Excellent video Charles! Some months ago I disassembled and opened my headlights, also a Passat B5.5, using the oven method. I didn't knew I could remove the wiring harness. Anyway, it doesn't fried anything because low temp should be used to soften the OEM seal. I found out half of the inner wiring cracked (plastic wrap) and was ready to short anyday. Fixed with the shrinking tubing. Extensive cleaning and the main reason for opening was that the plastic rods for adjustment were broken, so I couldn't aim my headlights at all! Used some JB Weld along with some wiring around critical points and waited for a day and a half for the thing to cure. I didn't got the butyl seal to close the headlamps and used instead the black stuff from Permatex. Here I learned something: It bonds well for closing but you need to let it breathe at least 48 hours to let it bleed so the chemicals in the sealer go off, otherwise those vapours end clouding the inside of the assembly. Now I see you got a new wiring harness, better option than wrestling around opening all that piece. Thanks for the video and the spot on advise.
Great work! I really like the way other manufacturers its simply pull the connectors from the bulbs, and remove the loom connector. Whole thing takes 20-30 minutes being careful. VW makes a great car, this just seems more complicated than it needs to be.
Awesome video....as an electrician a little tip. Tie the fishing line to the old turn signal wires BEFORE you yank them out. It will save you from having to fish them back through after the fact. ;) Going to be doing this repair to my B5.5 in a couple days.
I'd like to comment on the fact that vw sells the harness by itself vs forcing the customer to by the headlight assembly. Most makes wouldn't do that. Very cool of vw
Great DIY repair video as always. I'm HOPEFULLY going to use this series of diagnosing turn signal troubles and my mechanically-inclined mind to diagnose and repair my 2004 Honda Civic Si Hatchback that has lighting and other electrical issues after being a theft recovery...headlights were originally 9005/9006 setup. The wiring harness was cut for both sides. When the car was repaired the missing 9005/9006 bulb sockets were replaced with a socket for a 3-prong 9003 single bulb oem harness socket. I ordered new replacement headlight assemblies since one of the headlight lenses had been severely damaged by a large stone on the highway. My question is: When I ordered the new headlight assemblies, I ordered for a 2004-2005 model not knowing what I was getting into. The new assemblies came with adapter harnesses to adapt the 2002-2003 single 3-prong 9003 socket to the 2004-2005 9005/9006/H1 dual bulb headlight assembly connectors. I thought it was going to be an easy switch. BOY WAS I EVER WRONG!! With the new assemblies installed and using the provided wiring adapters, only the passenger high beam works and only driver's low beam works. I still have not been able to get the front turn signals to work in any capacity, trying almost every adapter and wiring configuration I can possibly imagine. If I rewire the headlight connectors back to their original configuration from 3-prong to 9005/9006/H1 oem 2004-2005 sockets, will I need to run new, separate grounds for each of the new sockets...pass. high beam, pass. low beam, driver high beam and driver low beam...in order for them to work properly? As I said I'm elbows deep in troubleshooting the turn signals. All the lighting relays and fuses have been checked and independently double checked. No bad fuses nor bad relays. Rear and fender-mounted signals work, just not the front ones mounted in the headlight assemblies. And my air bag light is on on my dash, the cruise activation button no longer lights up and cruise does not operate at all, difficult to keep windshield wipers in high speed operation position at the column multifunction switch and the horn was apparently rewired to a momentary push switch mounted in the dashboard next to the steering wheel. I think all these issues are somewhat related. All functions go through the multifunction switch/clock spring assembly. Other than the fuse box and the battery, it's the only connection that they all share, to my knowledge. Please if ANYONE has any genuine ideas, I would be glad to hear them. I absolutely love this car, even with these issues. I could buy a completely new engine bay harness...headlights, turn signals, marker lights, horns, foglight wiring access sockets, etc.- no engine/trans harness...directly from Honda but with shipping and insurance it would cost more than $500. Being disabled since 2014, with 4 of the most selfless kids and an amazing, supportive, beautiful, smart wife who works very few hours and attends college full-time... Let's just say a $500 wiring harness is the least of my priorities on my "to-do" list. Choosing to buy groceries, pay rent, utilities, make doctor appointments, have gas money for my wife to get to school and work...spending $500 on a wiring harness for my car isn't even an option. That's why I'm having to fix this myself. No garage or shade tree will even touch it. PLEASE HELP!!
HumbleMechanic man I tell ya what all of us vdub guys have all did this at least once or twice also them mk4 1.8t coil pack wiring was bad for doing this too
Geez. I had this happen with my E55 headlights, I use repaired with liquid tape and cutting out some sections. I did not see a part available for the internal wiring like VW offers. This crumbling wiring is insane and quite annoying.
tie the fishing line to the original indicator spade type connector and pull the line through at the same time as removing the old cable. do this with both indicator wires. Saves you the difficulty of trying to feed the line through by itself.
great video! one comment, instead of the hassle of fishing the blinker wires through, cut them 5 inches from the socket and sliced them back together, you do it anyway for your xenons
Great video as always. I came across this one in search of a possible fix for the headlights in my 06 Audi S4. Are these harnesses available for other VAG?? And where do you buy them?? I'd even consider an aftermarket solution to the fragile, overheated, mostly missing mess of insulation in my headlights. 🤨☺
Thanks Charles, but somehow, I don't like my chances of that. It might need to be aftermarket repair loom. Perhaps a retrofit from one of all the looms I see online for all the LED or Bi-Xenon retrofits
It would be interesting to see the wiring replaced while keeping the old connectors (depinning, rewiring with new wire, etc), sort of like a custom harness. The wiring harnesses are quite a bit expensive for some of the pockets out there, so would be great to see ways to save money and fix what VW decided to cheap out on (wiring insulation that is).
