TSBELE093

GROUP
ELE
MODEL
2014~2015MY
Soul (PS)
NUMBER
093
DATE
December 2015
TECHNICAL SERVICE BULLETIN
SUBJECT:
HEADLAMP BULB CONNECTOR REPLACEMENT
This bulletin provides information about replacing the bulb connector in the headlamp assembly
on some Soul (PS) vehicles, equipped with non-projector style headlamps and produced from
August 26, 2013 through April 20, 2015, which may exhibit a heat-deformed headlamp bulb
connector. To correct this concern, replace the affected headlamp bulb connector by following
the procedure outlined in this TSB. NOTE: vehicles equipped with projector-style
headlamps are NOT affected.
Contents (per kit)
Figure
1. Headlamp Bulb Connector (x1)
①
②
2. Heat Shrink Tube (x3)
3. Crimp-on Connector (x4)
③
4. Split Wire Loom (x1)
④
 NOTICE
Do NOT replace the headlamp assembly for the connector concern, as described
above. Unnecessary headlamp assembly replacement claims may be subject to
charge-back.
File Under: 
Circulate To:
x General Manager

x Service Advisor(s)

x Service Manager

x Parts Manager

x Technician(s) 
x Body Shop Manager  Fleet Repair

Page 2 of 10
SUBJECT:
HEADLAMP BULB CONNECTOR REPLACEMENT
Service Procedure:
1. Record the customer’s radio presets.
2.
Disconnect the battery terminals and
remove the battery (A) from the
vehicle.
A
3.
4.
Remove one (1) bolt securing the
junction box (B) to the chassis. Then,
move the junction box inward to allow
for greater access to the back of the
headlamp housing.
B
Remove the headlamp dust cap (C) from
the headlamp housing.
C
TSB: ELE 093 Soul (PS) December 2015
Page 3 of 10
SUBJECT:
5.
HEADLAMP BULB CONNECTOR REPLACEMENT
Disconnect the headlamp connector
(D) from the bulb and confirm heat
deformation. If heat deformation is
confirmed
on
either
headlamp
connector, replace the connectors on
BOTH the RH and LH headlamp
assemblies.
D
Headlamp removed from vehicle for illustration purposes
6.
Use a pair of wire cutters to remove the
connector (E) from the headlamp
wiring harness. NOTE: cut the wires
as close to the base of the
connector as possible.
E
TSB: ELE 093 Soul (PS) December 2015
Page 4 of 10
SUBJECT:
HEADLAMP BULB CONNECTOR REPLACEMENT
7.
Inspect the bulb to make sure that
there is no heat damage present.
NOTE: if the bulb is damaged,
replace as necessary.
8.
Use a pair of wire strippers to strip
10mm (0.4”) from the three (3)
headlamp harness wires (F), as shown.
Normal Bulb
F
TSB: ELE 093 Soul (PS) December 2015
Heat Damaged
Page 5 of 10
SUBJECT:
9.
HEADLAMP BULB CONNECTOR REPLACEMENT
Use a pair of wire strippers to strip
10mm (0.4”) from the three (3)
replacement headlamp connector (G)
wires, as shown.
G
10.
Insert one (1) heat shrink tube (H) onto
each of the three (3) headlamp
harness wires. NOTE: be sure to
push the heat shrink tubes into the
headlamp housing to allow for
working space.
H
TSB: ELE 093 Soul (PS) December 2015
Page 6 of 10
SUBJECT:
11.
HEADLAMP BULB CONNECTOR REPLACEMENT
Use a pair of wire cutters to separate
the crimp-on connectors (I), as shown.
I
12.
Insert the loose stranded wires from
each harness wire into each other, as
shown. NOTE: make sure the wire
pairs are matched by color.
13.
Use a crimp-on connector (J) to
connect each wire from the headlamp
harness to the wires on the
replacement headlamp connector.
J
TSB: ELE 093 Soul (PS) December 2015
Page 7 of 10
SUBJECT:
HEADLAMP BULB CONNECTOR REPLACEMENT
14.
Use a pair of wire crimpers to secure
the crimp-on connector in place, as
shown. Repeat crimping operation on
the remaining two (2) wire pairs.
15.
After crimping all three (3) connections,
perform a pull test on each of the
crimped joints (K) to verify a secure
mechanical connection.
K
16.
Using suitable soldering equipment,
apply solder (Rosin Core 60/40) to all
three (3) crimped connections (L), as
shown.
L
WARNING
•
Do NOT use acid core /
plumbing solder to perform the
repair.
•
Use care when using the
soldering tool to avoid damage
to the harness or possible
personal injury.
TSB: ELE 093 Soul (PS) December 2015
Page 8 of 10
SUBJECT:
17.
HEADLAMP BULB CONNECTOR REPLACEMENT
Slide three (3) heat shrink tubes (M)
over the three (3) soldered connections
on the headlamp harness.
M
18.
Use a heat gun to shrink all three (3)
heat shrink tubes (N) tightly over the
headlamp harness wires. NOTE: set
the heat gun to between 200 °F and
300 °F.
N
CAUTION
To prevent damage to the wiring
harness, do NOT use an open
flame, such as from a torch or
lighter, to shrink the tubes.
19.
Insert the split wire loom (O) over the
headlamp harness, as shown. NOTE:
be sure to insert the split wire loom
far enough into the headlamp
housing to allow for some exposed
wiring harness near the connector.
TSB: ELE 093 Soul (PS) December 2015
O
Page 9 of 10
SUBJECT:
20.
HEADLAMP BULB CONNECTOR REPLACEMENT
Insert the replacement connector (P)
onto the bulb and reinstall the
headlamp dust cap.
P
21.
Repeat the procedure above on the
passenger side headlamp starting from
step 4.
22.
Reinstall the junction box in place.
23.
Reinstall the battery in the vehicle.
24.
Verify proper headlamp bulb operation
(high and low beam).
25.
Restore the customer’s radio presets,
as recorded in step 1.
TSB: ELE 093 Soul (PS) December 2015
Page 10 of 10
HEADLAMP BULB CONNECTOR REPLACEMENT
SUBJECT:
AFFECTED VEHICLE PRODUCTION RANGE:
Model
Production Date Range
Soul (PS) (Excl. Exclaim models)
From August 26, 2013 through April 20, 2015
REQUIRED PART:
Part Name
Part Number
Qty.
Headlamp Connector
Repair Kit
92170 B2270FFF
2
Figure
RELATED PART:
Part Name
Part Number
Headlamp Bulb
Figure
18647 60559
WARRANTY INFORMATION:
Claim
Type
W
Causal
P/N
92102
B2270
Qty.
0
N
Code
A31
C
Code
Repair
Description
Labor Op
Code
Op
Time
Replacement
P/N
Qty.
ZZ2
(ELE 093)
Headlamp
Connector
Replace
(LH/RH)
92102F00
0.6
M/H
92170
B2270FFF
2
TSB: ELE 093 Soul (PS) December 2015