Headlight wiring deterioration

[zafirovp]

Im sure that most of us have cracked isolation inside the headlights. I had BMW and Porsche with the same problem.
How can I fix this stupid mistake made by the German law for biodegradable wiring isolation.
Maybe cutting the wires, soldering and heat shrink will solve the problem? Is there any way to disconnect the cables from the connector in order to put heat shrink without cutting the wire? Do I have to open the headlight assembly (in oven), or only the plastic caps.



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[dan2485]

extract the pins out of the plug one by one, then put heatshrink over the wires.

By the look of that the wiring has got hot and gone brittle.

if it was me i would cut back the wires and put new terminals on them.

[B5NUT]

As above I think you have had a fault and it's caused the wiring to get hot. My A6 is a 2006 model and I've just had my headlights out and the wiring was fine.

[MarkTM]

Zaf, it may also help if you were to add your model/engine/transmission/year to your signature strip so you don't have to remind those when posting

[vwcabriolet1971]

Check with dealer that a repair wire/connector is available. This should have new connector filled with wires of the correct colour. I've had VAG tailgate repair connector/wires before - quite inexpensive . Damage looks confined to short length so repair conn./ wiring should be O.K. This makes for an easy quality repair - either use insulated in-line crimps or solder conns. + heat shrink tubing.
Scrap yard supply of complete conn + wires ?