HumbleMechanic that's great, can't wait to see. I'm in the middle of swapping a VR6 in my MK4, and I have a cut up harness as well as I want to do a wire tuck, which is a pain in the butt for the MK4. Also, what else could I use for depinning the connectors other than that expensive tool? I just need something for one time use as I dont plan to touch the harness any time soon after I'm done with it
i thought it maybe had to do something with maybe the condition of where you live, something like extreme heat and cold like down here in texas, it ruins everything
Hi Charles, With the headlight harness issue what is the cause? Was it to high of current draw , cheap factory wiring sheathing or heat from the headlights?. Was this a common problem and is the replacement harness upgraded oem or aftermarket. Another great video mate. Cheers Mark.
Stumbled across this looking for a simple removal to replace and surprised they added this route. Is it worth it to wrap with a sacrificial tape layer to prolong the life of the wiring insulation or will it make any difference with the 18ga wiring (halogen, not led)?
decades later another mechanic finds the repair and says, "Check this out, back in the day they spent countless hours replacing the crappy wires so they could drive in the dark..hahaha...ha...ha" with cartoon mouth moving out of sync. I gotta do this soon to my own x4 so I laugh at myself. great vid. thanks for the heads up.
Great job. But for the entire video I was thinking bad thoughts about the MD in VW who outsourced that rubbish wiring. This should plainly just not happen.
I have an audi with this same problem, namely the insulation somehow "evaporated" from the wires, leaving a bunch of bare wires inside the plastic case that all shorted out. I have never seen this bizarre phenomenon on any other brand of vehicle.
Hey this is what was wrong with the headlights on my gti that I emailed you about, I just painted it up with liquid electrical tape for now, it was sooooo much easier then this.
I was wondering why are the pins on a lot of connectors so small? I was meaning like the window switches on the master control. The only was I see the repair would be replacement of the harness. Could you do a video on one of these and how to test these? I was never sure how to test or depin these.
+Brian Skinner I think I've done depinning video before. The pin size is based on the wiring connector and the wire size. Smaller connections usually have smaller pins. Also smaller wires use smaller pins
just finished a thermostat job on a passat with the 2.8, 5 hours for a 10 dollar part, got it together and didnt think about the housing surface being eaten up just enough not to seal... coolant everywhere lol
Not hating, not being a smart ass. Clicked on this because I've had a few issues with the '80 Powerwagon. Near the start I realized this had nothing to do with my halogen set up. Headlight switch is on the dash, pull out the knob for lights. Some how I watched the hole video. It's like watching a NASCAR race waiting for the crash.
Awesome video .. I need the harness for a 2010 facelift A3 . Mine has the Xeon projector headlight . My harness is completely shorted out . Is there a part number for this harness ?
Hey Charles HumbleMechanic! Great Video! I have a B6 Passat and the Headlight Won't Turn OFF. Even when the whole car is shut off and all the doors locked. Its only the drivers side one. I heared it could just be the battery just needs replacing - could that be it? Ever run into this issue?
Nah, I doubt it will ever be a recall. The odds of actual fire are pretty low. Each section is fused. This is somewhat common. I have fixed a lot of bad wiring to the headlight bulb. This is the worst I have seen
Just a thought (from a 12v installer). Why not just snip the turn signal wires at the plug and use the original wires to pull the new ones? Instead of pulling them out and using fishing line
well done! I have same problem my is VW Jetta S 2014 2.0L I couldn't find whole harness replacement kit my DRL wire burn I try to recreate twist together and didn't work. I think the housing itself need replacement where can I order harness whole kit?
I would like to attempt to replace my standard halogen headlights (with no projector) with a LED projector type on my VW. It would be nice to present a video on how to DIY. Thanks. Nice video!
I used silicone wire and re pined the harness plug. a little solder and high temp heat shrink all is working again rebuilt the engine harness on my 1980 Volvo with silicone and Teflon wire as this era car had "biodegradable" wire
Scott Johnson oh lovely as if the squirrels didn't destroy a perfectly good wiring harness fast enough they had to have the wires destroy themselves 😂.. I mean I guess it's a good way to ensure that people always need to fixing something and therefore giving you money in one way or another
I fixed my sister's old car's headlight wiring that someone "fixed" by jamming a block of wood between the melted plug and the core support. The car caught fire a few weeks later from some shoddy wiring under the dash.
