Headlamp Wiring Harness Functional Verification/Replacement
Important:Perform this procedure only if new park/turn bulb installed in "Headlamp Jumper Harness/Resistor Installation" procedure is not functional.
1. Remove headlamp assembly by removing headlamp assembly retaining pins.
2. Position the headlamp assembly away from the vehicle to access the headlamp electrical connector.
3. Disconnect the headlamp jumper harness electrical connector from the headlamp assembly.
4. Place this headlamp assembly to the side.
Important:
If other side headlamp assembly turn signal bulb also is inoperative, then obtain known good headlamp assembly or known good headlamp wiring harness assembly to perform Step 9.
5. Remove other side headlamp assembly by removing headlamp assembly retaining pins.
6. Position the headlamp assembly away from the vehicle to access the headlamp electrical connector.
7. Disconnect the headlamp harness electrical connector from the other headlamp assembly.
8. Place the other headlamp assembly in the opening for the original headlamp assembly and connect headlamp jumper harness connector to headlamp assembly.
Important:
This diagnosis step will verify if electrical concern for the bulb being inoperative is in the headlamp assembly or the wiring prior to the headlamp assembly.
9. Turn on the hazard warning flashers to verify if the turn signal bulb is working.
^ If the bulb is now working with the different headlamp assembly, then the headlamp wiring harness in the original headlamp assembly needs to be replaced (contains park/turn socket). Disconnect headlamp assembly from headlamp jumper harness. Proceed to Step 10.
^ It the bulb is still not working, then concern is in wiring between forward lamp harness connector and body control module (BCM). Disconnect headlamp assembly from headlamp jumper harness. Diagnose and repair condition (refer to diagnostics for B3948 or B3949, depending on which code is set, in the Lighting Systems section of the 2003 or 2004 Saturn ION Service Manual, Vol.3), then proceed to Step 20 in "Headlamp Jumper Harness/Resistor Installation."
10. On original headlamp, remove both the park/turn access cover and headlight bulb access cover by rotating counterclockwise.
11. Remove 6-pin headlamp wiring harness connector from tab on headlamp housing.
12. Push rubber grommet into headlamp assembly and also push 6-pin connector through opening where grommet was previously located.
Important:
Remove headlamp bulb and headlamp retaining nut from headlamp assembly/connector prior to wiring harness removal.
13. Carefully remove wiring harness through the park/turn bulb access opening.
Notice:
The park/turn sockets are NOT interchangeable between colors. The "keying" of the socket and how it secures to the inside of the headlamp is different. Do NOT replace a black colored socket with a natural colored socket or a natural colored socked with a black colored socket. Sockets must be replaced with the same color socket. Replacement of a socket with a different colored socket may result in damage to the connector and/or an inoperative exterior lighting system.
14. Note the color of the park/turn socket material. There are two material colors, black, P/N 22696735, or natural, P/N 10362907. Obtain the wiring harness with the correct socket color.
15. Install wiring harness through park/turn bulb access opening, starting with the headlamp connector.
16. Push headlamp connector up into headlamp opening.
17. Pull 6-pin connector through grommet opening in headlamp assembly and then pull grommet and seat it into the opening. Fasten the 6-pin connector to the tab on the headlamp housing.
18. Install headlamp bulb and headlamp retaining nut to headlamp assembly.
19. Install the park/turn bulb into the socket and then install the socket into the headlamp housing by rotating the socket clockwise.
20. Install both the park/turn access cover and headlight bulb access cover by rotating clockwise.
21. Position headlamp assembly in vehicle opening and connect remaining headlamp jumper harness connector to connector on the headlamp assembly.
22. Install headlamp assembly into headlamp bracket and install headlamp assembly retaining pins by pushing down on the pins.