Attachment III - Technical Information
OVERVIEWWhen performing this Recall procedure, you will:
^ replace the existing wiring harness connector with a redesigned connector assembly.
^ inspect the original headlamp (HL) switch and connector for melting.
^ If the original switch or connector is melted, replace the HL switch.
NOTE:
It is estimated that less than 5% of vehicles involved in this Recall Program will require switch replacement. Parts will be randomly selected for return and analysis. Parts that do not exhibit melting as indicated in Step 7, will be charged back.
^ Verify the repair.
SERVICE PROCEDURE
1. Install the memory saver, then disconnect the battery negative cable.
2. Remove the lower steering column opening panel (knee bolster). See Figure 1.
3. Remove the retaining screws from the left side instrument panel (IP) finish panel, then position the finish panel away from the IP. See Figure 1.
4. Remove the bezel illumination bulb from the bezel, if equipped. See Figure 2.
5. Disconnect all electrical connectors from the components attached to the left IP finish panel. Then, remove the IP finish panel assembly from the vehicle. See Figure 2.
CAUTION
Cut and splice only one wire at a time. The wire colors on the new HL switch connector do not match the existing wiring harness colors.
6. Install the new HL switch connector kit as follows:
a. Obtain Headlamp Switch Connector Repair Kit # F5RZ-14A411-BA.
b. Select the first circuit to be spliced from the vehicle wire harness and cut it as close as possible to the HL switch connector. On some vehicles, terminal cavities # 7 and # 9 are populated with two (2) wires in each cavity. If two (2) wires are present, splice them as indicated in Figure 3.
c. Select the corresponding circuit from the new HL switch connector as shown in Figure 4.
d. Strip 1/4" insulation from the selected wires.
e. Install the appropriate splice connector using crimp tool # AD1522 or equivalent rachet action crimp tool. Be sure to select the correct splice color (size) from the Splice Connector Application Chart.
SPLICE CONNECTOR APPLICATION CHART
f. Test the integrity of all splices after crimping. Grasp the wires at each splice and pull gently. If any wire is not attached securely, replace the splice connector and crimp firmly.
g. Repeat Steps B through F for the remaining wires, one at a time.
h. Cut all unused wires flush with the back of the new HL switch connector as indicated in Figure 4.
NOTE:
For vehicles not equipped with HL switch knob illumination or fog lamps, be sure to cut all unused wires flush with the back of the pigtail connector (as shown in Figure 4). Do not attempt to remove terminals from the connector assembly. Connector or terminal damage may result.
i. Heat each splice connector thoroughly until the tubing shrinks and adhesive flows from each end. Use Rotunda Heat Gun R07-10300 or equivalent.
j. Bundle the wires and wrap with tape as shown in Figure 5.
7. Carefully examine the original wiring harness connector and the mating surfaces and terminals of the switch. Visually inspect the area around every terminal paying special attention to terminal # 15.
If the wiring harness connector or HL switch terminal area is melted, replace the HL switch (# F5RZ-11654-J). Refer to Step 8 through 11 for switch replacement procedures.
NOTE:
The estimated rate of HL switch replacement is less than 5% of the recall vehicle population. All replaced parts must be retained for return analysis in accordance with the procedures found in the current Warranty and Policy Manual.
Proceed to Step 12 if the harness connector AND switch terminal area are not melted. Do not replace the HL switch.
8. Remove the headlamp switch retaining screws from the rear of the finish panel, then separate the headlamp switch from the finish panel. See Figure 2.
9. Remove the headlamp switch knob by inserting a suitable tool into the hole in the bottom of the headlamp switch knob. This will release the knob locking tab.
10. Transfer the knob and bezel assembly to the new HL switch. See Figure 6.
11. Install the new HL switch assembly to the left IP finish panel.
12. Connect all electrical connectors to the components attached to the left IP finish panel.
13. Install the bezel illumination bulb into the bezel, if equipped.
14. Install the left instrument panel finish panel.
15. Install the lower steering column opening panel.
16. Connect the battery negative cable, then remove the memory saver.
17. Test operation of the lighting system. Confirm that the instrument panel lamps, tail lamps and all other lighting systems function properly.