Lighting - Headlamp Condensation - Seal Test
NO: 35-15DATE: 5-02-2008
MODEL: See chart below
MODEL YEAR: See chart below
CHASSIS: See chart below
SUBJECT:
Headlamp Condensation - Seal Test
REFERENCE: N/A
NOTE!
If using a printed version of this TNN, first check for the latest online version.
AFFECTED VEHICLES
DESCRIPTION:
Condensation or moisture may occur in the headlamp assemblies, some have been replaced. During material analysis it has been found that many did not have a faulty seal or crack in the headlamp assembly. A pressure test has been developed to determine if a headlamp assembly is faulty. This information is being provided so you can identify normal or abnormal performance and understand the test method.
NOTE:
Because our headlamps have an open ventilation system and air contains moisture, a limited amount of condensation may occur naturally.
Technical Material Analysis (TMA) will be testing returned headlamp assemblies via the method on the following pages. If the headlamp assembly is operating as intended your warranty claim will be rejected.
SERVICE:
To avoid repeat repairs or unnecessary headlamp replacements for cases of condensation in headlamp assemblies:
1) Evaluate if the condensation is normal or abnormal.
2) In some cases abnormal condensation can be caused by a missing rubber plug in one of the unused holes in the electrical connector. Moisture can easily enter the headlight assembly if a plug is missing. Verify the presence of all plugs, replacing the headlamp will not resolve the condensation issue if a hole in the connector is not plugged.
3) Inspection of lens: In a few cases the assemblies analyzed had a small crack around the clips retaining the lens to the housing. These cracks were caused by excessive clip tension. This has been addressed and should only be an issue on a low number of early vehicles
4) If in doubt about abnormal moisture and there are no missing plugs, and / or no cracks in the lens / housing: you may choose to perform a headlamp seal test and if no leak is detected DO NOT replace the headlamp assembly. The headlamp assembly is operating as intended and your warranty claim will be rejected.
Remove Headlamp
Remove the headlamp from the vehicle, as illustrated.
Create Sealed Connector
Install the plugs in the connector housing as shown here.
(1) Housing (PN 30658204)
(2) Plug (PN 9168959) install 4 of these
(3) Plug (PN 9168960) install 8 of these
Seal the Headlamp
Remove the baffles / vents (1)
Install the sealed connector (2)
Test Headlamp
Install measuring tool 9512985 with cylinder leak tester 9512775, as illustrated.
Connect to the lower ventilation hole.
Seal the upper bleed hole using butyl tape
(PN 1161783) or similar material.
Calibrate the tool: check that it is 0 psi (0 bar).
Adjust the control valve so the pressure rises to 40 mbar (.6 psi).
Close the restriction valve and wait 30 seconds. If the pressure maintains 20 mbar (.3 psi), or more the headlamp can be considered to be sealed.
Remove:
- butyl tape
- the sealed connector
- test equipment
To install, reverse the removal procedure.
Warranty Claim Information