CAN you please do a video on a Golf MKV xenon light harness wire issues because range motor won’t work and VCDS is saying Headlight Range Adjusting Motor (V48) 010 - Open or Short to Plus and I don’t want to replace the headlights
Can you get from FCP Euro too? Doesn’t look like a regular lay person can replace the front light harness. Dealership claims my harness is shot and wanted to charge me $350 for a kit🤷🏽♀️, said replacing the bulb wouldn’t work. I’ll try replacing the bulb first though, they are pretty dishonest so I can never trust them!
Damn it! I can't find the fluid anywhere is this like the third inline exhaust bearing computer modualizister hidden like everything else? I have been using old fluid for the above at the dismantling yards! Where is a good spot to buy the five finger blinkles flued of got yo $ mod!
Hey idk if you still reply to comments on here but I need an answer kinda quick. My headlight connectors went out on both sides and I wanted to know if I buy new ones if they’re the same on both right and left side
Way to go Volkswagen I have a 2007 Passat which makes me crazy when I have to change the lightbulb I would think German engineering could come with great design these headlights are Japanese all away
I know that you probably covered the headlight harness issue years back, but still I want to humbly ask you, since upon checking with the dealer, the price of one is almost as replacing the whole headlight. I am retired and I cannot afford it in my fixed income with today's food pricing Is there anyway you could show the pinout of a 2008-2010 touareg( 6 pins in the connector only) headlight wiring as to what position wire from the connector goes to which light bulb. I would like to do the repair with soldering and new wiring from the connector to every light bulb. Thank you in advance...
Where can I find the parts? I'm looking for a wiring harness for a 2001 Audi Allroad. The headlights in the vehicle now blow the fuse for the low beams, according to my wiring diagram they are wired incorrectly, likely from someone installing lights from a similar vehicle that has different connections. Now I need to rewire it and the harness inside is crumbling a bit. Would rather replace than make something from scratch
Working on this right now on an 07 Passat wolfsburg edition. Can't seem to get the pins out of the connectors, and can't find a part number to look up to get a replacement harness. Getting frustrated :/ do you happen to have the part number for this harness, or have a link to the tool needed to remove the wires from the connector? I can repair the harness with heat shrink tube but im trying to avoid cutting and splicing the wires. The heat shrink tube will slide over the end of the pins in the main connector, but not the end that connects to the bulbs unfortunately.
I would have cut it and then attaching new cables to the old ones would make it possible to toe the new cable from right to left using the old. A little bit like new brake cables^^
Fellows, any suggestions as where I can get a replacement wiring already mounted for the Passat B5 97-00 ?? Tons of ads on eBay but all of them only apply for the B5.5 :(
My question is why bother to take the contacts out at all? Why not just cut the existing wire end and cut the new blinker wire and solder them together and then as you pull out the old wire your using the old wire to pull the replacement wire into place. Cut out the temporary solder connection and then reconnect the blinker wires with the rest of the harness. Then put some heat shrink tubing over the solder joint and Bob’s your uncle!
I have the same insulation issue as in your video, called audi (a3 8p), internal headlight harness is not avaliable independently. is there a vw headlight that shares the same internal wiring and connectors that is available?
Good job man!I wanna do exact same with my 2006 Audi A4 with original factory HID headlights, plus I have to change or convert my original 14 pin socket to 10pin, do you think is it a big deal?
@@HumbleMechanic thanks man I might try to figure out where the connection is broken and try to fix this one. WOW the wires in these are so brittle, I've taped them up some.
Hello, are all the turn signals (front, rear,and mirror) on same fuse (06 vw jetta), or is the mirror one separate?..no voltage to pass. Side turn signal( on mirror) ..all other turn signals work..where do i start (to find the problem) thank-you
Actually de-pinning the connector is easy if you have the right tool. Other than not screwing around with the turnsigal, much of the job would have been the same
Hello, HumbleMechanic I've looked everywhere and cannot find the "how to" I was hoping you could help me with a task that is driving me nuts, and I really need help with. I have an old civic the turn signal and headlights switch broke and as expected with a 37 year old car I cannot find a replacement. I need to wire the headlights to a three position switch (high, Low, off) as well as the city lights and turn signal. can you help me with instructions, or show me where to find it? I really appreciate any help you can offer. Thank you - Semper Fi
Wouldn't it have been easier to split the lens? if the glue is butyl its 15' in the oven job. Did the headlights on my mk1 TT and the cables were disintegrating, just like in your video. Main pin housing is exactly the same, amazed you could take it off blind.
Maybe would have been easier. There is usually more than one way to do the job right. I don’t love splitting headlights because it opens the opportunity for water intrusion. But that could have worked just fine
Just bought a 2007 VW Jetta 2.5L 6 speed 4 door. They didn’t give me much information on it. The passenger side low and high beams are not working. When I popped the trunk there were two other headlight assemblies in the trunk with harness and plug still attached. Do you think it’s worth me trying to install the passenger side one from the trunk by splicing in the new harness to see if this solves my problem? I also find it strange that other lights on my passenger side don’t work , like the front right signal and marker and also the mirror signal on the passenger side. I’m lost with this, I’ve never seen this many lights go out on one side... Any ideas???? Any and all help would be greatly appreciated.
I have a question ... I had a blowout in my 94 prelude. The damages were my fender was messed up, my bumper ripped off, and main problem is the my wiring harness for the right side of my head light s were ripped out. From the inside of my car . Can seem to find the harness anywhere or what it's called lol can you help me please?
