Headlamps and/or Daytime Runnign Lamps (DRL) Inoperative and/or Hot Plastic Odor (Inspect SP201 Splice Pack and Directly Splice Headlamp Wires, If Necessary)

Some customers may comment that the headlamps and/or DRLs are inoperative and/or that they smell a hot plastic odor.

This condition may be caused by electrical issues with the SP201 splice pack.

Inspect the SP201 splice pack for thermal damage or poor connections and repair by directly splicing headlamp wires, if necessary.

Service Procedure

1. Disconnect the negative battery cable.
2. Remove the instrument panel cluster. Refer to Instrument Panel Cluster (IPC) Replacement in SI.
3. Detach the SP201 splice pack from the tie bar.
4. Inspect the SP201 splice pack for any thermal damage. If any damage is present, proceed to Step 5.



5. Cut the three purple wires indicated by callouts 1 through 3 well away from any melted or damaged areas close to the splice pack. The two inboard wires may be found in the cavities indicated by either callout 2 or 3. (Wires in illustration above are shown at position of callout 2.)
6. Strip approximately 20 mm (0.79 in) of insulation from the ends of the three wires and splice using blue splice sleeve, P/N 12089190). Insert the wire from callout 1 into one end of the sleeve and the wires from callout 2 or 3 in the other end. Seal the splice sleeve using Ultra Torch or another approved heating tool. Refer to Splicing Copper Wire Using Splice Sleeves in SI.
7. Reattach the SP201 splice pack to the tie bar.
8. Install the instrument panel cluster. Refer to Instrument Panel Cluster (IPC) Replacement in SI.
9. Connect the negative battery cable.
10. Verify that the headlamps and DRLs are fully operational.

For vehicles repaired under warranty, use: