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Headlights wiring harness

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Headlights wiring harness

 
Old 07-07-2016, 12:01 AM
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Headlights wiring harness

I have finally taken out the front bumper and the headlights. The wiring insulation is almost completely cracked up.
I don't seem to be able to remove the wiring harness inside the housing.
Is there anyway to do this without having to remove the glass cover? I am trying to avoid this, looks more complex and I may cause major damage to the lights.
Thank you. Shan.
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Old 07-07-2016, 11:28 AM
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Originally Posted by shan View Post
I have finally taken out the front bumper and the headlights. The wiring insulation is almost completely cracked up.
I don't seem to be able to remove the wiring harness inside the housing.
Is there anyway to do this without having to remove the glass cover? I am trying to avoid this, looks more complex and I may cause major damage to the lights.
Thank you. Shan.
Shan,
If you take a pic I might be able to help. I changed out headlight fixtures this year
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Old 07-07-2016, 11:11 PM
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Thanks LexBrett2.
I am attaching some photos.
You can see the massive damage to the insulation.
The photo is from the RHS lamp. The LHS is equally rotten.
I am going to use the same sockets by removing the damaged wires and the metal clips
in them. I have already done this for the lights sockets. But I can't dislodge the black socket with 5 straight pins carrying 5 wires on the inside of the light housing. I intend to new wires and clips but the same original plastic casings. Thanks




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Old 08-19-2018, 09:39 PM
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Originally Posted by shan View Post
Thanks LexBrett2.
I am attaching some photos.
You can see the massive damage to the insulation.
The photo is from the RHS lamp. The LHS is equally rotten.
I am going to use the same sockets by removing the damaged wires and the metal clips
in them. I have already done this for the lights sockets. But I can't dislodge the black socket with 5 straight pins carrying 5 wires on the inside of the light housing. I intend to new wires and clips but the same original plastic casings. Thanks




Did you figure out how to take the wiring harness out? It looks like I may have to do the same on mine. The passenger light is out and bulb/fuses don't seem to be the problem. But the wiring is pretty much bare.
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Old 08-20-2018, 11:14 PM
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I could not get the replacement wire harness here in Malaysia, even though it was being advertised in eBay.
I could not get the OEM light sockets or the connecting plugs either. I was told to buy a new pair of lights.
So I got hold of some new wires, coloured but not following the original colour code, soldered on to the existing plugs
and refitted. There was one wire going deep into the lamp housing that I could not access. So insulated it by pushing in
a heat shield tubing as far as it could go. It was because of this wire, I did not buy the wire harness from eBay.
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Old 01-08-2019, 03:47 PM
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Originally Posted by shan View Post
I could not get the replacement wire harness here in Malaysia, even though it was being advertised in eBay.
I could not get the OEM light sockets or the connecting plugs either. I was told to buy a new pair of lights.
So I got hold of some new wires, coloured but not following the original colour code, soldered on to the existing plugs
and refitted. There was one wire going deep into the lamp housing that I could not access. So insulated it by pushing in
a heat shield tubing as far as it could go. It was because of this wire, I did not buy the wire harness from eBay.
Yeah I think I'm going to do the same thing here. Make a fresh wire harness and modify the headlights to make the plug in the bulb cover instead taking from the source and just kill the wires inside the headlights. This way changing the wiring would become a plug and play kind of deal and wouldn't cost as much.
Will post pictures when it's over.
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Old 01-11-2019, 10:25 PM
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This is indeed a problem with the wiring in C200 series headlights as they can't seem to breath & over years will deteriorate. I didn't have such a problem as mine are good but made sure they sit at the back more away from the bulb before I attach the boot. You could try to colour code
& the use joiners to crimp. If you can't get the right colours then colour mark on a strip of masking tape & attach to the wire. Just a thought.
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Old 01-11-2019, 10:26 PM
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Thats the worst I've ever seen. Lucky you didn't short?
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