Wow, american Passats does not have the motor to correct the tilt of the headlights from the dashboard in case the trunk is full. In Europe its not allowed to install aftermarket xenons without the proofed headlights and without headlightwashing equipement and automatic tilting equipement for the headlights. In my opinion the original xenon headlights looks way better than the HID headlights.
Hello, firstly I would like to wish your country well in this hard times the whole world is facing. I was trying to connect my vw polo 2003 headlights switch when two connections came into contact and the car blackedout and showed the EPC light and handbrake is blinking now the car won't start and there's a funny noise from the bonnet and its a small buzzing sound. The starter won't turn at all
It seems like mine always sticks or the crimp sticks. A trick to this or did my wife buy me a cheap tool for my birthday? Lol Honestly, she received it for review...so I am not out anything. Also, I received older 50/50 and resin soldier in a garage sale box. A good amount, really, but damn...it really doesn't flow. Is there a difference now that we are leadless in the flux or possible contaminate? I hate not being able to crimp and soldier everything. Man...I just snip and pull like residential wiring.
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This sets the standard for high-quality YouTubing. Amazing photography and no-bullshit commentary - this is how it's really done.
+Labrador McGraw thank you. I'm trying to work on the commentary. Hahha. I am always talking during the job. But if it's not a ton of value I cut it.
HumbleMechanic I don't think the commentary needs any work; it seems you've got the balance just right.
Excellent video Charles! Some months ago I disassembled and opened my headlights, also a Passat B5.5, using the oven method. I didn't knew I could remove the wiring harness. Anyway, it doesn't fried anything because low temp should be used to soften the OEM seal. I found out half of the inner wiring cracked (plastic wrap) and was ready to short anyday. Fixed with the shrinking tubing. Extensive cleaning and the main reason for opening was that the plastic rods for adjustment were broken, so I couldn't aim my headlights at all! Used some JB Weld along with some wiring around critical points and waited for a day and a half for the thing to cure. I didn't got the butyl seal to close the headlamps and used instead the black stuff from Permatex. Here I learned something: It bonds well for closing but you need to let it breathe at least 48 hours to let it bleed so the chemicals in the sealer go off, otherwise those vapours end clouding the inside of the assembly. Now I see you got a new wiring harness, better option than wrestling around opening all that piece. Thanks for the video and the spot on advise.
Great work! I really like the way other manufacturers its simply pull the connectors from the bulbs, and remove the loom connector. Whole thing takes 20-30 minutes being careful. VW makes a great car, this just seems more complicated than it needs to be.
VERY much more complicated than it needs to be
I can’t find this connector for a vw beetle turbo 2012 and their gonna total my car if I can’t find it if you know anything lmk
Awesome video....as an electrician a little tip. Tie the fishing line to the old turn signal wires BEFORE you yank them out. It will save you from having to fish them back through after the fact. ;) Going to be doing this repair to my B5.5 in a couple days.
I'd like to comment on the fact that vw sells the harness by itself vs forcing the customer to by the headlight assembly. Most makes wouldn't do that. Very cool of vw
They don't sell these for Mk5 Jetta/GTI as far as I know.. and that headlight is serious money
Brandon Foss yea. but look what you have to go through. more like a deturent
Adrian Nava enter at your own risk lol
When you choose to overlook the obvious design flaw to praise the implied "reduced cost" for the repair.
At 4:30 and I'm loving my Grand Am even more. Toolless headlight removal and the wiring is all external to the headlight assembly.
I have a grand am as well. Fun car
Great DIY repair video as always. I'm HOPEFULLY going to use this series of diagnosing turn signal troubles and my mechanically-inclined mind to diagnose and repair my 2004 Honda Civic Si Hatchback that has lighting and other electrical issues after being a theft recovery...headlights were originally 9005/9006 setup. The wiring harness was cut for both sides. When the car was repaired the missing 9005/9006 bulb sockets were replaced with a socket for a 3-prong 9003 single bulb oem harness socket. I ordered new replacement headlight assemblies since one of the headlight lenses had been severely damaged by a large stone on the highway.
My question is:
When I ordered the new headlight assemblies, I ordered for a 2004-2005 model not knowing what I was getting into. The new assemblies came with adapter harnesses to adapt the 2002-2003 single 3-prong 9003 socket to the 2004-2005 9005/9006/H1 dual bulb headlight assembly connectors. I thought it was going to be an easy switch. BOY WAS I EVER WRONG!!
With the new assemblies installed and using the provided wiring adapters, only the passenger high beam works and only driver's low beam works. I still have not been able to get the front turn signals to work in any capacity, trying almost every adapter and wiring configuration I can possibly imagine.
If I rewire the headlight connectors back to their original configuration from 3-prong to 9005/9006/H1 oem 2004-2005 sockets, will I need to run new, separate grounds for each of the new sockets...pass. high beam, pass. low beam, driver high beam and driver low beam...in order for them to work properly?
As I said I'm elbows deep in troubleshooting the turn signals. All the lighting relays and fuses have been checked and independently double checked. No bad fuses nor bad relays. Rear and fender-mounted signals work, just not the front ones mounted in the headlight assemblies.
