Pigtail Installation For DRL Module And/Or Signal Switch (TS 15 10244)

PIGTAIL INSTALLATION FOR DRL MODULE AND/OR SIGNAL SWITCH

TECHNICAL SERVICE BULLETIN

CONDITION

Certain 2004-2008 Forenza and 2005-2008 Reno vehicles may develop a condition where the connector(s) and or wiring at the connectors for the Daytime Running Lights Module (DRL Module) or Signal Switch will melt or otherwise have heat discoloration or damage.

CAUSE

Excessive heat develops at the DRL Module or the Signal Switch connector(s) and connector wiring. The excessive heat will discolor or cause damage to connector(s) and or connector wiring of the DRL Module or Signal Switch.

CORRECTION

If heat discoloration or damage to the DRL Module or the Signal Switch connectors or connector wiring is found, repair by installing the Pigtail Kit identified in this bulletin. Order and install only the Pigtail Kit for the damaged connector(s).

PARTS INFORMATION

Part Number	Part Name	Qty	Remark
36691-85Z00	WIRE ASSY, HARN REPAIR SIG & LT	1	Signal Switch Kit
36692-85Z00	WIRE ASSY, HARNESS REPAIR DRL	1	DRL Kit

WORK FLOW

It is recommended when cutting the vehicle harness in preparation for splicing, to only cut and splice one wire at a time to avoid damaging the electrical system. 

1. Cut and complete the splice (steps 2 through  8) of a single wire. Repeat for each wire until all wires have been spliced. Once all wires have been spliced, go to Step  9.

   Make the cut to the Instrument Panel Harness in the following locations:

   1. DRL Module: 50mm from connector end.
   2. Signal Switch: 80mm from connector end.
2. Strip 12 mm of insulation from the pigtail wires.
3. Strip 12 mm of insulation from the Instrument Panel Harness wires.
4. Place a section of heat shrink tube supplied in the Pigtail Kit onto the wire to be spliced. Be sure to use a section of shrink tube long enough to cover all exposed stands of wire and the crimp connector once the shrink tube has been shrunk.
5. Using a splice connector supplied in the Pigtail Kit, connect each pigtail wire to its corresponding wire on the Instrument Panel Harness. After the splice is completed tug on the wires to confirm the connection is tight and the wires hold together.

   Any crimp tool designed to be used with the crimp connector supplied in this Pigtail Kit can be used. Use only the correct size crimp jaw for the total wire strand cross section being crimped.

6. Position the heat shrink tube to cover the splice/crimp connector and any exposed wire strands. Use a heat gun to shrink the heat shrink tube.
7. You should see a small amount of sealant exposed from the ends of the shrink tube once the tube has been shrunk with the heat gun.
8. Cover each splice with insulating vinyl tape. (Repeat steps  2 through 8 for each wire.)
9. Bundle the wires together and wrap with insulating vinyl tape.
   IMPORTANT: If the DRL Module, the DRL Module Wiring, or the DRL Connector show evidence of any heat related damage, in addition to the wiring repair please perform the following Ground G203 check.