A/C - Windshield Heater is Inoperative
NUMBERXT501-036
DATE
16 Aug 2006
MODEL
X-TYPE
SECTION:
501-11 - GLASS. FRAMES AND MECHANISMS
Windshield Heater Inoperative
AFFECTED VEHICLE RANGE:
X-TYPE (with Heated Windshield only)
VIN:
C00001 to E65102
Model Year:
2002 to 2005
CONDITION SUMMARY:
WINDSHIELD HEATER INOPERATIVE
A customer may report a concern that the windshield heater may be inoperative.
Situation:
Water ingress into the windshield heater electrical connectors may be the cause.
Action:
Should a customer report this concern, and the condition has been verified, refer to the Repair Procedure detailed in this bulletin to install two new electrical connectors.
PARTS:
NOTE:
Wiring harness repair kit no. 418-S065, available from SPX, contains all the necessary shop supply tools and splicing components to complete harness repairs and connector installations. Shop supplies are not claimable under warranty.
WARRANTY:
NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
Normal warranty policy and procedures apply.
REPAIR PROCEDURE
REPLACE HEATED WINDSHIELD CONNECTORS
NOTE:
GTR lookup sequence is as follows:
GTR Home > NAS > Service Information/ X400 - X-Type/ > Workshop Manuals > Bookmark "Body and Paint/501-02: Front End Body Panels/Removal and Installation" Link "Cowl Vent Screen (76.10.01)"
1. Refer to GTR Section 501-02 operation 76.10.01 and remove the cowl vent screen.
NOTE:
Wiring harness repair kit no. 418-S065 contains all the necessary tools and splicing components to complete harness repairs and connector installations. The crimping tool must be set to the correct jaw size for the Butt Splice wiring connector used.
CAUTION:
Connectors must be spliced in accordance with the repair policy as laid out in the Wiring Harness Repair Guide (JTP586).
2. Disconnect the right-hand side heated windshield electrical connector. (Figure 1)
3. Cut the electrical wire bundle approximately 50 mm (2 in) from connector.
4. Remove 10 mm (0.5 in) of insulation from the wire. (Figure 2)
5. Install heat shrink and butt splice connector to wire. (Figure 3)
6. Crimp butt splice connector at one end as shown. (Figure 3)
7. Remove 10 mm (0.5 in) of insulation from the new electrical connector wire. (Figure 4)
8. Install bare wire into the other end of the butt splice connector and crimp. (Figure 4)
CAUTION:
When using a heat source, ensure that it is localized and causes no damage to surrounding materials.
9. Using a suitable heat source, shrink the sleeve over the butt splice, ensuring a complete seal at both ends of the sleeve. (Figure 5)
10. Carry out steps 3 to 9 for the remaining wire of the new electrical connector.
11. Connect the new right-hand side heated windshield electrical connector.
12. Release the left-hand side heated windshield electrical connector.
13. Carry out steps 3 to 10 to the left-hand side heated windshield electrical connector.
14. Connect the left-hand side heated windshield electrical connector.
15. Refer to GTR Section 501-02 operation 76.10.01 and install the cowl vent screen.