fog lamps install kit

fog lamps install kit
FOG LAMPS INSTALL KIT
PT CRUISER
INSTALLATION INSTRUCTIONS
Read entire instructions thoroughly before starting. For proper aiming of fog lamps, follow procedures in the service manual.
NOTES:
•
•
•
Left and right are determined from the driver’s seat (left side).
Fog lamps can only be operated with park and low beams.
This accessory lamp kit conforms with Federal Safety Standards when installed in accordance with the
instructions provided with this kit. State and local regulations may also apply. Please consult local regulatory
and law enforcement agencies in your area for specific details.
TOOLS REQUIRED:
• Large flat screwdriver
• 10mm wrench • Phillips screwdriver • 1/2" drill bit • Drill motor
• Utility knife • Wire routing tool • Electrical tape • Silicone sealant • Hooked pick tool
• Trim stick • 10mm socket • 7mm socket • Socket wrench • T10 torx driver
Item Qty.
CONTENTS:
4
3
1
2
7
Description
1
1
Fog Lamp Harness
2
1
Jumper Wire
3
1
15 amp Fuse
4
1
Headlamp Switch
5
10
Tie Straps
6
1
Right Fog Lamp
7
4
Hex Flange Nuts
8
1
Left Fog Lamp
9
1
Installation Instructions
5
9
6
8
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Upper Column
Shroud
1)
Disconnect air cleaner hose and pull out the air
cleaner assembly to access the battery.
2)
Using a 10mm wrench, disconnect and isolate
the negative battery cable.
3)
Pull down and disengage the I/P knee blocker.
4)
Remove two phillips screws, then disengage and
remove the upper and lower steering column
shrouds.
5)
Remove two phillips screws from the headlamp
switch. Pull out switch and unplug the 20-way
connector.
6)
Check for wiring in cavities 13 and 14 of the
connector.
Headlamp
Switch
Lower Column Shroud
Cavity 13
Cavity 14
20-way Headlamp
Switch Connector
NOTE:
If there is existing wiring present at these locations
it means that the vehicle has been pre-wired for fog
lamps. You will only need to install the new
headlamp switch and fog lamps from the kit.
Proceed to Steps 27 – 28 and 35 – 41.
If wiring is not present at these locations it means
the entire kit must be installed. Proceed with Step 7
or 7a.
Steering
Column
Vehicles with automatic transmission:
Clutch Master
Cylinder Grommet
7)
Fog Lamp
Harness
Drill a 1/2" hole through the unused clutch master
cylinder bulkhead grommet from the driver's
compartment outwards.
Vehicles with manual transmission:
7a)
Open a 1/2" slit in the main wire harness bulkhead
grommet from the driver’s compartment outwards.
8)
Using a wire routing tool, pull the fog lamp
harness (Item 1) into the driver’s compartment
approx. 1" past the last take out.
Main Wire
Harness Grommet
9)
Important: Close opening in the grommet with
silicone sealant to prevent noise and odor
intrusion.
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Cavity 14
Cavity 13
Pink/Green
10)
Carefully remove locking wedge from the 20-way
headlamp switch connector.
11)
Remove wire routing tool from fog lamp harness.
Route fog lamp harness up along the steering
column harness and insert pink/green and light
blue wires as shown.
12)
Re-install locking wedge to the connector.
13)
Pull four HVAC knobs straight out of the center
I/P cluster bezel.
14)
Remove center cover, then remove bezel
mounting screw and bezel.
15)
Remove two phillips screws from the I/P top
cover as shown. Lift up and back on the cover
just above the I/P cluster and disengage two
retaining clips.
16)
Remove two phillips screws from the lower left
I/P panel. Disengage three retaining clips and
one connector, then remove the panel.
17)
Remove I/P cluster bezel. Remove four cluster
mounting screws and the cluster.
18)
Remove four connector panel mounting screws
and the panel.
19)
Slip the 8-way cluster connector out of its mount.
Carefully pull the locking wedge from the
connector.
