Xenon headlamps not functioning - AF82.10-P-6004B

MODEL 203.0/ 2

MODIFICATION NOTES

4.8.04

Model 203.7 and 209 removed due to changed remedy

New AF prepared for mode 203.7 and 209: →

AF82.10-P-6004C

OPERATION NO. OF OPERATION TEXTS OR STANDARD TEXTS AND FLAT RATES

Category	Op. no.	Operation text
P	024131	Igniter for xenon headlamps, location:....replace
P	024132	Replace igniters for left and right xenon headlamps

Damage code	Cause	Remedy
82 279 73	The breakdown voltage required to activate the Xenon burner is not reached by the ignition module The headlamps are nonfunctional due to the Xenon burner not firing.	The ignition path has been modified in the ignition module. The manufacturing date of the ignition module is printed on the lamp unit's label (picture 1).
		Automotive-Lighting (AL) headlamps as of production date 22.04.2003 are no longer affected.
		1 Remove front wheel.	AP40.10-P-4050Z
		2 Remove front fender liner.	AR88.10-P-1300P
		3 Disconnect plug from headlamp.
		4 Unlock and remove housing cover on front of lamp unit at the tab.
		5 Twist plug of ignition module to the left and remove (figure 2).
		6 Remove retaining collar (figure 3). Scrap retaining collar.
		7 Remove burner. Do not touch the glass of the burner with bare hands. Use non-greasy, soft cloth.
		8 Cut off plug as close to the ignition module as possible (picture 3). Scrap ignition module plug.
		9 Cut off the three supply lines (red, black and green) as close to the ignition module as possible. This shuts downs the ignition module at the headlamp (image 4).
		10 Solder the adapter cable onto the supply lines (Figure 5) Use solder connector A 002 546 13 41 Be careful not the damage the headlamp housing with the hot air gun.
		11 Wrap solder connector with fabric tape.
		12 Remove the tabs from the holes of the lamp collar A 230 826 00 89 (figure 6).
		13 Insert burner and attach to lamp collar. Run the ground contact to the bottom (image 7). Do not touch the glass of the burner with bare hands. Use non-greasy, soft cloth.
		14 Push the new ignition module onto the collar until it snaps in (image 8). Ensure correct installation position: Right headlamp (A), left headlamp (B)
		15 Install in the reverse order
		16 Test operation of lamp unit.

Picture 1

Label on lamp unit with manufacturing date (arrow)

Fig 1: Identifying Label On Lamp Unit With Manufacturing Date

G04735737

Picture 2

Plug (arrow) on Xenon headlamp ignition module

Fig 2: Identifying Plug On Xenon Headlamp Ignition Module

G04735738

Figure 3

Retaining collar on Xenon headlamp ignition module

Fig 3: Identifying Retaining Collar On Xenon Headlamp Ignition Module

G04735739

Figure 4

Electrical lines on ignition module

Fig 4: Identifying Electrical Lines On Ignition Module

G04735740

Figure 5

Adapter lines

Fig 5: Identifying Adapter Lines

G04735741

Figure 6

Clip holes on lamp collar

Fig 6: Identifying Clip Holes On Lamp Collar

G04735742

Fig. 7

Insert Xenon burner

Fig 7: Identifying Xenon Burner

G04735743

Picture 8

Xenon headlamp ignition module, right (A) and left (B)

Fig 8: Identifying Xenon Headlamp Ignition Module Right And Left

G04735744

PARTS ORDERING NOTES

Part no.	Designation	Quantity
A 002 546 13 41	Solder connector	3
A 203 545 57 28	Repair kit for xenon headlamps	1