L-SB-0168-17

Headlamp Durability Enhancement
Service
Category
Vehicle Exterior
Section
Lighting (ext)
Market USA
Applicability
YEAR(S)
MODEL(S)
2011 - 2013
CT200H
ADDITIONAL INFORMATION
Introduction
Some 2011 – 2013 model year CT 200h vehicles may exhibit a condition where a halogen low
beam headlamp bulb lifetime is shorter than customer expectation. A modified wiring harness is
available to address this condition.
Warranty Information
OP CODE
DESCRIPTION
TIME
EL1708
Install No. 4 Wire Harness with Headlamp
Alignment (One Side)
1.7
EL1708A
Other Side
1.2
OFP
T1
T2
90981-13075
72
71
APPLICABLE WARRANTY
 This repair is covered under the Lexus Basic Warranty. This warranty is in effect for
48 months or 50,000 miles, whichever occurs first, from the vehicle’s in-service date.
 Warranty application is limited to occurrence of the specified condition described in
this bulletin.
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Page 2 of 10
Headlamp Durability Enhancement
Parts Information
PART NUMBER
PART NAME
QTY
04007-52147
Repair Kit, Headlamp Bulb
1
PART NUMBER
PART NAME
QTY
90981-13075
Bulb
2
82114-47010
Engine Wire No. 4
2
82999-52010
Sleeve Tube
2
82999-30010
Heat Shrink Tube
2
Headlamp Bulb Repair Kit Parts
Required Tools & Equipment
SPECIAL SERVICE TOOLS (SST)
PART NUMBER
QTY
Plastic Pry Tool Kit*
00002-06020-02
1
Terminal Removing Tool “F”
09991-00510
1
Wire Crimper*
09042-2C100
1
* Essential SST.
NOTE
Additional SSTs may be ordered by calling 1-800-933-8335.
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REQUIRED TOOLS & MATERIAL
QUANTITY
Nylon Ties
15
Measuring Tool (Metric Ruler)
1
Heat Gun
1
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Headlamp Durability Enhancement
Repair Procedure
1. Replace the headlamp bulbs.
2. AFTER confirming the headlamps work, verify headlight aim is visually correct and that there
are no signs of damage or alterations to wiring.
NOTE
If a NEW bulb has been installed and the bulb is still inoperative, this bulletin does NOT apply.
Continue diagnosis using the applicable Repair Manual.
3. Remove the front bumper cover assembly.
Refer to the Technical Information System (TIS), applicable model and model year
Repair Manual:

2011 / 2012 / 2013 CT 200h:
Vehicle Exterior – Exterior Panels/Trim – “Exterior Panels / Trim: Front Bumper: Removal”
4. Remove the affected headlamp assembly.
Refer to TIS, applicable model and model year Repair Manual:

