Headlights - Condensation

417-05

XK

DATE: 12/01
Amended 04/04

MODEL:
1997-*2004* MY XK Range

VIN:
001001 - *A39841*

Headlamp Misting - Improve Ventilation - Repair Procedure

Remove and destroy Bulletin 417-05 dated 12/01. Replace with this Bulletin.

Updated information is shown with asterisks.

Issue:

Some 1997-*2004* MY XK vehicles may experience a build up of condensation in the headlamp assembly. A T-piece vent pipe can be installed to aid air circulation to reduce condensation in the headlamp.

Action:

In case of a customer complaint of condensation build-up within the headlight assemblies, install the a T-piece vent pipe, following the procedure below.

MODIFICATION PROCEDURE





1. Inspect headlamp to see if stub pipe is present (Illustration 1).

Note:
If stub pipe is present, continue with workshop procedure from step 2, if stub pipe is not present, obtain a new headlamp assembly and continue from step 3.

2. Remove headlamp assembly (see Workshop Manual, JTIS CD ROM section: 417-01, SRO 86.41.33 or 86.41.36).

3. Reposition headlamp so the stub pipe to be drilled is facing downward.





4. Carefully drill a 9 mm diameter hole upwards into headlamp using the stub pipe as a guide (Illustration 2).

Note:
Maintain headlamp in the same orientation as for the drilling operation and shake out any drilling debris ensuring none remains in the headlamp.

5. Place headlamp on clean bench.





6. Install and align T-piece to stub pipe (Illustration 3).

Note:
Ensure headlamp stub pipe and T-piece mating surfaces are free from oil and grease.

7. Install the headlamp assembly (see Workshop Manual, JTIS CD ROM section: 417- 01, SRO 86.41.33 or 86.41.36).





Parts Information

Warranty Information:





Warranty claims should be submitted quoting the information found in the table.

This will result in payment of the stated time and, where applicable parts/miscellaneous expense codes as listed.