Hello all, having an issue where my passenger side headlight is out. I believe it started going out after a few minutes of turning on but lately was always off.

I replaced the bulb as the original looked bad with no luck. Then replaced the ballast with no luck again, swapped back to the original bulb, no luck. Made sure the two grounds near the headlight were decent.

So either it was the ballast and I got a defective new one (pic of new and old below)or something else is up.

Thoughts? Replace the HCM next? I'm avoiding pulling the other light but may have to.

 

The only way is to swap the headlights side to side and go from there.
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I finally got around to swapping headlights and long story short both work on the drivers side but neither in the pass side. Cleaned up the grounds again. Checked for ground continuity at the plug. Measured voltage for each wire, thought I was on to something with some <12 volt readings but the driver side was the same. Pic attached of my readings, looking into the harness side plug, letters are colors, numbers are volts.

I'm really at a loss now.

Any ideas on where to go from here?

 

separate fuses….you did check for power at the connector with a test light right?

 

Check the top left multiplug of the bcm/fusebox in the car, you can just pull it out without disconnecting anything, just ignition off.
Water from the washers can wick up into that multiplug.

 

Thanks John, will check that out.

Now that I think of it, there are some other electrical issues going on like won't lock and mirror dips but does not return automatically sometimes so maybe a corrosion issue.

 

John, you called it.

Pulled the plug and didn't see much going on but it's in a tough spot to see so took a pic and saw something on one of the pins. Used a toothpick to get it off and out turned out to be a tiny strand of wire. This is the connection to the one of the headlights. Put it back together and the headlight worked.

The female connections looked ok but after the plug was installed I noticed corrosion on the bottom 4 wires. Will be looking to fix that in the near future but for now I'm good.

Thanks for pointing me in the right direction





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This might be of interest....

 

Thanks John!

Has anyone figured out where to buy the individual female pins that are crimped on? I've looked "everywhere" but have not found them yet.

The Jag connection kit is too expensive and Motortronics is our of stock of their cheaper kit.

 

These are the ones for the blue connector which suffers on the sportbrake, ( I believe top left connector the gets damaged on the saloon uses the same pins )
https://www.automotiveconnectors.com...05-075mm2.html
( Yazaki part no 7116-3542-02 )

EDIT: BTW, The Glarks SN-28B crimp tool seems to work well on them
If you come across a source of the male pins ( the ones used on the circuit board ) please let us know.

 

Many thanks Phil!

I couldn't find any places with that contact in stock in the US so I ordered from the link you suggested. With a min order amount and shipping to US it came to $32 but still cheaper than other options. Thanks for the crimper recommendation too, I have one of those for my pinball hobby and will hope the jaws that are in it will work for these contacts too.

Now I'll have to choose a method for moisture blocking...

I appreciate all the replies to this thread!

 

Here's a picture, but you can just use butt connectors, this was a bit OTT.......

 

Great repair and as you said MUCH cleaner than the factory butt splice suggestion.
Plus now you have a nice dis-connect in place.
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