Trap-Resistant Trunk Kit Installation Procedures (99-T-50)

TRAP-RESISTANT LATCH AND INTERIOR RELEASE HANDLE INSTALLATION

1. Remove the 10A BODY fuse from instrument panel fuse block.
2. Open decklid.
3. Remove decklid latch retaining bolts.
4. Disconnect vehicle interior release cable.
5. For Sedans, disconnect lock cylinder rod from latch. For Coupes, remove lock cylinder rod from vehicle.
6. Disconnect electrical connectors.
7. Remove existing decklid latch and discard. Refer to Fig 1 .
8. Cut out center of interior release handle template and place over interior release handle.
9. Select hole locations on template for appropriate vehicle type and model year.
10. Mark hole location(s) on release handle as shown on template. Refer to Fig 2 .
11. Drill 3 mm (1/8 in.) hole at marks on handle. Refer to Fig 3 .
12. Install decklid lock cylinder rod to lock cylinder and new latch. Refer to Fig 4 .
    • For Coupes, install new lock cylinder rod (included in kit).
    • For Sedans, use grinder or wire cutter and carefully remove 2 mm (5/64 in.) of length from latch end of existing lock cylinder rod.
    IMPORTANT: Vehicles equipped with or without the remote keyless entry (RKE) feature use the same trap-resistant latch that is included in the kit. This latch will function properly on all vehicles.
13. Reconnect vehicle interior release cable end fitting into lower slot of new trap-resistant latch, and clip cable conduit to latch housing. Refer to Fig 5 .
14. Insert release handle cable end fitting into upper slot of new trap-resistant latch, and clip cable conduit to latch housing.
15. Install trap-resistant latch-to-decklid retaining bolts. Torque: 10 N-m (89 In -lbs). Refer to Fig 1 .
16. Connect cable end fitting to release handle lever on back side of release handle.
17. Connect cable conduit to release handle housing.
18. If not already connected, connect release handle wiring harness (included in kit) to release handle. Refer to Fig 6 .
IMPORTANT: Due to stiffness of cable conduit, it may be necessary to pre-bend cable conduit prior to handle installation.
19. Align handle to deck lid sheet metal as shown on appropriate model year. Refer to Fig 8 and Fig 9 .
20. Using the release handle as a template, mark one hole location on decklid sheet metal. Refer to Fig 7 .
    NOTE: If drill bit is allowed to drill into sheet metal at a depth greater than 6.5 mm (1/4 in.), outer surface of exterior panel may be penetrated.
    IMPORTANT: Due to stiffness of cable conduit, it may be necessary to pre-bend cable conduit prior to handle installation.
21. Center-punch and drill 3 mm (1/8 in.) hole at mark on decklid. Refer to Fig 10 .
22. Install release handle with one release handle-to-decklid fastener (P/N 11515005 included in kit). Torque: 2.6 N-m (23 in-lbs).
23. Using interior release handle as a template, align release handle to decklid according to appropriate model year illustration selected from step 20.
24. Drill 3 mm 1/8 in.) holes at remaining attachment locations and install remaining release handle-to-decklid fasteners (P/N 11515005 included in kit). Torque: 2.6 N-m (23 in-lbs). Refer to Fig 11 .
25. Install cable clip to release handle cable. Refer to Fig 12 .
    IMPORTANT: Cable clip must be installed to the decklid inner sheet metal panel in a location that will allow clip to fully seat in the space between inner and outer decklid sheet metal.
26. Mark a position on decklid inner panel that will allow cable clip to fully seat in decklid sheet metal. Position release handle cable clip as close as possible to center of cable.
    NOTE: If drill bit is allowed to drill into sheet metal at a depth greater than 6.5 mm (1/4 in.), outer surface of exterior panel may be penetrated.
27. Center-punch and drill 6.5 mm (1/4 in.) hole at mark on inner panel.
28. Apply 3M(R) WINDO-WELD Primer (P/N 08643) or equivalent to bare metal edges of hole.
29. Install release handle cable and cable clip to decklid Refer to Fig 11 .

Fig 1: Existing Decklid & Latch

Fig 2: Marking Hole Locations

Fig 3: Drilling Holes Marked On Handle

Fig 4: New Decklid Lock Cylinder Rod

Fig 5: Vehicle Interior Release Cable

Fig 6: Connect Release Handle Wiring Harness

Fig 7: Aligning Handle To Decklid Sheet Metal

Fig 8: 2000 S-Series Sedans

Fig 9: 2000 S-Series Coupes

Fig 10: Drilling Decklid

Fig 11: Attaching Remaining Fasteners

Fig 12: Release Handle Attachment Clip

TRAP-RESISTANT LATCH AND INTERIOR RELEASE HANDLE ELECTRICAL INSTALLATION - 2000 S-SERIES COUPES AND SEDANS

1. Wrap entire length of handle wiring harness with tape to prevent damage to wires.
2. Route handle wires along existing decklid harness over to bottom of decklid hinge. Refer to Fig 13 .
3. Insert handle wires into existing clips along deck lid harness.
4. Place handle ORN wire in approximately three feet of conduit (P/N 21023494) and route it through holes in the bottom of rear window panel over to the cargo lamp. Refer to Fig 14 .
5. Remove cargo lamp housing and disconnect cargo lamp if needed.
   IMPORTANT: Refer to included wiring schematic for wire color and circuit information.
6. Splice handle ORN wire to cargo lamp ORN wire, circuit 340, using splice sleeves supplied with kit.
7. Tape wire to prevent damage due to sharp metal edges.
8. Cut to length and splice handle WHT wire to vehicle ORN/BLK wire, circuit 737, using splice sleeves supplied with kit. The vehicle ORN/BLK wire can be found at decklid in-line connector near base of decklid hinge and will be located in one of the following cavities:
   • Cavity F on Sedans
   • Cavity H on Coupes

   Refer to Fig 15 .

9. Cut to length and splice handle BLK wire to vehicle BLK wire, circuit 550, using splice sleeves supplied with kit. The vehicle BLK wire can be found at deck lid in-line connector near base of decklid hinge and will be located in one of the following cavities:
   • Cavity E on Sedans
   • Cavity G on Coupes

   Refer to Fig 15 .

10. Secure all wires to vehicle with tape to prevent damage.
11. Connect cargo lamp connector and replace cargo lamp housing if removed.
12. Install 10A BODY fuse in instrument panel fuse block.
13. Reconnect existing latch electrical connector(s) to new latch.

Fig 13: Routing Handle Wires

Fig 14: Routing ORN Wire

Fig 15: Splicing Wires

Fig 16: Interior Release Handle Schematic

SYSTEM FUNCTIONAL CHECK

• Ensure new decklid latch is enabled only after two cycles of latch reset lever when decklid has been opened by the following methods:
  • Opened with key
  • Opened with vehicle interior release lever
  • Opened with remote keyless entry (RKE) transmitter (if equipped)
• Ensure folding seat back lock system is functioning properly.
• Fold down rear seat backs and check the following:
  • Verify trunk interior release handle functions with decklid closed.
  • Ensure interior release handle LEDs illuminate and stay illuminated when decklid is closed and are not illuminated when decklid is open.

CUSTOMER DEMONSTRATION AND OWNER'S HANDBOOK INSERT

Supply customer with Owner's Handbook insert and use the insert to demonstrate function of Trap-Resistant Trunk Kit.