Headlight Harness Connectors, Converting

Headlight Harness Connectors, Converting


Beginning with model year 1997 only replacement headlights with 5-pin connectors will be available.

Vehicles up to model year 1997 had wiring harnesses with a 3-pin and a 4-pin connectors.

Affected vehicles must be converted to a 5-pin connector.


NOTE: Repairs to wiring and connectors must be performed with VAS1978 wiring harness repair kit.


- Disconnect the applicable headlight connector.
- Make note of the colors of wires for the appropriate pin for both connectors.
- Disengage both connectors using tool from VAS1978 wiring harness repair kit.
- Remove both grommets.
- Cut ground wire at 3-pin connector close to harness insulation.
- Cut terminal 4 of 4-pin connector and connect appropriate yellow wire from repair kit.


NOTE:
- For the connection use a wire with the appropriate wire gauge and a terminal that fits the headlight connector.
- Before making the connection, shorten the wire enough to prevent it later from chafing or pinching.
- To feed terminals or wires through grommets be sure to use the appropriate tool from the VAS1978 wiring harness repair kit


- Guide wire through the grommet using tool from repair kit and connect terminal to cavity 1 of 5-pin connector.
- Guide ground wire (terminal 3 of 4-pin connector) through grommet using tool from kit and then connect terminal to cavity 2 of 5-pin connector.
- Guide terminal 1 of the 3-pin connector using tool from repair kit and then connect terminal to cavity 3 of 5-pin connector.
- Guide terminal 2 of 4-pin connector through grommet using tool from repair kit and then connect terminal to cavity 4 of 5-pin connector.
- Guide terminal 1 of 4-pin connector through grommet using tool from repair kit and then connect terminal to cavity 5 of 5-pin connector.
- Secure secondary clip of 5-pin connector and check that all wires are seated securely.
- Push grommet fully onto connector.

Cavity wiring positions:1)