Subject: | Fog Lamps Dim or Inoperative (Repair Wiring) |
Models: | 2003 Pontiac Sunfire |
Condition
Some customers may comment on the left or right fog lamp appearing dim or not
illuminating. In addition, the Service Engine Soon (SES) tell tale may be illuminated.
Using the Tech 2® diagnostic scan tool, you may encounter Diagnostic Trouble Code
(DTC) B2601.
Cause
The forward electrical harness that runs behind the front bumper bar has splices
at two locations that may be inadequately sealed from corrosive elements. Road splash,
especially during winter months, may force water into the harness causing increased
resistance and eventual separation of the splice.
Correction
Repair the splices for the left and right fog lamps using the procedure outlined
below.
- Open the hood.
- Remove the upper radiator support trim panel.
- Remove the driver's side grille and parking light. These can be removed
as an assembly.
- Remove the parking light bulb from the lamp assembly.
- Locate the forward harness behind the bumper bar. Release one of the retainers
to allow some slack so that you can access the harness easier.
- On vehicles where the fog lamps are inoperative, you may be able to locate
the target splice visually before removing the electrical tape wrap. A green mark
or spot may have leeched out through the tape leaving a visual indicator of where
to begin removing the tape. The splices are located In the general area behind the
removed grille. Carefully cut and remove the electrical tape wrapping the wire harness.
- Locate the purple (splice #213) and orange (#113) wire splices. You are
to correct both splices anytime a vehicle is brought in for a concern on the right
or left fog lamp.
- Strip back the orange wires until clean non-corroded wire is available.
- To resplice the wires, use GM butt-end connectors, P/N 12089189,
only. These connectors are equipped with self-soldering crimpable joints and heat
shrink tubes.
- Insert the bare wires fully into the body of the connector.
- Using the J 38125-8 electrical crimping tool, or equivalent,
fully crimp the body of the connector.
- Using the J 38125-5 Ultratorch, or equivalent,
heat the center of the connector and work left until the sealer begins to ooze out.
Starting at the center again, work right until the sealer oozes out that end.
- Cut a *3M® Electrical Moisture Sealant Patch in half. Apply the patch
to the splice as indicated on the package.
- Repeat the procedure for the purple wires.
- In the same area as the orange and purple splices but more toward the
driver's side, you will find a black wire splice. Inspect this splice for signs of
corrosion. You should not cut into or in any way disturb this splice unless you see
visual signs of corrosion. If evidence of corrosion is found, resplice the connection
in the same manner as the orange and purple wires.
- Tightly retape the harness, significantly overlapping the ends of the
original taped section to ensure adequate protection.
- Secure the wire harness to the rear of the bumper bar.
- Install the parking lamp bulb and socket to the parking lamp assembly.
- Install the grille and lamp assembly to the vehicle.
- Install the upper radiator support trim panel.
- Confirm proper operation of the fog lamps.
- Close the hood.
*We believe this source and their products to be reliable. There may be additional
manufacturers of such products/material. General Motors does not endorse, indicate
any preference for, or assume any responsibility for the products or material from
this firm or for any such items that may be available from other sources.
Parts Information
Part Number
| Description
| Qty
|
12089189
| Connector, Butt End Electrical Splice
| 2 or 3
as applicable
|
06149
| 3M® Electrical Moisture Sealant Patches (25 per box)
| 1 or 2
as applicable
|
The connectors are currently available at GMSPO.
The 3M® Electrical Moisture Sealant Patches are available direct from 3M®
at 1-800-364-3577.
Warranty Information
For vehicles repaired under warranty, use:
Labor Operation
| Description
| Labor Time
|
N6612
| Wiring and/or Connector Repair -- Exterior Lighting
| 0.3 hr
|