Service Procedure

Service Procedure

GMC Acadia

Note
Perform the following procedure on both the left and right headlamp.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.

2. Remove the front driver and passenger side tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in SI.

3. Remove the front wheelhouse liners. Refer to Front Wheelhouse Liner Removal in SI.

4. Remove low beam bulb service cap. Remove the front driver and passenger side low beam headlamp bulbs and pull the wiring harness to headlamp bulb through the service cap opening. Refer to Headlamp Bulb Replacement in SI.

Note
The service kit, P/N 22848987, includes two service pigtails (1), four splice clips (2), one piece of heat shrinking tube (3) and two bulbs (5). Use Special Tool J-38125-8 (4) to complete the repair.

5. Locate the two service pigtails (1) included in kit P/N 22848987.

6. Measure the length of the service pigtails. Measure the service pigtails from the back of the connector (1) to the end of the two wires. The length of the service pigtail should be 152 mm (6 in) in length.

7. Cut the two wires attached to the connector to 152 mm (6 in) in length (2).

8. Remove 13 mm (1/2 in) of insulation from the two wire ends of the service pigtails.

9. Replace the connector.

2. Remove 13 mm (1/2 in) of insulation from the two wire ends of the headlamp wires.

Caution
Use only the splice clips and heat shrink tube provided in service kit P/N 22848987. Other splice sleeves and heat shrink tube may not protect the splice from moisture or contain an adhesive that will cause headlamp gassing. Use Special Tool J-38125-8, crimp nest F, to complete the repair. Cut the heat shrinking tube into four 38 mm (1.5) sections.

3. Install one 38 mm (1.5 in) section of heat shrink tube around each of the headlamp wires.

4. Overlay the 13 mm (1/2 in) ends of exposed copper wires (1) over each other and crimp the splice clip over the wires using Special Tool J-38125-8, crimp nest F.

5. Inspect the crimp quality.

Caution
Keep the heat shrink above the splice when soldering the splice to ensure that the heat shrink is not prematurely shrunk and closed down over the wire or the splice area due to the heat from the soldering iron.

6. Solder the crimp and the splice clip.

7. Center the heat shrink tube (2) over the splice and use the Ultratorch, part numbers 12085116, J-38125-5, to shrink and seal the heat shrink tube (2) securely over the splice crimp and the insulated wires.

10. Install two new low beam headlamp bulbs.

11. Reinstall the wiring harness inside the headlamp housing and attach the connectors to the bulbs.

12. Adjust the location of the splice so that it is below the bulb and towards the back wall of the headlamp housing by manually pushing the splice clip down and rearwards toward the headlamp housing wall. Ensure both the harness and splices are not touching the lamp projector.

13. Verify that the headlamps are fully functional.

14. Replace bulb service caps.

15. Install the front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement in SI.

16. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in SI.

17. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.

Saturn OUTLOOK

Note
Perform the following procedure on both the left and right headlamp.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.

2. Remove the front driver and passenger side tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in SI.

3. Remove the front wheelhouse liners. Refer to Front Wheelhouse Liner Removal in SI.

4. Remove low beam bulb service cap. Remove the front driver and passenger side low beam headlamp bulbs and pull the wiring harness to headlamp bulb through the service cap opening. Refer to Headlamp Bulb Replacement in SI.

7. Cut the two wires attached to the connector to 76 mm (3 in) in length (2).

8. Remove 25 mm (1 in) of insulation from the two wire ends of the service pigtails.

9. Remove grommet (1) from side wall of headlamp housing.

10. Remove wiring harness (2) through open grommet hole in headlamp housing.

Note
If the head lamp wiring harness already has a service pigtail and connector attached with a splice, cut the wiring harness beyond the existing splice to ensure the old splice is removed from the head lamp harness.

11. Cut the existing low beam connector and 51 mm (2 in) of wire from the existing low beam wiring harness (1).

12. Fold over the exposed wire on the service pigtail so that there is 13 mm (1/2 in) of folded wire prepared for the splice crimp. Do not fold over the exposed wire on the existing headlamp wiring harness.

