Lighting - Xenon Headlamp Connector Replacement

Classification:
EL05-015

Reference:
NTB05-052

Date:
August 31, 2005

2002-2004 I35; XENON HEADLAMP CONNECTOR REPLACEMENT KIT

APPLIED VEHICLES:
2002-2004 I35 (CA33)

SERVICE INFORMATION

A xenon headlamp connector replacement kit (listed in the Parts Information below) is available for installation on Applied Vehicles.

The kit should be installed per the Service Procedure in this bulletin.





PARTS INFORMATION





SERVICE PROCEDURE

NOTE:
It may be helpful to reference ITB03-054 Essential Tools: Flame-Less Heat Gun J-46538 and Solder Sleeve Connectors J-47003 when performing the repairs in this Service Procedure.

1. Cut the wires of the replacement connectors to the appropriate lengths.

However measure carefully first to make sure you have enough length to reach the connection points at the headlamp assembly! vehicle harness cut points.

^ See Figures 2 and 3 for connector application.

2. Use Essential Wire Crimping/Stripping Tool # J-38751-2 (or equivalent) to strip off about 10 mm of insulation from the ends of the wires (see Figure 1). Then firmly twist together the exposed wires.. NOTE: Use the correct size opening in the Wire Crimping/Stripping Tool so you won't cut off any strands of wire. Less strands reduces the ability of the wire to handle the expected electrical load.

3. Pull three vinyl tubes from the kit. Slide one vinyl tube each onto the wiring (both wires) of the xenon headlamp the turn signal lamp and the parking lamp connectors only.

4. Working under the hood match the wires (all yellow) from the replacement connectors (4 connectors for each side of the vehicle) with the correct color wires from the vehicle harness.

NOTES:








^ On the vehicle harness side: The wire colors are different between the Left and Right sides (see Figures 2 and 3).

^ On the replacement connector side: Even though the two wires on each replacement connector are the same color (yellow) each of the wires must be connected to the correct wire color on the vehicle harness side . Figures 2 and 3 provide this information.





5. Slide the Solder Sleeve Connector over one of the wires (see Figure 4)





6. Firmly and securely twist the two wire ends together (see Figure 5).

^ Make sure the replacement connector lock is facing you so the two wires won't be swapped.

^ Refer back to Figure 2 and 3 as needed.





7. Now slide the Solder Sleeve Connector over so that the solder ring is centered around the exposed twisted wire area (see Figure 6)





8. Use the Flame-Less Heat Gun to heat the Solder Sleeve connector (see Figure 7). This operation will:





^ Melt the solder (silver ring inside solder connector) into the exposed twisted wire area (see Figure 8)

^ Melt the sealant (colored rings inside solder connector) onto the wires (see Figure 8)

^ Shrink the plastic sleeve onto the wires

WARNING:
The Flame-Less Heat Gun and the Solder Sleeve Connector become HOT during the soldering process. Allow the Gun and connectors to cool down before handling them.

Important Soldering Tips:

^ Position the Solder Sleeve Connector in the middle of the heat shield (of the Heat Gun).

^ Start heating the connector from the center and move back and forth (side to side) and around to allow even distribution of the heat to the entire connector.

^ Make sure the solder completely flows into the exposed twisted wires and the adhesive properly seals the wire insulation to the connector sleeve. Stop applying the heat immediately after this happens.

CAUTION:
Be careful not to damage the connector or wires with the heat gun:

^ Do NOT apply heat for more than about 40 seconds.

^ Do NOT overheat the connector or wires (i.e. severe darkening of connector sleeve or wire insulation).

9. Re-check the matching of the replacement wires to vehicle wire colors. Make sure the wires are correctly connected - i.e. no mis-matched wires (see Figures 2 and 3).

10. Install the corrugated outer tubing around the repaired harnesses.

^ Larger diameter corrugated tubing covers and groups together (bundles) the xenon headlamp turn signal lamp and parking lamp repaired harnesses.

^ Smaller diameter corrugated tubing goes around high beam headlamp harness.

^ Tape off ends of corrugated tubing with vinyl electrical tape

11. Attach connectors to the headlamp assembly and confirm:

^ Headlamps operate correctly (high and low beams, left and right sides)

^ Turn signals operate correctly (left and right sides)

^ Parking lamps operate correctly (left and right sides).





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