2011 / 2012 / 2013 CT 200h:
Vehicle Exterior – Lighting (Ext) – “Lighting (Ext): Headlight Assembly
(for Halogen Headlight): Removal”
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Page 4 of 10
Headlamp Durability Enhancement
Repair Procedure (Continued)
Figure 1.
1
6
8
2
5
7
3
4
8
1
Terminal Rem oving Tool “F”
5
Rem ove Violet Wire Harness from Connector
2
Headlam p Bulb No. 2 Connector
6
Front View
3
Engine ROOM Main Wire Harness (White-Black)
7
Cross Section
4
Engine ROOM Main Wire Harness (Violet)
8
Lock
5. Modify the existing headlamp harness and install the engine wire No. 4 harness.
NOTE
This wiring harness extends the factory headlamp wiring harness and will be placed
between the headlight socket and existing headlamp wiring harness. The harness will be cut
with a special crimping tool to make an adequate crimp. It is important to use the suggested
crimp tool and follow the instructions below to ensure a proper crimp.
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Page 5 of 10
Headlamp Durability Enhancement
Repair Procedure (Continued)
A. Remove the green cap from the
headlamp connector by carefully using
a small screwdriver or pick to detach the
cap as shown.
Figure 2.
B. AFTER the cap is removed, remove terminal 2 (violet wire) from the low beam headlight
connector wire using terminal removing tool “F.”
SST: P/N 09991-00510
(1) AFTER the terminal cap is removed,
gently insert the terminal removing
tool “F” into the connector between
the terminal and the terminal lock
(see Figures 1 and 3), then gently
push the terminal lock to the
outward side of the connector.
Do NOT overstress the lock or it
will NOT properly hold the terminal
when reassembled.
Figure 3.
1
NOTICE
When inserting terminal removing
tool “F,” pry carefully outward just
enough to remove the terminal
from the wire side. Excessive
pressure may damage the lock or
bend the tool.
(2) As the lock is held outward, gently
pull on the violet wire from the back
of the connector to remove it.
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1
Terminal Lock
Page 6 of 10
Headlamp Durability Enhancement
Repair Procedure (Continued)
C. Insert the terminal of engine wire No. 4
(white-black) into the headlamp bulb
No. 2 connector.
Figure 4.
1
2
3
1
Headlam p Bulb No. 2 Connector (Low Beam)
2
Insert Engine Wire No. 4 into Terminal
(White-Black)
3
Engine ROOM Main Wire Harness
(White-Black)
D. Cut the violet wire previously removed from the headlamp bulb No. 2 connector near
the terminal.
E. Remove the wire outer coat insulation
10 mm from the edge.
Figure 5.
1
3
4
NOTE
Measure the length of the wire
carefully to ensure the wire
fits properly.
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5
2
1
Engine ROOM Main Wire Harness (Violet)
2
Cut Here
3
Strip Off 10 m m of Insulation
4
Wire Insulation Coat
5
10 m m
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Headlamp Durability Enhancement
Repair Procedure (Continued)
F. Remove 10 mm of the wire outer coat
insulation from engine wire No. 4
(white-black wire).
Figure 6.
3
1
2
4
1
Strip Off 10 m m of Insulation
2
Wire Insulation Coat
3
Engine Wire No. 4
4
10 m m
G. Insert a section of heat shrink tubing (P/N 82999-30010) over the engine wire No. 4.
H. Insert the stripped bare wires into the sleeve tube (P/N 82999-52010), ensuring the wires
overlap in the center of the crimp.
I.
Using the wire crimper, apply a 2 crimp
to the center of the sleeve tube.
SST: P/N 09042-2C100
NOTE
The wire crimper tool handles MUST
be fully depressed for them to release,
so verify alignment is proper prior to
applying pressure to crimper handles.
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Figure 7.
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Headlamp Durability Enhancement
Repair Procedure (Continued)
J. Apply one additional crimp on both
sides of the center crimp, as shown.
Figure 8.
1
c
2
K. Slide the heat shrink tubing over the
crimp and apply sufficient heat with a
heat gun to close the heat shrink around
the wire insulation.
1
Apply a 2 Crim p Here
2
Crim ped Sleeve Tube
Figure 9.
1
2
1
Heat Gun
2
Shrink Tube
L. Insert the headlamp connector back into the headlamp socket.
M. Test for normal high and low beam headlamp operation with the headlamp temporarily
connected to the wiring harness.
6. Reinstall the headlamp assembly.
Refer to TIS, applicable model and model year Repair Manual:

2011 / 2012 / 2013 CT 200h:
Vehicle Exterior – Lighting (Ext) – “Lighting (Ext): Headlight Assembly
(for Halogen Headlight): Installation”
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Page 9 of 10
Headlamp Durability Enhancement
Repair Procedure (Continued)
7. Install the engine wire No. 4 wire harness on the driver or passenger side. Be sure to attach
nylon ties less than 100 mm apart.
NOTE
 Each nylon tie should be located no more than 100 mm from the next one.
 There should be no free play between the factory harness and the engine wire No. 4 wire
harness loom.
 The ties should face outside the vehicle.
 Be sure to trim the ties AFTER application.
A. Driver Side Installation:
(1) Install the connector from the engine
wire No. 4 harness connector into
the headlamp assembly.
(2) Route the No. 4 harness by
following the contour of the current
harness. (Test fit routing as
necessary to ensure fit.)
(3) Apply nylon ties less than 100 mm
from each other, facing outward.
NOTE
Seven tie wraps are needed for the
driver side.
(4) Trim the nylon ties AFTER installation.
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Figure 10. Nylon Ties Less Than 100 mm Apart
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Headlamp Durability Enhancement
Repair Procedure (Continued)
B. Passenger Side Installation:
Figure 11. Nylon Ties Less Than 100 mm Apart
(1) Plug the engine wire No. 4 harness
connector into the
headlamp assembly.
(2) Route the No. 4 harness by
following the contour of the current
harness. (Test fit routing as
necessary to ensure fit.)
(3) Apply the nylon ties less than
100 mm from each other,
facing outward.
NOTE
Eight tie wraps are needed for the
passenger side.
(4) Trim the nylon ties AFTER installation.
8. Reinstall the bumper cover.
Refer to TIS, applicable model and model year Repair Manual:

2011 / 2012 / 2013 CT 200h:
Vehicle Exterior – Exterior Panels/Trim – “Exterior Panels/Trim: Front Bumper: Installation”
9. Adjust headlamps.
Refer to TIS, applicable model and model year Repair Manual:

2011 / 2012 / 2013 CT 200h:
Vehicle Exterior – Lighting (Ext) – “Lighting (Ext): Headlight Assembly
(for Halogen Headlight): Adjustment”
10. Verify normal operation of ALL affected systems.
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