H7 bulbs low beam - Short life time
Models:
Zafira 99-2000, Astra-G 98-2000
Engines:
All
Option:
Group:
N - Electrical Equipment
Troublecode:
Non
Complaint:
Electrical failures
Burn out of H7 bulbs low beam.
Cause:
Excessive voltage, thus service life of the H7 bulbs low beam
may be reduced.
Production Solution:
Modified wiring harness has been introduced in production as
of following VIN:
Bochum: Astra Y2 199 906, Zafira Y2 199 913, Antwerp: Y5 231
749, Eisenach: Y6 087 573, Ellesmere Port: Y8 116 363.
Remedy:
Special Part:
No
Retrofit resistance wire for headlights.
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Working Procedure:
1. Open hood.
2. Disconnect battery.
3. Disconnect brown connector wiring harness of left low
beam.
4. Partially remove insulation.
5. Disconnect and skin brown ground cable 3 to 5 cm
behind connector wiring harness.
6. Install shrinkdown tubes and connect original cable
with resistance wire with smallest spring-finger connector (0,5 -1,0 mm2) of
cable repair kit MKM-923.
7. Heat shrinkdown tubes.
8. Fix insulation with insulation tape.
9. Route resistance wire beyond coolant retainer and fix
with a strap (I) .
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10. Connect brown connector wiring harness of left low beam.
11. Remove upper and lower air filter housing.
12. Disconnect brown connector wiring harness of right low
beam.
13. Partially remove insulation.
14. Disconnect and skin brown ground cable 3 to 5 cm
behind connector wiring harness.
15. Install shrinkdown tubes and connect original cable with
resistance wire via smallest spring-finger connector (0,5 -1,0 mm2) of cable
repair kit MKM-923.
16. Heat shrinkdown tubes.
17. Fix insulation with insulation tabe.
18. Connect brown connector wiring harness of right low beam.
19. Route resistance wire beyond upper and lower air filter
housing (II) .
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20. Install upper and lower air filter housing.
21. Connect battery.
22. Carry out operation checkout.
23. Close hood.
24. Reprogram volatile memories.
Spare parts: Part
No.: Catalogue No.:
Resistance wire (Astra-G) 9196665 90
12 029
Resistance wire (Zafira) 9196666 90
12 030
Strap, 120 mm 90381846 12
88 885
Bulb 90512338 20
98 928
Labour Times: TC: Hours:
T 8 129 80 Retrofit
resistance wire 90 0.7
hrs.
001 Replace
one bulb 0.1
hrs.
002 Replace
the second bulb 0.1
hrs.
The regular warranty procedure should be used for claiming
set-up-time.
