Automatic Headlight Sensor Repair Kit (12-136-12)

AUTOMATIC HEADLIGHT SENSOR REPAIR KIT

TECHNICAL SERVICE BULLETIN

INTRODUCTION

The purpose of this bulletin is to provide the proper procedures for installation of the Automatic Headlight Sensor repair kit. If you receive a customer concern of the headlights not coming on as darkness approaches (dusk conditions) with the headlight function switch set to "Auto" mode, a repair kit for the light sensor is now available to correct the condition. If the light control sensor fails, the headlights will not come on in "Auto" mode under any circumstances. However, the headlight function switch will continue to operate in the other two modes.

COUNTERMEASURE IN PRODUCTION

A countermeasure was incorporated at the 2013 MY start of production.

PART INFORMATION

NEW PART DESCRIPTION	PART NUMBER
Light Control Sensor	84088AJ000
Repair Kit	84089AJ000

SERVICE PROCEDURE

Confirm the sensor is failed by following the Auto Headlight System Check diagnostic procedure outlined in the applicable Service Manual.

After initial diagnosis is complete and it is determined the adapter harness is required, do not proceed further until recording the customer's radio station presets and disconnecting the battery terminals.

Remove the glove box lid assembly and back panel per the instructions in the applicable Service Manual.

Being extremely careful not to damage the surrounding dash trim surfaces, release the claws and clips as shown then remove the speaker grille using a plastic trim tool.

Squeeze the retaining claws on the light control sensor and push it out of the speaker grille. Then, disconnect the harness connector, remove the sensor and the exposed dash speaker.

Inspect the light sensor harness connector i194 shown below. If the wire in pin #3 is GR (green/red) or G (green), proceed with installation of the adapter harness and the replacement light control sensor.

Connector i194, as shown from the harness (back) side with a GR wire in terminal #3. 

Release the terminal lock as shown below to allow the wire in pin #3 to be removed from the connector using the release tool supplied in the harness kit.

Make sure the release tool is inserted in the proper location as shown above right or connector damage can result affecting its ability to retain the new adapter harness terminal.

Once the wire/connector has been removed, cut the terminal off the body harness wire as close to the end of the terminal as possible.

Carefully strip about 5/8" (15mm) of insulation from the body harness wire and from the end of the GR wire in the adapter harness kit. It is recommended to use the joint terminals included in the harness kit as shown to provide the best electrical continuity.

After staking the joint terminal with the proper tool, heat it with the tip of the soldering iron. Once the solder starts to flow after touching it to the heated terminal, allow the solder to sink into the wires and joint terminal to make the best connection. Once the soldered connection has cooled, wrap it with a piece of the butyl rubber material supplied in the harness kit. Then, apply a final wrap of the joint connection with electrical tape as shown below.

Firmly insert the adapter harness' W (white) wire terminal back into connector i194 pin #3 in the proper orientation as shown below. Make certain it locks into position properly with a "click" then pull on the wire lightly to make sure it does not come loose. Be sure to give it a final check after returning the terminal lock back to the "locked" position.

Secure the adapter harness to the body harness with electrical tape as shown.

Feed the harness back into the dash making sure it runs in FRONT of the vent duct. Route the harness along the right side of the blower case making sure it does not interfere with any of the surrounding components. Leave enough of the harness accessible on the top end to allow connection of the light sensor. Once the adapter harness is properly positioned, secure it to the main body harness using the tie wraps supplied in the kit. Cut off the excess ends of the tie wraps as shown below.

Confirm normal operation by following this procedure after reconnecting the vehicle battery terminals:

STEP	CHECK	YES	NO
1) Inspection of harness  -Remove the connector from the Light Control Sensor. -Turn on the ignition switch. -Measure the voltage between the Light Control Sensor connector and body ground. Connector&Terminal (i194) No.3 (+) to Body ground (-)	Is the voltage 9V or more?	Install the new Light Control Sensor then proceed to (2).	Check for proper soldering and connections of the Adapter Harness. If judged N/G, check the upstream circuits of the body harness for proper voltage or poor contact.
2) Check of Light Control Sensor  -Connect the connector of the Light Control Sensor. -Turn on the ignition switch. -Set the lighting switch to AUTO position. -Connect SUBARU Select Monitor and read the data of the wave form between the connectors of the Light Control Sensor. Connector&Terminal (i194) No.4 to No.6	Is the wave form normal? (The brighter the ambient light gets, the narrower the width "A" gets.)	Procedure to install Adapter Harness is complete. Proceed with reinstallation of the removed parts.	Replacement Light Control Sensor may be defective.

Once normal operation of the sensor is confirmed, reinstall the dash speaker, speaker grille, back panel and the glove box lid assembly. The inside of the windshield will need to be cleaned before returning the car to the customer.

To complete the installation procedure, confirm normal operation of the auto light function by following the 6 steps listed below. Check the on/off operation of the auto light function outdoors in daylight conditions as the auto light function may turn the headlights on if the vehicle is tested indoors.

1. Turn the ignition switch "ON"
2. Set the headlight switch to the "AUTO" position
3. Cover the auto light sensor with a thick cloth or suitable material.
4. Verify the headlights come on.
5. Remove the cover from the auto light sensor and verify the headlights shut off.
6. Reset all the radio station presets and the clock.

WARRANTY/CLAIM INFORMATION

If only the Illumination Sensor was found to need replacement, use the following coding information: 

LABOR DESCRIPTION	LABOR OPERATION#	FAIL CODES	LABOR TIME
Headlight Illumination Sensor	B838-251	DXD-38,39,42	0.2
Exterior Light System Testing	C838-001		0.5

If the Repair Harness is installed, use the following coding information: 

LABOR DESCRIPTION	LABOR OPERATION#	FAIL CODES	LABOR TIME
Automatic Headlight Sensor Repair Kit Installation	A888-251	DXV-48	1.3