Caution
Use only the splice clips and heat shrink tube provided in service kit P/N 22848987. Other splice sleeves and heat shrink tube may not protect the splice from moisture or contain an adhesive that will cause headlamp gassing. Use Special Tool J-38125-8, crimp nest F, to complete the repair. Inspect the crimp quality.

13. Cut the heat shrink tubing into four equal length pieces of 38 mm (1.5 in). Install the 38 mm (1.5) piece of heat shrink tubing over each of the existing headlamp wires prior to crimping. There are two pieces of 38 mm (1.5 in) heat shrink tube needed per head lamp.

14. Overlay the13 mm ( 1/2 in) of exposed wire from the existing head lamp wiring harness and the folded over 13 mm (1/2 in) exposed wire of the service pigtail and crimp the splice clip over the exposed wire (1) using Special Tool J-38125-8, crimp nest F.

15. Inspect the crimp quality.

Caution
Keep the heat shrink above the splice when soldering the splice to ensure that the heat shrink is not prematurely shrunk and closed down over the wire or the splice area due to the heat from the soldering iron.

16. Solder the crimp.

17. Center the heat shrink tube (2) over the crimp and use the Ultratorch, part numbers 12085116, J-38125-5, to shrink and seal the heat shrink tube properly over the splice crimp and the insulated wires.

18. Install two new low beam headlamp bulbs.

19. Reinstall the wiring harness and the grommet into the headlamp housing making sure to seat the grommet properly to prevent water leaks into the head lamp.

20. Attach the low beam connector to the bulb.

21. Adjust the location of the splice clip so that it is below the bulb and towards the grommet by manually pushing the splice clip down and towards the grommet. Ensure both the harness and splices are not touching the lamp projector.

22. Verify that the headlamps are fully functional.

23. Install the front wheelhouse liners. Refer to Front Wheelhouse Liner Replacement in SI.

24. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.

Cadillac CTS

Note
Perform the following procedure on both the left and right headlamp capsule.

1. Remove the headlamp capsules from the vehicle. Refer to Headlamp Capsule Replacement in SI.

2. Place the headlamp capsules on a workbench.

3. Remove low beam bulb service cap.

4. Pull the wiring harness to headlamp bulb through the service cap opening.

Note
The service kit, P/N 22848987, includes two service pigtails (1), four splice clips (2), one piece of heat shrinking tube (3) and two bulbs (5). Use Special Tool J-38125-8 (4) to complete the repair.

6. Locate the two service pigtails (1) included in kit P/N 22848987.

7. Trim the length of the service pigtail wiring so that there is 63.5 mm (2.5 in) of wire exiting the connector.

8. Strip 25 mm (1 in) of insulation from the ends of the service pigtail wires.

9. Strip 13 mm (1/2 in) of insulation from the ends of the existing headlamp wiring harness.

10. Fold over the exposed wire on the service pigtail so that there is 13 mm (1/2 in) of folded wire prepared for the splice crimp. Do not fold over the exposed wire on the existing headlamp wiring harness.

Caution
Use only the splice clips and heat shrink tube provided in service kit P/N 22848987. Other splice sleeves and heat shrink tube may not protect the splice from moisture or contain an adhesive that will cause headlamp gassing. Use Special Tool J-38125-8, crimp nest F, to complete the repair. Inspect the crimp quality.

11. Cut the heat shrink tubing into four equal length pieces of the 38 mm (1.5). Install the 38 mm (1.5) piece of heat shrink tubing over the ends of the existing headlamp wires prior to crimping. There are two pieces of the 38 mm (1.5) heat shrink tube needed per head lamp.

12. Overlay the 13 mm (1/2 in) of exposed wire from the existing head lamp wiring harness and the folded over 13 mm (1/2 in) exposed wire of the service pigtail and crimp the splice clip over the exposed wire (1) using Special Tool J-38125-8, crimp nest F.

