Repair Procedure

This bulletin involves using the extra wire circuit (L36), currently in the harness for use in European vehicles, to run in parallel with the existing brake circuit (L50).

1. Record all radio pre-sets.

2. Hoist vehicle.

3. Remove the left rear wheel and tire assembly.

4. Remove and isolate the negative battery cable.





5. Disconnect the 50 way bulkhead (connector C100) and remove the tape holding the rubber boot to the insulator. Figure 1





6. Locate the L36 (light green/dark blue) circuit in cavity 50 and the L50 (white/tan) circuit located in cavity 20 in the bulk head connector. Figure 2

7. Cut the L36 circuit near the bulkhead connector..

8. Strip the insulation off the end of the wire and splice into the L50 circuit.

9. Slide a piece of heat shrink tubing onto each wire.

10. Connect the two pieces of wire by twisting the ends together.

11. Solder twisted wire ends using rosin core solder.

12. Slide down the pieces of heat shrink tubing to cover the splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only.

13. Install and tape the bulkhead boot.

14. Install the bulkhead connector.

15. Open rear window.

16. Carefully pull back rear trunk carpet and disconnect the 3 way CHMSL connector (C308) from the body harness.

17. Locate the L50 (white/tan) circuit from the 3 way CHMSL (connector C308) takeout to the body harness.

CAUTION:
BEFORE PERFORMING THE NEXT STEP INSURE THAT THE L5O (WHITE/TAN) WIRE LEADS TO THE CHMSL. THERE ARE THREE L5O WIRES IN THE BODY WIRE HARNESS AT THIS POINT.

18. Cut the CHMSL L50 (white/tan) circuit 3" back towards the passenger side.

19. Strip some insulation from the L36 (light green/dark blue) circuit in the body wire harness.

20. Cut the wires and slide a piece of heat shrink tubing onto each wire of the connector wiring.

21. Splice the L50 (white/tan) circuit from the 3 way CHMSL (connector C308) takeout to the L36 (light green/dark blue) circuit.

22. Connect the wire by twisting the ends together.

23. Solder twisted wire ends using rosin core solder.

24. Slide down the pieces of heat shrink tubing to cover each splice. Be careful to center each splice inside the tubing. Heat the tubing to shrink and seal the splice. Use the approved air heat gun only.

25. Wrap the complete splice in tape.

26. Tape the cut end of the L50 (white/tan) circuit.

27. Connect the 3 way CHMSL jumper.

28. Connect the battery and check for normal operation of the brake lamps and CHMSL.

29. If normal operation is found, tape the harness.

30. If brake lamps or CHMSL are inoperative, inspect wire splices and repair as needed.

31. Install rear trunk carpet.

32. Install negative battery cable.

33. Install left rear wheel and tire assembly and lower vehicle.

34. Reset all radio pre-sets recorded in step 1.