Lighting - Xenon Headlamp Connector Replacement Kit

Classification:
EL02-034

Reference:
NTB02-096

Date:
September 26, 2002

2002-2003 MAXIMA; XENON HEADLAMP CONNECTOR REPLACEMENT KIT

APPLIED VEHICLES:
2002 and 2003 Maxima

SERVICE INFORMATION

A replacement connector kit is available for xenon headlamp assembly connectors that

^ need to be replaced because of accident damage, or

^ because of damage that occurred due to headlamp assembly theft.

^ The kit includes connectors for the Xenon Headlamps, High Beam Headlamps, and Front Turn Signals.

If the headlamp assembly wire harness connectors need to be replaced, follow the Service Procedure to install the Harness kit listed in the Parts Information.

SERVICE PROCEDURE

NOTE:
It may be helpful to reference the Nissan/Infiniti Connector and Terminal Pin Service Manual when performing the repairs in this Service Procedure. This manual is found in ASIST - Info Tool Box - Tools and Equipment.

1. Cut the wires of the replacement connectors to the appropriate lengths.

^ Make sure there is enough length to reach the connection points at the headlamp assembly from the vehicle harness cut points.








See Figures 2 and 3 shown for connector application.

2. Slide a vinyl tube onto the wiring of the replacement connectors.





Xenon headlamp and front turn signal connector only (see Figure 1).

3. Strip about 1/2 inch of insulation off the end of each wire, in preparation for soldering. Strip the ends of the wires from the vehicle harness and from the replacement connectors.

4. Match the wires (all yellow) from the replacement connectors (3 on each side) with the correct color wires from the vehicle harness.

The wire colors from the vehicle harness are different between the Left and Right sides (see Figures 2 and 3).





5. Slide a piece of heat shrink tubing onto each wire to be soldered (see Figure 4a).

6. Solder wire ends as follows:

a. Perform soldering as stated in these steps to avoid a "cold" solder joint (i.e., a joint that will not hold together).

b. IMPORTANT, only use lead-free solder specified for electrical connections.

c. Place the soldering iron tip against the bottom side of the wire strands and heat the wires (see Figure 4b).

d. 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 4b).

7. After the soldered joint cools down

a. Slide the heat shrink tubing over the soldered joint.

b. Heat the tubing with a heat gun until it seals the joint (see Figure 4c).

IMPORTANT:
Each wire connection joint MUST be soldered and then sealed with the heat shrink tubing. This must be done because of the high current on the xenon headlamp wires and moisture in this location.

DO NOT use 3M Scotchloks(R) or butt connectors for splicing at these locations.

8. Re-check the "matching" of the replacement wires to vehicle wire colors. Make sure the wires are correctly connected - i.e., no mis-matched wires (see Figure 2 and 3).





9. Install corrugated outer tubing around the repaired harnesses. Tape off ends with vinyl electrical tape (see Figure 5).

10. Attach connectors to the headlamp assembly and confirm:

^ Headlamps operate correctly (high and low beams, left and right side).

^ Turn signals operate correctly (left and right side).





PARTS INFORMATION

CLAIMS INFORMATION

The repair outlined in the bulletin is for damage that is not covered by the vehicle warranty.