And my air bag light is on on my dash, the cruise activation button no longer lights up and cruise does not operate at all, difficult to keep windshield wipers in high speed operation position at the column multifunction switch and the horn was apparently rewired to a momentary push switch mounted in the dashboard next to the steering wheel. I think all these issues are somewhat related. All functions go through the multifunction switch/clock spring assembly. Other than the fuse box and the battery, it's the only connection that they all share, to my knowledge.
Please if ANYONE has any genuine ideas, I would be glad to hear them. I absolutely love this car, even with these issues. I could buy a completely new engine bay harness...headlights, turn signals, marker lights, horns, foglight wiring access sockets, etc.- no engine/trans harness...directly from Honda but with shipping and insurance it would cost more than $500. Being disabled since 2014, with 4 of the most selfless kids and an amazing, supportive, beautiful, smart wife who works very few hours and attends college full-time...
Let's just say a $500 wiring harness is the least of my priorities on my "to-do" list.
Choosing to buy groceries, pay rent, utilities, make doctor appointments, have gas money for my wife to get to school and work...spending $500 on a wiring harness for my car isn't even an option. That's why I'm having to fix this myself. No garage or shade tree will even touch it. PLEASE HELP!!
It's great to be back in a VW. Driving a BMW for so long was strange. LOL ;)
HumbleMechanic 😂😂😂
:D
have to drive my skoda, because some asshats stole my ronal turbos from my mk1 leaving it on woodblocks -.-
HumbleMechanic man I tell ya what all of us vdub guys have all did this at least once or twice also them mk4 1.8t coil pack wiring was bad for doing this too
+Tony Mullins truths
Geez. I had this happen with my E55 headlights, I use repaired with liquid tape and cutting out some sections. I did not see a part available for the internal wiring like VW offers. This crumbling wiring is insane and quite annoying.
tie the fishing line to the original indicator spade type connector and pull the line through at the same time as removing the old cable. do this with both indicator wires. Saves you the difficulty of trying to feed the line through by itself.
great video! one comment, instead of the hassle of fishing the blinker wires through, cut them 5 inches from the socket and sliced them back together, you do it anyway for your xenons
There was this passat behind me today with headlights twitching like a Christmas tree, now I know why lmao, great DIY video !
Great video as always. I came across this one in search of a possible fix for the headlights in my 06 Audi S4.
Are these harnesses available for other VAG?? And where do you buy them?? I'd even consider an aftermarket solution to the fragile, overheated, mostly missing mess of insulation in my headlights. 🤨☺
I’d always check with the dealer to see if that’s the fastest way to get and answer
Thanks Charles, but somehow, I don't like my chances of that. It might need to be aftermarket repair loom. Perhaps a retrofit from one of all the looms I see online for all the LED or Bi-Xenon retrofits
It would be interesting to see the wiring replaced while keeping the old connectors (depinning, rewiring with new wire, etc), sort of like a custom harness.
The wiring harnesses are quite a bit expensive for some of the pockets out there, so would be great to see ways to save money and fix what VW decided to cheap out on (wiring insulation that is).
+Gatis Girdenis I've been thinking about picking one up from the salvage yard and doing exactly that.
HumbleMechanic that's great, can't wait to see. I'm in the middle of swapping a VR6 in my MK4, and I have a cut up harness as well as I want to do a wire tuck, which is a pain in the butt for the MK4.
Also, what else could I use for depinning the connectors other than that expensive tool? I just need something for one time use as I dont plan to touch the harness any time soon after I'm done with it
good video mate . you coud have used the old brown and green to pull the fishing line thou
Ahh that period when VW decided to use the crumbliest flakiest pastry for their wiring insulation.
Yep. I have fixed a lot of headlight bulb connections like this. But mine is far and away the worst
I was wondering what the deal is here. What garbage
Hopefully the replacement had different insulation.
i thought it maybe had to do something with maybe the condition of where you live, something like extreme heat and cold like down here in texas, it ruins everything
Great job Charles!! You should do one of these for the MKIV Golfs.
Hi Charles, With the headlight harness issue what is the cause?
Was it to high of current draw , cheap factory wiring sheathing or heat from the headlights?.
Was this a common problem and is the replacement harness upgraded oem or aftermarket.
Another great video mate. Cheers Mark.
Hi temps inside the housing, and poor shielding of the tires I assume. :)
@@HumbleMechanic shielding of the "wires" ?
Thanks bro...I learn something new....I am electrician..so...let DIM...do it myself....save a lot of time and money...
On my B5, I stripped off the old, cracking insulation and replaced using 1.5mm shrink tubing.
oh geez HM,watching you remove the wiring reminded me of a surgical procedure..perhaps we can call you doctor HM...excellent vid Charles. cheers
Thanks so much
I don't need to know how to do this as I don't have a passat anymore but your voice is soothing so why not XD XD.
:) Thanks you
Great video! Very useful indeed. Thank you. How about one with vw jetta mk5?
Nicely done, but I am appalled by how bad the original wiring was!
