GM Service Manual Online
For 1990-2009 cars only

Fog Lamps Dim or Inoperative (Repair Wiring)

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.

  1. Open the hood.
  2. Remove the upper radiator support trim panel.
  3. Remove the driver's side grille and parking light. These can be removed as an assembly.
  4. Remove the parking light bulb from the lamp assembly.
  5. 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.
  6. 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.
  7. 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.
  8. Strip back the orange wires until clean non-corroded wire is available.
  9. 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.
  10. Insert the bare wires fully into the body of the connector.
  11. Using the J 38125-8 electrical crimping tool, or equivalent, fully crimp the body of the connector.
  12. 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.
  13. Cut a *3M® Electrical Moisture Sealant Patch in half. Apply the patch to the splice as indicated on the package.
  14. Repeat the procedure for the purple wires.
  15. 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.
  16. Tightly retape the harness, significantly overlapping the ends of the original taped section to ensure adequate protection.
  17. Secure the wire harness to the rear of the bumper bar.
  18. Install the parking lamp bulb and socket to the parking lamp assembly.
  19. Install the grille and lamp assembly to the vehicle.
  20. Install the upper radiator support trim panel.
  21. Confirm proper operation of the fog lamps.
  22. 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