20)
Insert fog lamp harness blue wire as shown.
21)
Re-lock the locking wedge, and re-mount the
connector.
22)
Re-install connector panel, I/P cluster, and cluster
bezel.
Lt. Blue
20-way Headlamp
Switch Connector
Center I/P
Cluster Bezel
Center Cover
I/P Top
Cover
Blue
I/P Connector
Mounting Panel
Cavity 1
8-way I/P Cluster
Connector
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Jumper Wire
23)
Remove two phillips screws from the fuse block
holder. Carefully pull out yellow locking wedge
from the fuse block that surrounds the fuses.
24)
Remove jumper wire (Item 2) from the fog lamp
harness. Insert jumper wire and pink/green wire
as shown.
25)
Re-install locking wedge. (Use a pocket knife to
align fuses to slots in the wedge.) Re-install the
fuse holder.
26)
Insert supplied 15 amp fuse ( Item 3) into cavity
#8 of the fuse block.
27)
Remove existing headlamp switch from multifunction switch and install supplied headlamp
switch (Item 4) using a T10 torx driver.
28)
Install switch assembly to steering column. Plug
and lock 20-way connector into the headlamp
switch.
29)
Using a few of the supplied tie straps (Item 5),
secure fog lamp harness to the steering column
harness and I/P harness.
Pink/Green
Cavity 28
Fuse Holder
Cavity 8
Multi-Function
Switch
CAUTION !
Headlamp
Switch
Fog Lamp Harness
Make sure to secure the fog lamp harness away
from any heated or moving parts.
30)
Connect and re-install the lower left I/P panel.
31)
Carefully engage two retaining clips on the I/P
top cover.
32)
Re-install two top cover mounting screws, center
cluster bezel and mounting screw, and center
cover.
33)
Re-install upper and lower steering columns
shrouds and knee blocker.
34)
Inside the engine compartment route fog lamp
harness forward and down between the battery
and the left inner fender.
Left Inner
Fender
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Lower
Horn
35)
Ensure that the steering wheel is unlocked, then
raise and secure the vehicle on a lift.
36)
Position the right front tire outwards. Using a
7mm socket, remove two forward-most screws
and one push-in fastener from the wheelhouse
splash guard.
37)
Using a 10mm socket, remove bolt that attaches
the lower mounted horn to the right frame rail.
38)
Disengage two snap clips that attach the right
fog lamp blank to the fascia opening. Remove
and discard the blank.
39)
From inside the fascia, place right fog lamp
(Item 6) into the opening as shown. Secure in
place with supplied hex flange nuts (Item 7) using
a 10mm socket.
40)
Plug and lock fog lamp harness connector into
right fog lamp.
41)
Repeat procedure to install the left fog lamp
(Item 8).
42)
Using 7mm socket, install power harness ground
wire to the vehicle as shown.
43)
Tie strap power harness to the lower radiator
support.
44)
Lower the vehicle. Re-connect negative battery
cable, then re-install air cleaner assembly.
45)
Refer to the service manual for proper aiming
procedure.
46)
Test the fog lamps using procedure on Page 6.
Fog Lamp
Blank Clips
Right Fog
Lamp
Right Fog Lamp
Connector
Fog Lamp Harness
Ground Wire
Front Fascia
Lower Radiator
Support
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Wiring and components shown are supplied with kit. When the fog lamp switch is closed, the switch
sends 12v to the fog lamps. The 12v is supplied to the headlamp switch at pin 13 from the HI beam relay
circuit. When the HI beams are turned ON, the fog and low beams turn OFF. The ground is provided by
the eyelet on the lower radiator support. Power is supplied to terminal #1 on the instrument panel to light
the “FOG” symbol on the display.
TEST PROCEDURE:
Fog lamps will only work with the park lamps or headlamps ON and set to LOW-BEAM. The fog
lamps are turned ON when the end of the headlamp switch is pulled out. The indicator lamp in the
I/P cluster will only light up if the park lamps are ON or headlamps are on LOW-BEAM and the
switch is ON.
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