Can I ask how the wiring harness got so bad in the first place?? But great job 👍☺ keep up with the good work
Age, temps and poor sheathing
My question also because it's only 2 yrs old? A 2017 Shouldn't need replacing that soon?
Stumbled across this looking for a simple removal to replace and surprised they added this route. Is it worth it to wrap with a sacrificial tape layer to prolong the life of the wiring insulation or will it make any difference with the 18ga wiring (halogen, not led)?
decades later another mechanic finds the repair and says, "Check this out, back in the day they spent countless hours replacing the crappy wires so they could drive in the dark..hahaha...ha...ha" with cartoon mouth moving out of sync. I gotta do this soon to my own x4 so I laugh at myself. great vid. thanks for the heads up.
Great job. But for the entire video I was thinking bad thoughts about the MD in VW who outsourced that rubbish wiring. This should plainly just not happen.
+Andrew Thompson lol I feel ya.
⁹
I have an audi with this same problem, namely the insulation somehow "evaporated" from the wires, leaving a bunch of bare wires inside the plastic case that all shorted out. I have never seen this bizarre phenomenon on any other brand of vehicle.
1986 an prior volvo 240s have this issue with the main engine wiring harness as well as other areas
Hey this is what was wrong with the headlights on my gti that I emailed you about, I just painted it up with liquid electrical tape for now, it was sooooo much easier then this.
Also can you do a video on aligning the beams? nothing worse then headlights that look like a botched boob job.
I do need to to that. I want to set up the proper way to do it and show that first. Then show the DIY way.
I was wondering why are the pins on a lot of connectors so small? I was meaning like the window switches on the master control. The only was I see the repair would be replacement of the harness. Could you do a video on one of these and how to test these? I was never sure how to test or depin these.
+Brian Skinner I think I've done depinning video before.
The pin size is based on the wiring connector and the wire size. Smaller connections usually have smaller pins. Also smaller wires use smaller pins
Hey Charles great video what's the part # for that harness?
just finished a thermostat job on a passat with the 2.8, 5 hours for a 10 dollar part, got it together and didnt think about the housing surface being eaten up just enough not to seal... coolant everywhere lol
+Zach Cypert yeah those get a new housing every time. Theybget so brittle
HumbleMechanic good to know!
If VW and other manufacturers had specked it properly none of this should be necessary
Holy hell this looks like the wiring on my Peterbilt 379 😂 nightmare replacing
Not hating, not being a smart ass. Clicked on this because I've had a few issues with the '80 Powerwagon. Near the start I realized this had nothing to do with my halogen set up. Headlight switch is on the dash, pull out the knob for lights. Some how I watched the hole video. It's like watching a NASCAR race waiting for the crash.
Nice job, covered all bases.
+J. Hunto's Garage thank you sir.
Awesome video .. I need the harness for a 2010 facelift A3 . Mine has the Xeon projector headlight . My harness is completely shorted out . Is there a part number for this harness ?
Hey Charles HumbleMechanic! Great Video! I have a B6 Passat and the Headlight Won't Turn OFF. Even when the whole car is shut off and all the doors locked. Its only the drivers side one.
I heared it could just be the battery just needs replacing - could that be it? Ever run into this issue?
This seems like a recall needing to happen. The potential for a electrical fire seems high. Is this that common on these cars?
Nah, I doubt it will ever be a recall. The odds of actual fire are pretty low. Each section is fused.
This is somewhat common. I have fixed a lot of bad wiring to the headlight bulb. This is the worst I have seen
What would be the average cost to get the new wiring harness installed? Wanted to do it myself but rather not take any risks
Probably 3 or so hours?
vw touareg the labor is 2 hours at $125.00 you are looking at $250.00 and extra for parts, each harness is $86.00
Just a thought (from a 12v installer). Why not just snip the turn signal wires at the plug and use the original wires to pull the new ones? Instead of pulling them out and using fishing line
Zachary Welvaert he said he wanted to keep it intact.
well done! I have same problem my is VW Jetta S 2014 2.0L I couldn't find whole harness replacement kit my DRL wire burn I try to recreate twist together and didn't work. I think the housing itself need replacement where can I order harness whole kit?
I would like to attempt to replace my standard halogen headlights (with no projector) with a LED projector type on my VW. It would be nice to present a video on how to DIY. Thanks. Nice video!
Its illegal if its not originally not made for LED light!! I have fined for 50$ doing that, avoid it mate🤧😞
I used silicone wire and re pined the harness plug.
a little solder and high temp heat shrink all is working again
rebuilt the engine harness on my 1980 Volvo with silicone and Teflon wire as this era car had "biodegradable" wire
Scott Johnson oh lovely as if the squirrels didn't destroy a perfectly good wiring harness fast enough they had to have the wires destroy themselves 😂.. I mean I guess it's a good way to ensure that people always need to fixing something and therefore giving you money in one way or another
I fixed my sister's old car's headlight wiring that someone "fixed" by jamming a block of wood between the melted plug and the core support. The car caught fire a few weeks later from some shoddy wiring under the dash.
WOW!
CAN you please do a video on a Golf MKV xenon light harness wire issues because range motor won’t work and VCDS is saying Headlight Range Adjusting Motor (V48)
010 - Open or Short to Plus and I don’t want to replace the headlights
How the heck did VW/Audi make such horrible wire sheathing?
