It seems that last year the positive battery terminal came out of the battery. No big deal, I replaced the battery and it was all good.

Afew months later the head lights quit working. After chainging the switch on the column, new bulbs and all sorts of stuff no go. My father in law put a voltage tester on the head light plugs and got voltage there (which really means nothing).

Anyways, today my wife took it to a pontiac dealership and paid for them to diagnose the problem. Turns out battery acid leaked out of the battery and ate up the wiring/module that is under the battery tray. The dealership wants $600 to fix it. I think I can do it for less than $200. What I would like to know is if anybody has any schematics or wiring diagrams.

My goal is to snag a JY module with the plugs and about 6 inches of wiring and replace the whole mess. I'm hoping that all the wires will match up with color coding, but don't hold out much hope of that working out.

I havn't seen it for myself and won't have a chance to tear into it until monday morning. So most everything above is a best guess. Any thought, ideas, tips, experience or anything else would be awesome.

you dont really need the whole harness........remove the d/s inner wheel well and remove the washer jug.....if it is like the other cavaliers that i have seen there is a head light splice in that harness that runs between the frame and washer jug.....the wire should have some green crap in it causing the lights not to work.....just replace that section of wire and make sure you solder the conections and use shrink wrap to seal them properly then your good to go......

If this is for the sunfire in your registry, I have some info that might help you.

You might need these part numbers if you are going to replace one or more individual pins in the harness.

thin pin p/n: 15326268
wide pin p/n: 15304730

Here is a link to a website that shows the harness and pins you might need to replace: http://www.powerandsignal.com/docs/Catalog/GTmixed.pdf

I have the wiring diagram somewhere. I'll try to find it for you.

If you could list exactly what is happening to your headlights, I might be able to help more. For example, is only one light working? Do the DRL's work?

Thanks, I have the paper at my mother in law's with the estimate from the dealership (with part numbers). I'll compaire it to what you listed, but I'm fairly certain it's the same. Those harnesses are like $100 a pop from the dealership.

Socksrocker wrote:If you could list exactly what is happening to your headlights, I might be able to help more. For example, is only one light working? Do the DRL's work?

Sorry I missed the rest of your post. I have no DRL's, low beams, or high beams on both sides. I've replaced the switch on the column, new bulbs, and all the common stuff.

I paid a pontiac dealership to diagonose the problem, and they said it was the wiring and connectors below the battery tray. I still need to confirm the part numbers you gave me with the estimate I got from them.

When you put the car in gear with the lights turned off, the headlights and the DRL indicator light blink like 5 times, then the service light comes on. If you turn the headlights on before you put it in gear, the head lights do not come on, but the service light does not come on.

Wow, it sounds like you have replaced everything except that connector under the battery.

Not having either of the lights work would require that two or more pins in the harness are bad. It sounds like you are going to have to get to that connector and start testing for continuity.

I have a wiring schematic for an 02 cavalier's headlight system I can send you. I am almost certain that the wiring is the same between my cav and your sunfire. Hopefully someone can chime in and confirm this for us. I will send it to the email address in your profile since you asked for it in your original post.

You sound like you have a good handle on what you are doing, but if you need help using a multimeter to test for continuity or where you should have continuity, just ask.

The tech at the pontiac dealership gave me an invoice with part numbers that tells exactally what I need. There are 2 wiring connectors below the battery tray that need replaced.

What happened is the positive battery terminal pulled out of the old (AC Delco) battery and splashed battery acid down on the connectors and wiring. So I know exactally what I need to replace. I just need to find the time to tear it down, take an inventory of exactally what I need parts, tools, and materials, and then put it together. I dunno how much of the wiring that goes to the plugs are eaten up, so I don't want to buy the parts till I see if I need to hit the yard for large chunk of the headlight harness or not.

The wiring harness would be awesome. I'd much perfer just hitting the hard and splicing the wires up color by color, but my father in law wants to buy the connectors from AC Delco and have me rewire it myself.

It seems like either way, you are going to be tearing into those harnesses.

Good luck with whatever you choose to do and don't hesitate to ask for more help if you need it.

Ok, I'm looking at the invoice. The part numbers for the connectors I need are 15306122 & 15306348. One is listed as $106 and the other is listed as $103.

I probably won't get a chance to tear into the car until next week. I've got to clean out garage space for the car before I start tearing the car down.

Tim, just for the heck of it I checked out those part numbers on gmpartsdirect.com. Even by their list price, the dealership is way overcharging you. If you can't find those connectors at a junk yard in your area and you can wait about two weeks, gmpartsdirect.com is your next best bet to get them. They have them both and run $48.21 and $47.04 plus shipping. Looks like you could get them both from them for what you would pay for one at the dealership. Just thought I would give you another avenue to go incase you can't find them in your area. Good luck!!



98 Z24

RIP Specks