Headlight Connector - Replacement

Classification:
EL01-005

Reference:
NTB01-028

Date:
May 15, 2001

HEADLIGHT CONNECTOR REPLACEMENT

APPLIED VEHICLES:
All Nissan - except vehicles equipped with Xenon(TM) headlights

SERVICE INFORMATION

Nissan has established replacement headlight connectors and service procedures to replace damaged connectors on the applied vehicles. If the headlight wire harness connector is damaged, causing intermittent or improper headlight operation, or the connector otherwise needs replacement, follow the procedures in this bulletin.





Refer to the "Diagnosis/Repair Flow Chart" shown to diagnose and resolve this incident, should it occur.

SERVICE PROCEDURE

Headlight Wire Harness Connector Replacement Procedure

1. Disconnect the vehicle-side wire harness connector from the headlight bulb.

2. Cut the vehicle wire harness about an inch back from the headlight harness connector.

3. Cut the wires of the replacement connector to the appropriate length.

4. Strip the end of each wire (on the vehicle wire harness side and on the replacement connector wires).





5. Slide a one-inch piece of dual-wall heat shrink tubing (3M(TM) P/N 054007-55917 or equivalent) onto each wire of the vehicle wire harness (see Figure 1a).

6. Connect each wire (of the replacement connector) to the vehicle wire harness making sure the wires are correctly connected (i.e., no mis-matched wires). See Figure lb.

IMPORTANT:
Only use lead-free solder when performing step 7 below. Also, step 7 must be performed as stated to avoid a "cold" solder joint (i.e., a joint that will not hold together).

7. Solder each wire connection joint as follows:

A. Place the soldering iron tip against the bottom side of the wire strands and heat the wires (see Figure lb).

B. Once the wires are hot, apply the solder to the top side of the wire strands until they are fully coated with melted solder (see Figure 1b).

8. After the soldered joint cools down, slide the heat shrink tubing over the soldered joint and heat the tubing with a heat gun until it seals the joint (see Figure 1c).

IMPORTANT:
Each wire connection joint MUST be soldered and sealed with the heat shrink tubing due to the high wire current and moisture in this location. DO NOT use Scotch-Loks (TM) or butt connectors for splicing at this location.





PARTS INFORMATION





CLAIMS INFORMATION