Lighting - Moisture Inside of Headlamps

VOLUME
3

GROUP
Electrical

NUMBER
008

MODEL
Spectra

DATE
July 2004

SUBJECT
2004MY Spectra with 2.0L Engine - Headlamp Ground Wire Sealing

This bulletin provides information on a repair procedure for 2004MY Spectra with 2.0L Engines to prevent moisture from entering the headlamp assemblies. Some 2004MY Spectra 2.0L Engine vehicles built before 2/27/04 may have a condition that allows moisture to enter the headlamp assemblies. To prevent moisture from entering the headlamp assemblies use the following procedure:

Note:
If moisture is visible in either headlamp, it must be replaced.

REPAIR PROCEDURE:





1. Open hood, find ground locations for the left and right headlamp assemblies. Remove the hood switch to access the right headlight ground lug.





2. Locate the left headlamp ground.





3. Cut the tape around the left and right ground lugs and fold back to access the wire ends.





4. Place sealant nozzle at the ground lug where the tape was folded back and apply sealant to completely seal the wire ends.

5. Completely cover the exposed copper strands and area under the tape to prevent water from "wicking" down to the headlamp assemblies.

6. Fold the tape back over the ground lugs after applying sealant.

Note:
Use only the silicone sealant specified in the Parts Information section - *Dow Corning(TM) 3140 RTV Silicon sealant or Permatex� Clear Silicone Adhesive sealant, as the wrong type of sealant could corrode the copper wires.

7. Reinstall the hood switch.

AFFECTED PRODUCTION RANGE:

2004MY Spectra with 2.0L Engines produced between 12/01/03 and 2/27/04.

PART INFORMATION:

Dow Corning(TM) 3140 RTV Silicone Sealant - Dow Corning P/N 3140

Permatex(R) Clear Silicone Adhesive Sealant - Permatex P/N 66B/80050





WARRANTY CLAIM INFORMATION: