Any electrical experts? Headlights not working

[PawnSacrifice]

Sorry, tomTVR, slightly off topic, but just quickly...

If you want I can send you pictures, smaller scale, of something that I've done - will be writing up later this week when finished anyway.

Good man. I wondered how you were getting on with it!!!

Thanks, just needed a free weekend to take the car off the road... you're advice was really helpful, gave me confidence to crack on as well (you should post that message as a How To), all on the car, just need to sort the switches now. Hopefully in the evenings this week.

Back on topic, BTW, tomTVR, if you need any details on the wiring I'll be able to get you the pin numbering and what goes where later this evening.

 

[tomTVR]

PawnSacrifice thank you for the advice.

I'm only hard wiring them on my current headlight to see if its possible. The isides are totally ruined, the connections to the motor have melted. If its possible then i can use this method on my new headlights when they arrive and i will use some connectors if/when i do it properly. Yes its still a bodge job, but when the loom/connector is going to set me back £116 then its well worth it in my opinion! Likewise i already plan to silicone up the old plug socket (on the new lights) and seal the wires into a new hole, i have had enough problems with condensation!

I think the main thing is connecting the wires in the correct order. Im going to give it a go now and report back.

 

[cj10jeeper]

tom - just remember that the connectors on the back of the headlights do get wet as water and spray get around the access panels. For this reason your connector - whatever you choose it to be needs to be waterproof or at least pretty durable.

Sadly in the harsh environment 'bodge' jobs won't last a Winter season, so make it a good one

 

[tomTVR]

Ok i have given it a go with no luck. There are far too many combinations of wires and i havent got a clue which one connects to which.

I have also found the passenger headlight (the problem one) has different coloured wires going into it than the drivers.

Could anyone with halogen lights please describe or show me a picture of the wires going into the passenger side headlight connector?

Otherwise i am seriously stuck!!!!!

 

[PawnSacrifice]

Okay, had a look and...

You can see the signal information online at:
http://spaghetticoder.org/bmw/wds/e85/

Format is - Pin no - signal code - wire colour - wire size in mm squared

Left headlight:
Pin 1. 31L Brown 2.5mm
Pin 2. 56BL Yellow/Green 2.5mm
Pin 3. 56AL White/Green 1.5mm
Pin 4. 58VL Black/Green 0.5mm
Pin 5. 49VL_1 Blue/Green 0.75mm
Pin 6. 49VL_2 Blue/Green 0.75mm
Pin 7. 31L Brown 2.5mm
Pin 8. Empty - BIXENON

Side light - pins 1 and 4
Low beam - pins 2 and 7
High beam - pins 1 and 3
Indicators - pins 1 and 5 / pins 1 and 6

Right headlight:
Pin 1. 31L Brown 2.5mm
Pin 2. 56BR Yellow/Blue 2.5mm
Pin 3. 56AR White/Blue 1.5mm
Pin 4. 58VR Black/Blue 0.5mm
Pin 5. 49VR_1 Blue/Brown 0.75mm
Pin 6. 49VR_2 Blue/Brown 0.75mm
Pin 7. 31L Brown 2.5mm
Pin 8. Empty - BIXENON

Side light - pins 1 and 4
Low beam - pins 2 and 7
High beam - pins 1 and 3
Indicators - pins 1 and 5 / pins 1 and 6

Pin layout...


Hope that helps. I hope either the cables inside are the same left and right or they match up to the external colours. It looks are though the base colours are the same left and right, can you just double check the info above, ie check against the working cable.

Good luck

 

[tomTVR]

Great information thank you. I will try it tonight or tomorrow and report back.

So we are guessing the yellow wire on the inbound side doesnt go anywhere?

 

[tomTVR]

Nice one, that information was a godsend.

I found some extension cable and a household connector made it much easier.



The lights now work as they should but the unit is ruined beyond repair so a long way yet to get it fully fixed.

 

[PawnSacrifice]

Glad you got there.

How on earth did you waterproof that lot? Or are they going inside the light for now?

I was going to recommend some connecters - www.e2auk.co.uk - I have been using their superseal connectors which are water tight, but a bugger to fit together because of it. However the ones I've been using are possibly not big enough for the 2.5mm cables.



If you want to try a search the connector part is 631010. You may find a breaker that will chop the end off a loom for you - although I assume the plastic is in one piece, if they are common to other sockets / plugs, you may be able to buy the bullet plugs from BMW. Maybe have a chat with a friendly indi?

 

[billygilly]

Nice one, that information was a godsend.

I found some extension cable and a household connector made it much easier.



The lights now work as they should but the unit is ruined beyond repair so a long way yet to get it fully fixed.

Hoollly F*"K!!

 

[tomTVR]

Hoollly F*"K!!

Just to confirm, i'm only using that connector to make it easier to match up the corresponing wires, that wont be going back in the car like that!

 

[billygilly]

OK cool, was a bit worried about insulation

 

[tomTVR]

Glad you got there.

How on earth did you waterproof that lot? Or are they going inside the light for now?

I was going to recommend some connecters - http://www.e2auk.co.uk - I have been using their superseal connectors which are water tight, but a bugger to fit together because of it. However the ones I've been using are possibly not big enough for the 2.5mm cables.



If you want to try a search the connector part is 631010. You may find a breaker that will chop the end off a loom for you - although I assume the plastic is in one piece, if they are common to other sockets / plugs, you may be able to buy the bullet plugs from BMW. Maybe have a chat with a friendly indi?

I have already ordered some waterproof plugs from ebay:

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=180364034399&ssPageName=STRK:MEWNX:IT

Although having just read the advert properly it seems that a couple of my wires are going to be 1mm too wide. So i'll need to either trim the wire down a little or bore out the connectors very slightly. I'm not too fussed, its not going to be submerged and will finish it off with electrical tape. The main thing is to be able to have a nice clean break as apposed hardwiring it straight accross which would be too much of a bodge job even by my standards!

 

[cj10jeeper]

Glad yo at least have the wire order sorted

You need to be sure the connectors you are purchasing are capable of carrying the amperage, so trimming wires is dangerous and if the pins too small unlikely to be able to carry the amperage.

Either results in potential overheating and disasterous melting situations, not unlike people who wires aux light in without a relay and wonder why it all goes up in smoke.

BTW - have you asked BMW parts desk for the light connectors. They have lots of fittings like that that do not appear on basic parts sites (just lke the retrofit cables used in some projects)

 

[tomTVR]

Hmmm its saying 14 amp max. What rating are the wires?

I suppose it wouldnt hurt to try the dealer. The only problem is i'm not sure how to explain to them what i'm after. One of the ones i have is destroyed beyond recognition and the other is connected to the car which is grounded!

 

[PawnSacrifice]

2.5mm2 should be around 20amp, although it does seem to vary between manufacturers. Some Googling should get you the answer for the BMW wire ratings.

I put the connector number in one of the previous posts for you - 631010 - on BMW's wiring diagram it's X130 and X135.

 

[a11y]

Guess I'll be removing my bags of dehumidifying crystals tonight then...

Typically, I only installed them at the weekend when I was swapping my winter for summer wheels. I thought it was a great idea too. I don't have major condensation issues, just the occasional small bit of misting up after washing the Z4. Oh well!

 

[tomTVR]

Guess I'll be removing my bags of dehumidifying crystals tonight then...

Typically, I only installed them at the weekend when I was swapping my winter for summer wheels. I thought it was a great idea too. I don't have major condensation issues, just the occasional small bit of misting up after washing the Z4. Oh well!

Thank goodness for that, im not the only one! Even now looking back i thought it was a really clever idea. I just assumed that once saturated they would hold their shape. Instead the crystals dissoloved and formed a lake of death which has destroyed everything. Its hard to convey what a total mess has been caused by something so basic.

You might be ok if you are using silica crystals but if they are calcium chloride then GET THEM OUT!

 

[cj10jeeper]

Depends if that's the rating for each pin, but if it is then should be fine. A 55w bulb should be around 5A but it dependes how many each wires is driving at max.

You'll just be creating a weak point in the system if you trim/bore connectors.

I still don't understand how you plan to coeenct to the rear of the light without the correct plug?

 

[tomTVR]

2.5mm2 should be around 20amp, although it does seem to vary between manufacturers. Some Googling should get you the answer for the BMW wire ratings.

I put the connector number in one of the previous posts for you - 631010 - on BMW's wiring diagram it's X130 and X135.

I have also managed to get the following numbers from each part of the connector.

Female side: PBT ASA GF20, BMW 8 352 571, 1-865073- (
Male side: PBT ASA GF15, 965 070 -1

I think these are the numbers but they are extremely hard to read


Googling all of these numbers plus those which you have supplied hasnt really got me anywhere. I think i'll take all of these numbers plus the charred remains of the two connector halves down to BMW and ruin the parts managers morning..

 

[tomTVR]

I still don't understand how you plan to coeenct to the rear of the light without the correct plug?

I'm going to solder them directly onto the wires inside the headlight and insulate them to a high standard. Then i will drill a hole in the black casing and feed them though before siliconing around the wire hole and inside where the block connector would have gone.

I will have slightly better access to the wiring due to a simultaneous project i'm working on. :wink:

http://cgi.ebay.co.uk/2x-80mm-White-Angel-Eyes-Ring-Halo-Car-light-Lamp-416-/280608203690?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item41558d63aa