Front Map/Courtesy Lamp - Incorrect Operation
NO: 08-54-94GROUP: Electrical
DATE: Oct. 14, 1994
SUBJECT:
Front Map/Courtesy Lamp Operation
MODELS:
1995 (AS) Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO SHORT WHEEL BASE VEHICLES NOT EQUIPPED WITH AN OVERHEAD CONSOLE.
SYMPTOM/CONDITION:
The dimmer switch for the instrument panel can be used to prevent all interior lighting from coming on when any door is opened. Some early 1995 model vehicles were assembled with a harness, P/N 4688670, that does not allow this feature.
DIAGNOSIS:
Open the drivers door and place the dimmer switch for the instrument panel lighting to its full left position (past the detent). If the front map/courtesy lamps are still illuminated, perform the repair procedure.
PARTS REQUIRED:
1 5267152 Terminal, 16 Way Connector
1 4604597 Terminal, 3 Way Connector
1 4778570 Tube, Heat Shrink
AR 4688546 Lamp Assembly, Front Map/Courtesy
AR NPN Wire, 18 Gauge Pink With Light Blue Tracer
AR NPN Solder, Rosin Core
AR NPN Tape, Duct
REPAIR PROCEDURE:
This bulletin involves changing the front map/courtesy lamp power source from the M1 (battery feed) to the M11 (switch feed).
1. Record the customers preset radio stations.
2. Disconnect the negative cable from the battery.
3. Remove the two phillips head screws directly below the glove box release handle that attach the wiring connector bracket to the bottom of the instrument panel. Pull the bracket/connector assembly down to obtain access.
4. Separate the 16 way connector and remove the pink wire with light blue tracer from position 3 of the female side of the 16 way connector.
5. Cut the terminal off the end of the pink wire with light blue tracer and strip approximately 3/8 in. of insulation from the end of the wire.
6. Obtain a 10 foot length of 18 gauge wire (preferably pink with light blue tracer). Strip approximately 3/8 in. of insulation from one end of the wire.
7. Insert the stripped ends of the original and the 10 foot length of pink wire with light blue tracer into new terminal, P/N 5267152. Crimp and solder (use rosin core solder only) the wires to the terminal.
8. Insert the terminal into the position 3 of the female side of the 16 way connector and reconnect.
9. Re-attach the connector/bracket assembly to the bottom of the instrument panel with the two phillips head screws previously removed in step 3.
10. Open the glove box door and disconnect the two plastic door check straps. Let the glove box door hang down.
NOTE:
BE SURE TO NOTE ANY ANTI-BUZZ/SQUEAK/RATTLE (BSR) FOAM AND ENSURE IT IS PROPERLY POSITIONED DURING REASSEMBLY.
11. Remove the screw at rear of the upper A-pillar trim. Pull the upper A-pillar trim up and away from the A-pillar to remove it. There are two "dual lock" fasteners that will separate when the trim is pulled from the A-pillar.
12. Remove the screw from the lower A-pillar trim. Pull the lower A-pillar trim up and away from the A-pillar to remove it.
13. Remove the three screws attaching the right sun visor to the roof.
14. Remove the right and left sun visor clips.
15. Remove the front map/courtesy lamp assembly from the roof by carefully pulling down on the outside edges of the assembly.
16. Route the new 10 foot length of 18 gauge pink with blue tracer wire from the 16 way connector up the right A-pillar and across the roof to the map/courtesy lamp assembly.
17. Disconnect the 3 way connector from the front map/courtesy lamp assembly.
18. Remove the terminal from position 1 of the female half of the 3 way connector with the solid pink wire.
19. Cut the terminal from the end of the wire. Loop the end of the solid pink wire back and place shrink tube, P/N 4778570, over the wire. Heat the shrink tube with a heat gun until the tubing is tightly sealed and sealant comes out both ends of the tubing.
20. Cut the 10 foot length of 18 gauge pink with blue tracer wire to an appropriate length for easy connection to the 3 way connector. Strip approximately 3/8 in. of insulation from the end of the wire. Insert the stripped end of the pink wire with light blue tracer into new terminal, P/N 4604597. Crimp and solder (use rosin core solder only) the wire to the terminal.
21. Insert the new terminal into position 1 of the female half of the 3 way connector and connect the halves of the connector together.
22. Connect the negative battery cable to the battery and verify the front map/courtesy lamps can be turned off by placing the dimmer switch in the defeat position. Also verify the front map/courtesy lamps can NOT be turned off by pressing them when a door is open and the dimmer switch is NOT in the defeat position. If the front map/courtesy lamps can be turned off by pressing them when a door is open and the dimmer switch is NOT in the defeat position, replace the front map/courtesy lamp assembly, P/N 4688546.
23. Secure any loose wiring with duct tape to prevent BSR'S.
24. Re-assemble by reversing steps 10 through 15.
25. Reprogram the customers radio station presets and set the clock.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-90-93 0.8 Hrs.
FAILURE CODE: XX - Service Adjustment