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(351-2526) Halogen headlamp dipped beam not coming on

Symptom: Halogen headlamp dipped beam not coming on

TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 351-2526
Date: ........... Februari 2005
Market: all
Halogen headlamp dipped beam not coming on

Cars affected

Saab 9-3 (9440) with halogen headlamps within the following Vehicle Identification Number ranges:

31000001 - 41056598 (M03-04)

46000001 - 46017150 (M04 CV)

Background

In a small number of cars the wiring harness in the halogen headlamp may be inadequately crimped. This can result in the dipped beam not coming on.

In the case of customer complaint, the following procedure must be carried out.

Symptom description

Halogen headlamp dipped beam not coming on



Parts required

12 762 390 Repair kit (2 per car) (CA: 12762390)

Procedure

Note

The procedure must be carried out on both of the car's headlamps.



1. Remove the headlamp, see WIS 3. Electrical System - Lighting and signalling systems - Exterior lighting - Adjustment/Replacement - Headlamps.

2. Remove the headlamp's protective cover.


3. Remove the bulb holder by turning it anticlockwise slightly and pulling it from the reflector.

4. Remove the bulb.

5. Cut off the brown cables (x 2) approx. 9 cm, and the yellow cable approx. 10 cm from the connector. The length of the cut-off cables is equivalent to the length of the repair kit's cables.


Note

Make sure that the shrink tubes are in position before the repair kit's wiring harness is fitted.


6. Strip the cables (approx. 6 mm) and fit the repair kit's wiring harness, use the blue pliers (1 mm² cable) from 86 12 939 Toolbox, wiring harness

7. Secure the shrink tubes over the joints by heating with a hot-air gun.

8. Remove the bulb holder from the detached connector by loosening both clips with a screwdriver.


9. Fit the bulb holder on the new connector in the correct position, as illustrated.



10. Fit the bulb in the bulb holder.

11. Fit the bulb holder by turning it in clockwise into the headlamp.



12. Fit the headlamp's protective cover.

13. Fit the headlamp, see WIS 3. Electrical System - Lighting and signalling systems - Exterior lighting - Adjustment/Replacement - Headlamps.

14. Carry out steps 1 to 13 on the other headlamp.


Warranty/Time Information

In the case of customer complaint and if the car is within the warranty period , use the following information to fill out the claim:

Failed Object: 35110

Fault/Reason code: 62

Location code: 09 (US=9)

Warranty Type (US): 01

Repair/Action code: 01

Labour Operation (US): 3511002

Labour operation (CA): N0918 (right) 0.4 hr, N0919 (left) 0.4 hr

Time: 0.8 hr