Stavsig

The insulation inside r/side headlight shed off and shorted wiring. I replaced both headlight with new Hellas but the right side did not come on. I have replaced HEADLIGHT SWITCH, FRONT SAM AND FUSEBOX, Checked all the fuses but nothing comes out the SAM to the headlight wire connector (No #5 underneath SAM unit. Help!!!

slammer111

If this is the case, unfortunately the front SAM may be cooked. The SAM is involved as it's part of the Canbus monitoring system (checkes if the bulbs are burned out) for the external lights.

Does the car show a bulb out error?

Stavsig

Yes it shows the high and low beam and park/ turn signal out on the r/ side. I put in a used SAM but same thing.

slammer111

Try swapping headlights (as in the entire assemblies) and see if the problem moves to the other side of the car. The connectors should be the same between L and R.

Stavsig

R/side has no power in connector but ground is fine.

slammer111

Start tracing the wiring. Also check the connectors themselves.

Remember that the car will cut power to a circuit if it thinks the bulb is out. That may be what you're actually seeing. Cars are too smart for their own good.

When you swapped headlights, did you also "turn off" the car before restarting?