Any chance these are available for the Cayenne 955?
Hey Charles! where did you get the wiring for the headlight?
For this one, it’s available from the dealer.
Can you get from FCP Euro too? Doesn’t look like a regular lay person can replace the front light harness. Dealership claims my harness is shot and wanted to charge me $350 for a kit🤷🏽♀️, said replacing the bulb wouldn’t work. I’ll try replacing the bulb first though, they are pretty dishonest so I can never trust them!
Your blinker fluid is empty bro.
+Jorge Carbajal Muñoz damn. The warning light didn't even come on. Lol
Damn it! I can't find the fluid anywhere is this like the third inline exhaust bearing computer modualizister hidden like everything else? I have been using old fluid for the above at the dismantling yards! Where is a good spot to buy the five finger blinkles flued of got yo $ mod!
Hey idk if you still reply to comments on here but I need an answer kinda quick. My headlight connectors went out on both sides and I wanted to know if I buy new ones if they’re the same on both right and left side
Way to go Volkswagen I have a 2007 Passat which makes me crazy when I have to change the lightbulb I would think German engineering could come with great design these headlights are Japanese all away
I know that you probably covered the headlight harness issue years back, but still I want to humbly ask you, since upon checking with the dealer, the price of one is almost as replacing the whole headlight.
I am retired and I cannot afford it in my fixed income with today's food pricing
Is there anyway you could show the pinout of a 2008-2010 touareg( 6 pins in the connector only) headlight wiring as to what position wire from the connector goes to which light bulb. I would like to do the repair with soldering and new wiring from the connector to every light bulb.
Thank you in advance...
Where can I find the parts? I'm looking for a wiring harness for a 2001 Audi Allroad. The headlights in the vehicle now blow the fuse for the low beams, according to my wiring diagram they are wired incorrectly, likely from someone installing lights from a similar vehicle that has different connections. Now I need to rewire it and the harness inside is crumbling a bit. Would rather replace than make something from scratch
Working on this right now on an 07 Passat wolfsburg edition. Can't seem to get the pins out of the connectors, and can't find a part number to look up to get a replacement harness. Getting frustrated :/ do you happen to have the part number for this harness, or have a link to the tool needed to remove the wires from the connector? I can repair the harness with heat shrink tube but im trying to avoid cutting and splicing the wires. The heat shrink tube will slide over the end of the pins in the main connector, but not the end that connects to the bulbs unfortunately.
I would have cut it and then attaching new cables to the old ones would make it possible to toe the new cable from right to left using the old. A little bit like new brake cables^^
Oh sorry I thought you were about to repair the harnes rewirering the old plugs with new cables 🙃
27 dec 2019 2:30 am est:thanks, i wonder whether car-head-light-cable connect to battery or alternator ?
Fellows, any suggestions as where I can get a replacement wiring already mounted for the Passat B5 97-00 ?? Tons of ads on eBay but all of them only apply for the B5.5 :(
My question is why bother to take the contacts out at all? Why not just cut the existing wire end and cut the new blinker wire and solder them together and then as you pull out the old wire your using the old wire to pull the replacement wire into place. Cut out the temporary solder connection and then reconnect the blinker wires with the rest of the harness. Then put some heat shrink tubing over the solder joint and Bob’s your uncle!
I’m not sure that’s any easier. Lol
Just found this video. Looking for internal harness for Mercedes-Benz Hella bi-xenon headlight. Any idea where I can order one?
where can i get the replacement harness?
I have the same insulation issue as in your video, called audi (a3 8p), internal headlight harness is not avaliable independently. is there a vw headlight that shares the same internal wiring and connectors that is available?
how are the pins supposed to be removed from the main connector? I wanna just pop the pins out and put heat shrink over the exposed wiring.
There is 2 locks on the connecter. The secondary is purple. and the primary, you need a release tool.
are replacement headlight wiring harness for 2004 Touaregs with Bixenons available?
I have a 06 mk5 and i put a 08 mk5 engine in it can the wiring harness of the 08 cause issues with the older things?
Good job man!I wanna do exact same with my 2006 Audi A4 with original factory HID headlights, plus I have to change or convert my original 14 pin socket to 10pin, do you think is it a big deal?
+Farzad Danesh changing the sockets will be kind of a pain. But as long as you have both connector ends and the wiring diagram you’re fine.
I'm having trouble finding a wiring harness for the headlights on my 02 Cabrio. Any suggestions?
That is likely obsolete. If your are lookin for the whole harness for the front lightla, I’d buy a junkyard one and rehab it
@@HumbleMechanic thanks man I might try to figure out where the connection is broken and try to fix this one. WOW the wires in these are so brittle, I've taped them up some.
How did you determine problem was 'Headlight Assembly' ???
I can’t figure out how to remove the power cable that is holding the assembly inside still. Is it a pull lever or push?
