Headlamps - Moisture/Condensation
NO.911
GROUP
35
SECTION
3
DATE
May 1997
RE:
Corrective action to counter moisture in headlamps
940, 960
REFERENCE: TP 3502201, SECTION 3(35-39) LIGHTING, INSTRUMENTATION AND OTHER ELECTRICAL EQUIPMENT; 700/900 1982-
Corrective action to counter moisture in headlamps
Background:
Moisture/condensation can occur in the headlamps after car washing or engine washing. The moisture occurs because of water seeping into the headlamps through:
^ the ventilation hole on the underside of the headlamp when water condenses from the warm radiator
^ water jets aimed at the upper ventilation hole of the headlamps
Corrections:
Moisture/condensation in the headlamps can be minimized by increasing ventilation to the headlamps and installing rubber tubes between the ventilation holes and the bumper sides.
Materials: Rubber hose 2 x 600 mm (23.6") 949931-0
2 x 770 mm (30.3") 949931-0
Butyl tape 1321227-9
Index: 940
960 -1994
960 1995-
940, 960 (-1994)
Cut 4 pieces of rubber hose according to:
^ 2 x 600 mm (23.6")
^ 2 x 770 mm (30.3")
Open both covers in the front bumper.
- Cut one end on each hose at an angle to prevent it sealing if it is installed to high up.
- Wind a length of butyl tape (B) around the hose approximately 10 mm (3/8") from the angled cut when installing in the ventilation hole.
NOTE:
The longer part of the angle cut end should be facing forward when installed.
- Press the longer (770 mm, 30.3") rubber hoses into the inner headlamp ventilation holes.
- Press the shorter (600 mm, 23.6") hose into the outer ventilation holes.
- Form the butyl tape into a seal against the ventilation opening.
- Route the long rubber pipes over the bumper mountings.
- Install all hoses with butyl tape in front cover plate (A).
- Press butyl tape around the ventilation holes so that there is a seal.
- Secure hoses in bumper side pieces with butyl tape as illustrated (B).
- Check that the hoses are routed to avoid water locks.
Repeat the methods for the other headlamp.
960 (1995-)
Cut 4 pieces of rubber hose according to:
^ 2 x 600 mm (23.6")
^ 2 x 770 mm (30.3")
- Remove existing water traps (A) by poking them with a screwdriver.
The water traps are accessible from the underside.
- Wind a length of butyl tape (B) around the hose approximately 10 mm (3/8") from the angled cut when installing in the ventilation hole.
- Press the longer (770 mm, 30.3") rubber hoses into the inner headlamp ventilation holes.
- Press the shorter (600 mm, 23.6") hose into the outer ventilation holes.
- Form the butyl tape into a seal against the ventilation opening.
- Secure the hoses to the front cover plate with butyl tape (C).
- Press butyl tape (B) around the ventilation holes so that there is a seal.
- Secure the hoses with butyl tape in the bumper side pieces as illustrated (D).
- Check that the hoses are routed to avoid water locks.
Increase the upper ventilation
- remove the rubber plug in the upper ventilation hole.
- cut away approximately 7 mm (9/32").
- reinstall rubber plug.
Repeat the methods for the other headlamp.
WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01
Operation No. Labor description Time allowance
35911-2 Improved headlamp ventilation 0.3 hr
according to service Bulletin 3-35-911