Lights - Headlight Electrical Connection Repair

Condition

Headlight Electrical Connection, Repair
If service or accident damage necessitates headlight wiring harness repair or replacement, install wiring harness Part No.3B0971671 following procedure below.





94 06 11 Sept. 28, 2006 2013015 Supersedes T.B. Group 94 number 04-01 dated March 11, 2004 due to inclusion into Elsaweb

Technical Background
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Production Solution
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Service





NOTE: Always use VAS "1978A Wire Harness Repair Kit.

Review and follow Safely Precautions in VAS 1978A Instruction Manual prior to performing any wiring harness repairs.

- Remove headlight assembly.Refer to Repair Manual, Electrical Equipment, Repair Group 94.
- Remove headlight bulb access covers -arrows-.





- Remove high beam bulb electrical connector -black arrow-.
- Remove and inspect high beam bulb.

NOTE: Do not touch bulb with bare bands.

- Detach headlight assembly electrical connector from housing -white arrow-.





- Remove low beam bulb electrical connector -black arrow-.
- Remove and inspect low beam bulb.

NOTE: Do not touch bulb with bare bands.
- Remove parking light socket and bulb -white arrow-.





- Route low beam wiring to high beam access hole -arrow-.





- Cut turn signal wiring (green & brown wires) in location shown -black arrow-.
- Remove wiring harness from headlight assembly -white arrow-.

On vehicles w/o self aiming headlights.Tape unused wiring back to harness.

- Cut turn signal wiring (green & brown wires) of new wiring harness, 190mm from housing connector.
- Route wiring harness through headlight assembly.
- Install and connect parking light.
- Route low beam wiring.
- Install and connect low beam light.
- Install and connect high beam light.
- Strip insulation on all turn signal wire ends approximately 6-7 mm (1/4 inch).





- Use red butt connectors (P/N 111971940A) and red dot crimp on Crimp Tool VAS 1978/1 to splice turn signal wiring (green & brown wires) -arrows-.
- Install access covers.
- Install headlight assembly.Refer to Repair Manual, Electrical Equipment, Repair Group 94.

Tip: Part number(s) are for reference only.Always see ETKA for the latest part(s) information.





Warranty








Required Parts and Tools