W202 Headlight Bulb Connector has melted!!

steve kane

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For some while we thought that one of our headlights was not alight all the time, as we drove along sometimes the lights became noticibly brighter, but whenever I checked the lights all seemed to be okay, anyway eventully one went out and when I came to replace the bulb I found that for no obvious reason the plastic inside of the electrical connector that pushes onto the bulb terminal had mented and no amount of plully and levering will get the bulb out, I guess that there must have been a poor connection there and this caused some arcing or overheating. Its the Near Side Dip lamp and its not too easy to get at but I cannot see that I can easily replace the wires and connector complete, does anyone know how easy the wireing comes out? if its a lot of work I plan to just snip off the old connector and solder on a replacement, are these available or if not does anyone have one about I could purchase?
I would suggest that if you think you have an intermittant fault with a headlamp its worth checking the connections PDQ before it melts itself to destruction!!
Steve.
 

television

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They are cheap from a breaker complete with wire that you could join into your own harness.

Yes arcing is fatal in fuse boxes etc where some items like fans can draw 20 amp. If everyone with an older car cleaned all of the fuses and holder with a non drying switch cleaner many of the silly fault would not occur
 
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steve kane

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Many thanks TV, the problem of course is that there are just so many electrical connections on a car,,where would you start? but the sentiment is quite correct. I dont have a scrappy near me so I think i might put an advt for a connector in the Spares Wanted section, hopefully someone will be breaking an old Merc, I wonder if they all use simmerler connectors?
Steve.
 

television

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Robparker a forum member is breaking 3 202 cars,these things are not handed,, you will find robparker about 5-6 pages bck in the for sale columns.


To cap your post there was the guy with xenon lamps who had a bulb out and went to halfords where they removed the lamp and told him to go to MB,,,on the drive there the man said that it was alight even without the bulb,, it was a light alright and on fire where the 3k voltage had been arcing
 
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steve kane

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Many thanks for your help the problem is now solved, a friend picked up a bulb holder for me on Monday and I crimped it on, and the little bunnies of Hampshire are once again basking in the warm glow two headlamps!!
Now I have to tackle the glowering ABS lamp and I think I will start by taking a peek at the front wheel sensors, is there anything in particular I ought to be checking or looking for?
Steve.
 

television

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All connection to the ABC controller ECU should have the pins cleaned, I think I have some info on this that has sorted out a few cars
 
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steve kane

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Many thanks Malcolm, will I find the artical about the ABS ECU by just searching under ABS problems or is there a more direct link/keyword?
Steve.
 

television

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I cant remember but I supplied the info and I will have that info,, do you have the ESP lamp on as well or only ABS
 
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steve kane

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Hello Malcolm, and many thanks for your help, its just a ABS light thats showing. I tried searching quickly earlier today for "Cleaning ABS ECU contacts" but nothing came up, I will have a trawl through the ABS section to see if I can find it later this eve.
Steve
 

television

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101 in this link is the ABS control box. from memory each wheel sensor should measure around 1k ohm. The connections on the box 101 should be checked. you could also give the box at tap, to check if any dry connections inside.


I cannot fine the car in question though I think it was a diesel,,but that does not matter
 

bigasotonuk

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Hi,
For information,
If you have an early pre-face lift 202 (without any form of traction control IIRC) you will only have 3 ABS Sensors, 1 for each front wheel and only 1 for the rear, which is fitted in the diff. the cable connector can be got at from inside the boot.
 
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steve kane

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Many thanks indeed Malcolm, its much appriciated, I will try to check out the contact on the control box as well as giveing the wheel sensors a quick look over for any obvious faults and report back, it might be a week or so before I get the chance to do it though,
once again, many thanks,
Steve.
 

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