OVERVIEW:
This bulletin involves improving the headlamp housing ventilation by installing new style vents and plugs.
NOTE:
**Please inform the customer that, it may take a couple of weeks of headlamp use to eliminate any residual condensation after this repair is performed.**
MODELS:
2004 - 2005 (ZH) Crossfire Coupe/Crossfire Roadster
SYMPTOM/CONDITION:
The vehicle operator may describe that moisture accumulates on the inside of the lens in one or both headlamp housings.
DIAGNOSIS:
If the technician finds condensation on the inside of the lens in either headlamp housing, perform the Repair Procedure.
PARTS REQUIRED:
SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
NOTE:
This repair must be performed inside a building.
1. Open the hood.
2. Install a battery charger and verify that the charging rate provides approximately 13.5 volts.
3. Remove the vent hoses and the rubber caps from the both headlamp housings (Fig. 1).
NOTE:
In Figure 1, the left side headlamp housing is shown. The right side headlamp housing is typical.
4. Turn on the headlamps, including the high beams. Allow the headlamps to remain on for a minimum of 45 minutes or until the headlamp housings dry out. When both headlamp housings are dry, proceed to the next step. The headlamps are to remain "On" until Step # 9.
5. Beginning on the left side of the vehicle, install two of the small rubber plugs from the new seal kit; on the headlamp housing where the vent hoses were previously removed, (# 1 & # 4) (Fig. 1).
NOTE:
Figures 2 and 3 below, show the headlamp housing removed from the vehicle for clarity. It is not necessary to remove the headlamp housing from the vehicle to perform the repair. The left headlamp is shown, the right headlamp is typical.
6. Install the new rubber cap with the special vent on the large inboard hole in the headlamp housing (Fig. 1).
7. Install the large rubber cap that was removed in Step # 1 on the large outboard hole in the headlamp housing (Fig. 1).
8. Repeat Step # 5 through Step # 8 on the right side of the vehicle. When Step # 5 through Step # 8 have been completed on both sides of the vehicle, proceed to the next step.
NOTE:
If the Headlamps are turned off at any time between Step # 4 and Step # 9, start over from Step # 4.
9. Turn off the headlamps and battery charger. Disconnect the battery charger from the battery.
10. Close the hood.
NOTE:
**Please inform the customer that, it may take a couple of weeks of headlamp use to eliminate any residual condensation after this repair is performed.**
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.