13. Inspect the crimp quality.

Caution
Keep the heat shrink above the splice when soldering the splice to ensure that the heat shrink is not prematurely shrunk and closed down over the wire or the splice area due to the heat from the soldering iron.

14. Solder the crimp.

15. Center the heat shrink tube (2) over the crimp and use the Ultratorch, part numbers 12085116, J-38125-5, to shrink and seal the heat shrink tube properly over the splice crimp and the insulated wires.

16. . Install two new low beam headlamp bulbs.

17. Reinstall the wiring harness into the headlamp housing.

18. Adjust the location of the splice clip so that it is below the bulb and at the bottom floor of the housing. Ensure both the harness and splices are not touching the lamp projector.

19. Install headlamp capsules. Refer to Headlamp Capsule Replacement in SI.

20. Verify that the headlamps are fully functional.

21. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.

Cadillac SRX

Note
Perform the following procedure on both the left and right headlamp capsule.

1. Remove the headlamp capsules from the vehicle. Refer to Headlamp Capsule Replacement in SI.

2. Place the headlamp capsules on a workbench.

3. Remove the low beam and high beam bulb service caps.

4. Pull the wiring harness to headlamp bulb through the high beam service cap opening.

Note
Access to the low beam connector (1) is accomplished by routing the connector through the high beam access cap opening (located lower on lamp) (2) as shown in illustration.

Note
The service kit, P/N 22848987, includes two service pigtails (1), four splice clips (2), one piece of heat shrinking tube (3) and two bulbs (5). Use Special Tool J-38125-8 (4) to complete the repair.

6. Locate the two service pigtails (1) included in kit P/N 22848987.

7. Trim the length of the service pigtail wiring so that there is 63.5 mm (2.5 in) of wire exiting the connector.

8. Strip 25 mm (1 in) of insulation from the ends of the service pigtail wires.

9. Strip 13 mm (1/2 in) of insulation from the ends of the existing headlamp wiring harness.

10. Fold over the exposed wire on the service pigtail so that there is 1/2 inch of folded wire prepared for the splice crimp. Do not fold over the exposed wire on the existing headlamp wiring harness.

Caution
Use only the splice clips and heat shrink tube provided in service kit P/N 22848987. Other splice sleeves and heat shrink tube may not protect the splice from moisture or contain an adhesive that will cause headlamp gassing. Use Special Tool J-38125-8, crimp nest F, to complete the repair. Inspect the crimp quality.

11. Cut the heat shrink tubing into four equal length pieces of 38 mm (1.5). Install the 38 mm (1.5) piece of heat shrink tubing over each wire prior to crimping. There are two pieces of 38 mm (1.5) heat shrink tube needed per head lamp.

12. Overlay the 13 mm (1/2 in) of exposed wire from the existing head lamp wiring harness and the folded over 13 mm (1/2 in) exposed wire of the service pigtail and crimp the splice clip over the exposed wire (1) using Special Tool J-38125-8, crimp nest F.

13. Inspect the crimp quality.

Caution
Keep the heat shrink above the splice when soldering the splice to ensure that the heat shrink is not prematurely shrunk and closed down over the wire or the splice area due to the heat from the soldering iron.

14. Solder the crimp.

15. Center the heat shrink tube (2) over the crimp and use the Ultratorch, part numbers 12085116, J-38125-5, to shrink and seal the heat shrink tube properly over the splice crimp and the insulated wires.

16. Install two new low beam headlamp bulbs.

17. Reinstall the wiring harness into the headlamp housing and attach the connector to the low beam bulb.

18. Adjust the location of the splice clip so that it is below the bulb and at the bottom floor of the housing. Ensure both the harness and splices are not touching the lamp projector.

19. Install headlamp capsules. Refer to Headlamp Capsule Replacement in SI.

20. Verify that the headlamps are fully functional.

21. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI.