2000-2002 Mazda 626 OEM Foglight Installation Instructions.pdf

8/21/2019 2000-2002 Mazda 626 OEM Foglight Installation Instructions.pdf

1/20

it

GENUINE

ACCESSORIES

I

NSTALLATION

I

NSTRUCTI

ONS

FOG

LIGHTS

APPLICABLE

MODELS:

2000>626

PART

NUMBER:

0000-82-A01

{14}

0000-82-A02

(v6l

FOG

LIGHT

PACKAGE

CONTENTS

FOG

UGHT

HOUSING

W BRACKETAND

BULB

iLH &

RH)

EXTERIOF

HARNESS

TOOLS

REQUIRED

W,qA

lt

o()

"u

AWL

PLIERS

SIDE

CUTTEFS

€H;H

n

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DRLL

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\\

1l I

€s ffi

\]

LJLJffi

-r-',iio**

ffi

F'BEF

srlcK

GHEASE

PENCILOR

MAFKING

FLUID

\--\

l--/M

\ t

(yuv

\-A

SAFETY

GOGGLES

PRorEclvE

%

I

J-\--/

**'fJJBHi#''

l;J a [] l-]'o*o'*

[lU

idU

DRILL

BITS

1/8" 3/16" 114"

318',

3rnm 5mm

6mm

10mm

ffifiil

TT

lli,l

FLAT

HEAD

AND

PHILLIPS

HEAD

SCREW DRIVEB

I

lt

I

RATcHET e

ro urur

socrnf

3'EXIENSToN

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lill

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9i16'COMBINATIC

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wD-40

*-@

f-

cRIMP-LocK

(4)

@

_ l-{

H llillnrv.r'rur

rzl

nivruur@

g

BOLT

(2)

g

ffiE

OLLAPSE

g

TOOL

(1)

BIV-NUT

INSTALL

BOLT

(1)

TEMPIATE

(For

LH

&

RH)

\>

WASHERS

(8)

@

i4

I

v

COABSE

THREAD

scRtw

(4)

INSTALLATION BEOUIRES

BEZEL

KIT.

PART

NUh,IBER:

000GAZ-A10-XX

NOTE:

XX=COLORCODE

CONTENTS:

BODY COLOR

BEZELS

{LH

&

RH)

SPACERS

(LH

A

HH)

SPEED

NUTS

(10)

scFEws

(4)

INTERIOR HARNESS

DAYTIME

RUNNING

++

PAGE

1


2/20

Block

1

(Before

lnstallation)

A.

Read through

entire installation

manual

prior

to

performing

installation.

B.

Remove negative

battery

cable and

apply

emergency

brake.

C.

Be sure exterior

of

vehicle

is

clean

and free of dirt

and/or salt.

Block

2

(Grille

Removal)

A.

Using a

tape

wrapped

screwdriver

disengage

the 4 clips

as shown.

B.

Remove

Grille.

Block

3

(Side

Marker

Light

Removal)

A.

Remove

screw affixing

side marker

light.

B.

Carefully

push

side

marker

light

in

direction of arrow

to

disengage

light

from

retaining

clip.

C.

Remove

bulb socket from light

and

carefully

set aside.

D.

Repeat

for

other

side

of vehicle.

{r,W*-;;';

lt t t--

ll

f/ f'

lt

l

1r'


3/20

Block

4

(Front

Bumper

Removal)

A.

Remove 4

plastic

push pins

-

2

per

side.

B.

Remove 10 Phillips head

screws -

5

per

side.

NOTE:

Be

sure to

remove

hidden

screw inside fender

well.

C. Remove 2

-

10mm nuts

-

1

per

side.

D.

Disengage

bumper cover from

clips

on either side

of

grille.

E.

Carefully remove

bumper

and set

aside in a safe non-scratching

area.

t

x

B

A-,

+.eB

Block

5

(Horn

Removal)

A.

Remove

1 - 10mm hex head

bolt

affixing

horn

to

vehicle

body.

B. Remove horn and

set aside.

C.

Repeat

for

other side

of vehicle.


4/20

Block

6

(Bumper

Beam

Preparation)

A.

Affix

supplied

template

to bumper with masking

tape as shown

in illustration.

NOTE:

Affix with

white

side of

template facing out

for

drivers

side and

gray

side out

for

passenger

side.

(White

side of template

faces

outward for

drivers

side,

gray

side out

for

passenger

side).

B. Mark

drill

locations

with center

punch

and remove

template.

C.

Pilot

drill

allfour locations

lo

1lB"

(3mm)

D. Finish

drill

the Outer

holes

(Location

1)to

3iB"

(1Omm).

E. Finish

drill

the

inner

holes

(Location

2)

to 3116"

(5mm).

F.

lnsert

and

compress

Riv-Nut

into 3/8"

(10mm)

outer

holes referenced

in

step

"D"

using

supplied

bolt and

tool

supplied in

kit.

NorE:

see

illustration

for

example

of use

of Riv-Nut

collapsing

tool.

---4

"=4-/

Uncompressed

Compressed

lnboard

Smm

Hole

Coarse Thread

Screw

Location

(LOCAT|ON

2)

Outboard 1Omm

Hole

Riv-Nut

Location

(LOCATION

1)

Note:

White

side

of template

faces

outward

for

drivers

side, Gray

side

faces

outward

for

passenger

side.

NOTE:

Be

sure Bolt Threads

are

lubricated

with WD-40 and &

tooth

side

of

tool

faces Riv-Nut


5/20

Block

7

(Affixing

Light

to

Bumper

Beam)

A. Loosely attach

lamp assembly

to

Riv-Nut in

bumper

using one 6mm

X

30mm

machine thread

bolt, washers,

and shims supplied

in kit.

Tighten

until snug.

(Figure

1)

NOTE:

lnsert one

washer/shim

in-between

the

bracket and the

Riv-nut

(outboard),

and

two

washer/shims in-between the bracket and

bumper surface

(inboard).

See Figure 2 for

example

of shim/washer configuration.

B. lnsert

a

25mm

X 6mm

coarse thread screw

and washer

into

the

5mm

(inboard)

hole

and

tighten until snug.

(Figure

2)

NOTE:

Be

sure

both the bolt and the screw are

not over

tightened,

just

snug.

Washer

Bumper

j/

Reintorcemen{

t

(@

@---1ot'


6/20

Block

8

(Bumper

Fascia

Preparation

-

Cutting

Bezel Opening)

A. Set

bumper

face

down on

a clean non

scratching

surface.

B. Locate the index marks on

the inside

surface

of

the

bumper

fascia.

C.

Using a

Dremel

or

equivalent,

carefully

cut

just

inside the index line.

TIP: To make

the scribed line

more

visible

during

the

cutting

process,

trace

scribed

line on bumper

fascia

with white

paint

or equivalent.

CAUTION:

Be sure when

cutting fascia,

to cut

exactly on or

just

inside index

line

and

keep Dremel

perpendicular

to cutting surface"

D.

After completing

the cutting

process,

use

a

file

or coarse

sandpaper to

remove

any

burrs or high spots around

perimeter

of

bezel

opening.

\

{\


7/20

Block 8A

(Bumper

Fascia Preparation

-

Bezel

Pin Hole)

A. Leave bumper

face down on

a

clean non

scratching

surface.

B. Center

punch

the EXAGT center

location

of each of the ten drill

locations

(5

per

side) on the

inside

of the bumper fascia.

C.

Carefully drill

each

of the

ten

locations

with

a

114"

(6mm)

drill.

NOTE:

Be sure the drill

point

does

not

walk during drilling

process.

This

can

best

be

prevented

by

keeping the

drill

perpendicular

to the drilling surface.

View

From

lnside Fascia


8/20

Block

8B

(Bumper

Fascia

Preparation

-

Bezel

Alignment Pins

-

Continued)

D.

Test

fit

bezel to fascia

and

determine

where

additionalfascia

material

should

be

removed.

NOTE:

Following

drilling, it

will

be

necessary

to

adjust

the

angle

of the

outboard most

hole

location

on the

passenger

and

driver's

side.

See Figure

1.

E.

Using a

thin

round

file,

ream

the outboard

most

hole

to the

same angle

as

the

corresponding

pin

on the fog

light

bezel. See Figure

1.

Gaution:

WHEN

FlLlNG,

Do

NoT FILE

BEYOND THE

ourstDE

EDGE

oF THE

HOLE DESIGNATED

BY FIGURE

2. ADDITIONALLY,

REMOVE

ONLY A

SMALL

AMOUNT

OF

MATERIAL AT

A

TIME WHEN

ADJUSTING

BEZEL

FIT.

-/

y'\,

Figure

1

F

vehicre center

Vehicle

outiuell|

Drill

Angle

Figure

2

Solid

Line indicates

outer

perimeter

of

bezel.

File

Hole

To Match

Outboard

Bezel

Pin

Angle

x

When

adjusting hole

__-f

-1--

--r--\--

_

_-


9/20

Block 9

(Bezel

lnstallation)

A.

Place bezel into corresponding

holes in

bumper.

B.

From the

backside

of the bumper,

place

the

corresponding

spacer over

the

posts

of

the

bezel.

C.

Place a speed

nut

over

each

post.

D. Using

a

suitable tool, firmly

press

each

speed

nut until it is

completely seated

against the spacer

installed

in step

B.

NOTE: A

deep well 7mm

socket

w/extension

is

helpfulwhen

performing

step D.

E.

Confirm that

the

bezel mates

to the bumper fascia well and there are no

gaps

present.

F. Set bumper aside

in

a safe area for re-installation


10/20

Block

10

(Under

hood

Harness

lnstallation)

A.

Remove

fuse

box

cover

located

just

behind

vehicle

battery.

NOTE:

Be

sure

negative

battery

cable

is

disconnected

before

proceeding.

B.

Using

a 1Omm

socket,

remove

and

retain

the bolt

securing

the triple

relay

bracket

to

vehicle.

C.

lnset

bolt

removed

in

step B through:

-

Ground

connector

eyelet

of

the fog light

harness.

- Fog

Light relay,

Triple

relay

bracket,

Threaded

back

lnto its

original

position.

...Andretighten.

NOTE:

The

Negative

lead

of the

fog

light

harness

differs from

the

positive

lead

in

that

the negative

lead

Does

Not

have

an in-line

fuse

holder.

D.

Using

a 1Omm

socket,

remove

the

nut

securing

the

single

wire

positive

lead

to

the

fuse

box.

E.

Remove

the single

wire

positive

lead

connector

from

stud. Place

positive

lead

of fog

light

harness

onto

stud

and

re-install

single

wire

positive

lead.

Route

fog

light

harness

between

battery

and

fuse

box

towards

driver's

side

of

vehicle.

Re-install

fuse

box

cover.

F

G.

Positive

Lead

(Single

Wire)

Triple

Relay

Bracket

Bolt

Fog

Light

Harness

Ground

Location


11/20

Block 11

(Under

hood Harness

lnstallation

-

Continued)

A. Locate white connector taped to

main headlight harness located between battery

and driver's side

headlight.

B. Carefully free white connector

from

main harness

and

connect

to

matching

connector on

Fog

light

harness.

C. Locate and remove headlight

connector from back

of

driver's side headlight.

D. Splice the RED/BLACK

wire

of the headlight

harness and

the

RED/BI-ACK

wire of

the

Foglight harness together using a supplied Crimp-Lock.

Trim

headlight harness

sleeve as

needed

to

crimp at

least 1" away from connector.

E.

Re-connect headlight harness

to

headlight.

ONT

F. Feed

remaining

harness down

through

hole between

headlight

and

battery.

G.

Route harness

to each

fog

light and connect securely.

l. Secure harness

to

thin metal

support

directly behind

bumper

reinforcement

using

2 o'f the supplied

tie

wraps.

ROUTE

HARNESS

DOWN

THROUGH

THIS

HOLE

TOWARDS

FOG LIGHTS

a


12/20

B.

Block 12

(lnterior

Harness

&

Switch

lnstallation)

A.

Locate a vacant

switch

location

to the left of

the steering

column,

just

to the

right

of

the

power

mirror

switch.

Using a fiber

stick, carefully

pry

on top of

switch

blank until

clip disengages.

Repeat

for

bottom edge,

then

remove

switch

blank and

discard.

Mate interior

harness

and fog

light

switch together.

Feed interior

harness

through switch

opening

and

inside

dash to

fuse

box

area.

Do

not

fully insert

switch

into

dash

opening until the

system

has

been tested.

*

lnterior

harness

Wswitch

connected

c.

D.

E.

I

I

I

I

I

i

I

l

v

i


13/20

Block

13

(lnterior

Harness Gonnections)

A. Remove driver's

side

kick

panel.

(SEE

FIGURE

1)

B.

Locate the vehicle

harness

which runs vertically to

left

of the

fuse

panel.

Within this

harness,

locate the

gray

wire.

C.

Using

a

crimp lock,

connect

the GRAY

wire from the vehicle harness to the

matching GRAY

wire

from

the

fog

light harness.

D.

Locate the vertical

23

pin

connector

at

the top

left front

of the

fuse

panel,

disengage

and

remove connector

from fuse

panel.

Within this connector,

locate the RED

wire.

E.

Splice

the

RED

wire

of the headlight

harness

and

the

RED

wire

of

the

Fog light

harness together using

a

supplied Crimp-Lock.

Be sure to apply Crimp-Lock at

least 1" away from

23

pin

connector.

F.

Neatly

tie

wrap

allwires

to the vehicle

harness where

it

can't

be seen by

the

customer.

l^

lll

l"

)

i

I

I

I

I

I

B,C

FIGURE

1

FASTENER

FRONTSIDE

"H

TRIM

PlN.

'rt

\ -.'ll

li.

lh

/b

ijD

ftb


14/20

B.

c.

Block

13A

(u.s.

Vehicles

ONLY

-

without

Daytime

Running

Lights)

A.

Locate

and

disconnect

the

10

pin

connector

next

to

the steering

column.

This

connector

is located

directly

next

to the

yellow

airbag

connector.

E

cut

away

some

of the wire

sheathing

to better

expose the

wires

beneath.

Locate

the

dark GREEN/RED

wire.

Do not

confuse this

wire

with

the

light

GREEN/RED

wire

located

in

the same

harness.

Using

a

crimp lock,

connect

the

dark

GREEN/RED

wire

in

the vehicle

harness

with

the matching

wire in

the

fog

light

harness.

Re-connect

the

10

pin

connector.

Yellow

Air

Bag

Connector

D.

10

Pin

Connector


15/20

Block 138

(Canadian

Vehicles

ONLY WDaytime

Running Lights)

A. Using

a 1Omm

socket,

remove

the

nut at

the bottom of the fuse

panel.

B.

Disengage

the

clip at

the top

of the

fuse

panel

and

gently pull

fuse

panel

away from

body

to

gain

access

to the

rear of

the

panel.

C.

Locate

the

13

pin

black connector and

remove

from

CPU.

D. Using a small screwdriver or terminal

tool,

open

the

terminal

gate

on connector

and

locate the only

vacant

position

in

the

13

pin

connector.

E.

lnsert supplied terminal into

the vacant

position

of

the

13

pin

connector.

NOTE:

Be

sure

the orientation of

the terminal is correct

before trying to

insert it into

the

connector.

F.

Close

terminal

gate

on the 13

pin

connector until it locks into

place.

G.

Splice

the

GREEN/RED

wire

inserted in

step

"E"

to

the GREENiRED

wire of

the

fog

light harness using

a

supplied Crimp-Lock.

H. Re-connect the

13

pin

terminal

to the fuse

panel.

L

Re-attach

fuse

panel

to

vehicle

and tighten 1Omm

nut.

n:ffi:"J#::iil"0"ro,"?.

I

inserting

into connector.

I

I

l

I

I

I

I

i

I

l

l

l

I

/tb

lrn

loi

fn\

NT

VIEW OF REAR

OF

FUSE

PANEL


16/20

Block 14A

(lnterior

Harness

Connections

-

Early Production)

A. Locate the single

white

connector taped to

the

harness

just

above the hood release

cable.

B. Carefully cut tape and

mate this

white

connector

with

the

corresponding white

connector of the

fog

light interior

harness.

CAUTION:

Be sure

the fog light

interior harness is not

tangled

with

the

existing

dash

wiring and components

or

you

may have difficulty reaching

some

of the

connection

points.

Block 148

(lnterior

Harness

Connections

-

Late 2000

Production)

Beginning

with

late 2000

MY

production,

the

single white connector may

not

be

present

as shown

in Block

13A. ln

this

event

you

will

need to

perform

this operation

in lieu

of

Block

134.

A.

Find

the 6

pin

blue

connector

affixed

to

a metal bracket located

between the

steering column

and

fuse

panel.

B. Remove

the

plastic

connector

housing from

the white fog light interior harness.

C.

lnsert

this connector

into

the

only

vacant socket

in

the

blue connector.

NOTE: After insertion, lightly tug

on white wire

of

fog light harness

to be

sure

terminal is

fully

inserted

and

locked into

place.


17/20

Block

15

(Final

Fit &

Adjustment)

Due

to

variability

in the vehicle's manufacturing

process

it

may

be necessary

to adjust

the

light

down

on

the

bumper

reinforcement

to

attain

proper

fog light

fit within

the

bezel.

The

steps below will aid

you

in

determining if

the

lights

will need

adjustment and

how

to

perform

these

adjustments.

A.

Re-install

bumper

fascia in reverse

order

of

removal.

B.

Using the

Tox

head screw

on the

fog

light, adjust light

up

or down to

attain the best

fit within

the

bezel

possible.

C. Step

back

from

the

vehicle and look

at the

gap

between

the bezel and the light.

The

light

should

be centered

in

the

bezel.

o

lf

the light is centered in

the

bezel,

STOP

No additional

adjustment

is

necessary. Proceed

to block 16.

o

lf

the

light

is not

centered

in

the

bezel, proceed to

step

"D".

D. Determine if light

sits too high

or

too low in bezel.

Too High: 1

.

Remove bumper fascia.

2. As

outlined

in

Block

7

-

Figure 2, add

1

additional

shim to

both locations

on both lights. This will move the light

down

within the

bezel.

3.

Reinstall bumper fascia and verify

correct

fit. lf light

still

appears

to fit

too

high

in

bezel

you

may

repeat the

process

and

add 1

additional

shim.

No

more

than

2

shims

may be used.

4. Proceed

to

Block

16

Too

Low:

lf

you

find

that

the

light

fits

too

low

in

the

bezel

another

problem

may be the cause.

lf

you

encounter

this

concern

you

will need to

loosen the bumper

reinforcement and shift it

upwards to

improve fog

light

fit. See

workshop manual

for

this

procedure.


18/20

Block

16

(Upper

Fog

Light

Bracket

Mounting)

After

completing

Block

15

and

you

are

sure

fog lights

fit

acceptably,

you

will

need

to

affix

the

upper

mounting

point

of

the

fog

light

bracket.

Perform

the

steps

below:

A.

Remove

bumper

fascia.

B.

From the

backside

of

the

bumper

reinforcement, push the

top

of

the fog

light

bracket

towards

the front

of

the

vehicle

until it

is flush

with

the

bumper

reinforcement.

C.

Using

an

Awl,

mark the

exact

center

location

within

this

oval

mounting

hole.

D.

Using

a angle

drill

and

a short

1/8"

(3mm)

bit,

drill

a

pilot

hole

for

each

side

of

the

vehicle.

E.

Final

drill

these

same

holes

to

3/16"

(Smm).

F.

lnstall a

coarse thread screw and washer into each hole and tighten.

G.

Complete

tightening

the

lower

bracket

mounting

bolt

and

screw

on

each

side.


19/20

Block 17

(Final

Fascia

lnstallation)

A.

lnstall

bumper fascia

in reverse

order

of

removal.

B.

Using

the

holes

in

the

bezel as a

template, mark drill locations

onto

the

bumper

reinforcement

using

a marker

or

paint.

C.

Drillthe

two locations on

both sides with

a 3116"

(5mm)

bit.

D. lnstall

a bezel mounting

screw

at each one

of

the 4

points.

E. Begin

tightening screws

until screws

start to

"pull-up"

on

the bezel

and

bumper.

NOTE: Do

not

over-tighten bezel

screws

or bezel or bumper

distortion

may occur.

:--l----=

Block

18

(Aiming

Procedure)

A.

Confirm

proper

fog light operation

by turning

on headlights

and

fog

lights.

Fog lights

should operate only on low

beam.

B.

Park vehicle

10

feet from

a clean vertical wall.

Be

sure vehicle is

perpendicular

to

wall.

(See

Block 18A for Fog Light

aiming

diagram).

C.

Measure down

to the

ground

from the center

of

the fog

light.

Subtract

1.5 inches

from

this measurement and

transfer

this

measurement

to

the

wall

with tape.

D.

Turn

on headlights and block beam

by

means

of

a

shop

towel

or

equivalent.

Caution:

Headlights and Fog Lights will

get

very hot

quickly.

Do not leave

covered

lights

on

for

any

extended

periods.

E. Turn Tox

head screw one

way

or

the

other to

raise

or

lower

the

fog light beam to

correct level.

NOTE:

lt

may be

difficult to see fog

light beams

if

ambient

light

is

too strong.


20/20

Block

18A

(Aiming

Diagram)

Horizontal

Centerline of Fog

Lights

Horizontal

Centerline

of Fog

Lights Minus

1.5

inches

\

neaatisnt/

-

Pattern'

\

rogugnt/

--1-

t_

tfr

I

I

Height

of

Fog

Lights

I

I

::l

.il

I

Block

19

(Post lnstallation)

A.

Reinstall

all

panels

and shields

removed

during installation.

B.

Fully insert

fog light

switch

into

dash

opening

until

a click is

heard.

c.

lnspect

allwiring

to be

sure

that

it is

properly

routed

and

secured.

D.

Clean vehicle

as necessary.

E.

Trim

tie wraps

as necessary.

F.

Reset

radio

presets.

INSTALLATION

COMPLETE

Documents

2000-2002 Mazda 626 OEM Foglight Installation Instructions.pdf