Awesome presentation. Thanks
Hello, are all the turn signals (front, rear,and mirror) on same fuse (06 vw jetta), or is the mirror one separate?..no voltage to pass. Side turn signal( on mirror) ..all other turn signals work..where do i start (to find the problem) thank-you
Were i can get a replacement harness like this for a 08 VW Touareg with factory HID lights?
would this be the same format as the back lights and th small side ones ? Trying to find/replace the parking lot and small light on the sides wires. 😀
The rear bulb array comes completely out
maybe use some heatshrink on the exposed wires ? but you'd have to pull the pins out of the connectors somehow
Actually de-pinning the connector is easy if you have the right tool. Other than not screwing around with the turnsigal, much of the job would have been the same
What is the the white clip wire connector in the head light.. 2006 passat headlight!
Would you by any chance have a way to wire from an 2015 Acura TLX led headlight to the newer 2018 Acura TLX led headlight .
great video again
Thank you :)
Hello, HumbleMechanic I've looked everywhere and cannot find the "how to" I was hoping you could help me with a task that is driving me nuts, and I really need help with. I have an old civic the turn signal and headlights switch broke and as expected with a 37 year old car I cannot find a replacement. I need to wire the headlights to a three position switch (high, Low, off) as well as the city lights and turn signal. can you help me with instructions, or show me where to find it? I really appreciate any help you can offer. Thank you - Semper Fi
Wouldn't it have been easier to split the lens? if the glue is butyl its 15' in the oven job. Did the headlights on my mk1 TT and the cables were disintegrating, just like in your video. Main pin housing is exactly the same, amazed you could take it off blind.
Maybe would have been easier. There is usually more than one way to do the job right. I don’t love splitting headlights because it opens the opportunity for water intrusion. But that could have worked just fine
@@HumbleMechanic appreciated that you reply to comments. Thanks.
Will this headlight harness work for Audi A6 also same years?
Brilliant little video 🇬🇧
Thank you
Torx Torx Torx Torx Torx Torx Torx Torx and lastly, a Torx.
+Big Dog50001 hahah. It's a VW you gotta have your torx.
do you know if they make a B6 Audi A4 harness like this, I know they are similar but i can't seem to find it by itself
I have the same problem with my Audi's A6 C6 xenon headlights. Can you direct me to some site where can i buy those wires?
Just bought a 2007 VW Jetta 2.5L 6 speed 4 door. They didn’t give me much information on it. The passenger side low and high beams are not working. When I popped the trunk there were two other headlight assemblies in the trunk with harness and plug still attached. Do you think it’s worth me trying to install the passenger side one from the trunk by splicing in the new harness to see if this solves my problem?
I also find it strange that other lights on my passenger side don’t work , like the front right signal and marker and also the mirror signal on the passenger side. I’m lost with this, I’ve never seen this many lights go out on one side...
Any ideas????
Any and all help would be greatly appreciated.
I have a question ...
I had a blowout in my 94 prelude. The damages were my fender was messed up, my bumper ripped off, and main problem is the my wiring harness for the right side of my head light s were ripped out. From the inside of my car . Can seem to find the harness anywhere or what it's called lol can you help me please?
Hello man!! Regards a from Mexico.
Just one question. Any sugest about where i Can buy this arnés? Any place in the internet? Thanks.
Hi there, please where do I find the headlight main plug?
Hi, i have an Audi A4 B6 with the same problem, and my wires harness its like yours can you tell me were i can buy it please?
Wow, american Passats does not have the motor to correct the tilt of the headlights from the dashboard in case the trunk is full.
In Europe its not allowed to install aftermarket xenons without the proofed headlights and without headlightwashing equipement and automatic tilting equipement for the headlights.
In my opinion the original xenon headlights looks way better than the HID headlights.
I agree on the look of OEM xenon. Sadly it was only offered in the W8(I think) of that generation.
Hello, firstly I would like to wish your country well in this hard times the whole world is facing. I was trying to connect my vw polo 2003 headlights switch when two connections came into contact and the car blackedout and showed the EPC light and handbrake is blinking now the car won't start and there's a funny noise from the bonnet and its a small buzzing sound. The starter won't turn at all
What year is your Volkswagen. ? Did that wirring harness come assembled already?
This is a 2005 and the harness came complete
Is it possible to order replacement wiring for Audi?
I'm having wiring problem with my 98 vw beetle does this apply to my problem?
Hi. Where can I get internal wires for a Bixenon headlight unit from a Jetta Gli MK5?
My solution is to buy xenon headlights from VX Tuning haha!
Plug on headlight ,where bulb is plugged into , is broken , can it be replaced easily??
Get a better crimping tool. The ratchet style ones are so much better and are great if you use a lot of crimps.
+Ian I have one. Actually 2 of them. They are great. Just didn't feel like digging it out. Lol
It seems like mine always sticks or the crimp sticks. A trick to this or did my wife buy me a cheap tool for my birthday? Lol Honestly, she received it for review...so I am not out anything. Also, I received older 50/50 and resin soldier in a garage sale box. A good amount, really, but damn...it really doesn't flow. Is there a difference now that we are leadless in the flux or possible contaminate? I hate not being able to crimp and soldier everything. Man...I just snip and pull like residential wiring.
I have a 2006 Jetta with both sides not working. I cannot find this wire harness anywhere. If I redo this myself, what would you recommend for wires?
Use SIlicone Wires. they are used for high heat environments.