Lighting - Xenon/Bi-Xenon Headlamp(s) Are Inoperative
Date: February 6, 2009Order No.: P-B-82.10/376f
Supersedes: P-B-82.10/376e dated August 29, 2008
Group: 82
Revision History
Revision Date Purpose
f 2/6/09 WIS Document References Corrected
e 8/29/08 1st Paragraph Updated (Removed Reference to Fault Codes)
d 5/23/08 Damage Type for Step 7 Updated
c 12/12/06 Warranty Information Updated
b 5/30/06 Warranty Information Updated
a 5/8/06 Applicable Models / Technical Content / Parts and Warranty Information Updated
- 3/17/04 Initial issue
SUBJECT:
Model 203.040/061/064/065/076/081/084/261/264/281/284/740/747/764
Model 209.365/375/376/465/475/476
Model 230.474/475/476/479
Xenon or Bi-Xenon Headlamps not Functioning
If you receive customer reports in the above model vehicles regarding the Xenon or Bi-Xenon headlamp not functioning, follow the test steps below to resolve. A function description can be found in WIS document GF82.10-P-2001P (203), GF82.10-P-0003Q (209) or GF82.10-P-3002R (230).
A. Fault Code Present
1. Check voltage at headlamps.
a. Check plug (1) of low beam (E1e2, E2e2) in lamp units (E1, E2) for voltage.
b. If no voltage is present, continue with test step 5.
c. If voltage is present, continue with test step 2.
2. Check burners by swapping across (right to left).
a. If the fault changes sides with the xenon burner, replace xenon burner. Refer to WIS document AR82.10-P-1201P (203), AR82.10-P-1201Q (209 minus code 614, minus code 615), AR82.10-P-1201QA (209 up to 16.5.05 with code 614), AR82.10-A-1201QB (209 as of 17.5.05 with code 614, minus code 615) or AR82.10-P-1201R (230).
b. If the fault does not change sides, continue diagnosis with test step 3. step 3.
3. Check ignition module.
a. Check manufacture date of ignition module found on a printed label (Figure 1, arrow) on the headlamp housing.
b. If the ignition module is later than the specified manufacture date, continue with test step 4.
c. If the ignition module is earlier than the specified manufacture date, continue with test step 6 for the 230, test step 7 for the 203.0 and 203.2 and test step 8 for the 203.7 and 209.
4. Check control unit. Replace the control unit only if a fault is present. If there is no fault, continue with test step 5.
5. Check voltage at front SAM (N10/1), plug 5, pin 4. If there is no voltage, check and correct to repair symptom.
6. For 230 models with this complaint and with headlamps manufactured on or before manufacture dates (Figure 1) in the above table, proceed as follows to resolve.
6.1 Remove affected headlamp(s). Reference WIS document no. AR82.10-P-4730R.
6.2 Unlock and remove housing cover on rear of headlamp unit at the tab.
6.3 Twist headlamp unit's ignition module plug to the left and remove.
6.4 Remove the screws from the ignition module cover.
6.5 Remove old and install new ignition module.
6.6 Reinstall remaining parts in reverse order.
6.7 Test operation of headlamp(s).
7. For 203.0 & 203.2 models with this complaint and with headlamps manufactured on or before manufacture dates (Figure 1) in the above table, proceed as follow to resolve.
7.1 Remove front wheel. Reference WIS document no. AP40.10-P-4050Z.
7.2 Remove front fender liner. Reference WIS document no. AR88.10-P-1300P.
7.3 Disconnect plug from headlamp.
7.4 Unlock and remove housing cover on rear of headlamp unit at the tab. on rear of headlamp unit at the tab.
7.5 Twist plug on burner to the left and remove (Figure 2, arrow).
7.6 Remove retaining collar (Figure 3, right circle) and scrap retaining collar.
7.7 Remove burner.
Caution!
Do not touch the glass portion of the burner with bare hands; otherwise the glass envelope will shatter when energized. Use a non-greasy, soft cloth.
7.8 Cut off burner plug as close to the ignition module as possible (Figure 3, left circle) and scrap burner plug.
7.9 Individually cut off the 3 supply lines (red, black and green) as close to the ignition module as possible (Figure 4). This shuts down the ignition module at the headlamp.
7.10 Solder the 3 wires from the new ignition module onto the supply lines (Figure 5) using solder connectors A002 546 13 41.
Note:
Be careful not to damage the headlamp with the heat gun.
7.11 Tape over the solder connectors with fabric tape.
7.12 Remove the tabs from the 4 holes of the lamp retaining collar A230 826 00 89 (Figure 6, arrows).
7.13 Insert burner and attach to lamp retaining collar. Run the ground contact to the bottom (Figure 7).
Caution!
Do not touch the glass portion of the burner with bare hands; otherwise the glass envelope will shatter when energized. Use a non-greasy, soft cloth.
7.14 Push the new ignition module (A002 546 13 41) onto the collar until it snaps in place (Figure 8).
Note:
Ensure the correct installation position (Figure 8, right headlamp A, left headlamp B). Install new housing cover at rear of headlamp.
7.15 Test operation of lamp unit
7.16 Install removed parts in reverse order.
8. For 203.7 & 209 models with this complaint and with headlamps manufactured on or before manufacture dates (Figure 1) in the above table, proceed as follow to resolve.
8.1 Remove front wheel. Reference WIS document no.AP40.10-P-4050Z.
8.2 Remove front fender liner. Reference WIS document no. AR88.10-P-1300P.10-P-1300P.
8.3 Disconnect plug from headlamp.
8.4 Unlock and remove housing cover on rear of headlamp unit at the tab and scrap housing cover.
8.5 Twist plug on burner to the left and remove.
8.6 Cut off burner plug as close to the ignition module as possible (Figure 9) and scrap burner plug.
8.7 Individually cut off the 3 supply lines (red, black and green) as close to the ignition module as possible (Figure 10). This shuts down the ignition module at the headlamp.
8.8 Solder the 3 wires from the new ignition module onto the supply lines (Figure 11) using solder connectors A002 546 13 41.
Note:
Be careful not to damage the headlamp with the heat gun.
8.9 Tape over the solder connectors with fabric tape.
8.10 Insert new ignition module into housing cover (Figure 12) and screw in place.
8.11 Screw plug of new ignition module into burner clockwise.
8.12 Rotate headlamp housing cover clockwise into place.
Note:
The fastening screw must be at the top (Figure 13).
8.13 Tighten fastening screw.
8.14 Connect headlamp plug.
8.15 Test operation of lamp unit.
8.16 Install removed parts in the reverse order.
Parts Information
Note:
The following allowable labor operations should be used when submitting a warranty claim for this repair. This information has been generated on May 23, 2008. Please refer to Netstar --> Star TekInfo --> Star Time for the most current labor time allowance.
In case of Warranty, use the table above.