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

MODEL 203.7, 209

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).
		Model 203.7: Hella headlamps as of 05.05.2003 are no longer affected. Model 209: Hella headlamps as of 28.04.2003 are no longer affected.
		Replace ignition module: ↓
		1 Remove front wheel.	AP40.10-P-4050Z
		2 Remove front fender liner.	AR88.10-P-1300P
		3 Disconnect plug from headlamp.
		4 Unlock housing cover on front of lamp unit at the tab, remove and dispose of cover.
		5 Twist the ignition module plug to the left and remove.
		6 Disconnect the three supply lines (red/black/green) as close to the ignition module as possible (picture 2). This shuts downs the ignition module at the headlamp. The three wires must be disconnected separately. To avoid a short circuit between the strands, never cut these wires together.
		7 Cut off plug as close to the ignition module as possible (picture 3). Scrap ignition module plug.
		8 Solder adapter cables to the supply lines, use solder connectors A 002 546 13 41 (picture 4). Be careful not the damage the headlamp housing with the hot air gun.
		9 Wrap solder connector with fabric tape.
		10 Insert new ignition module in the housing cover and screw in place.
		11 Rotate plug of new ignition module into burner.
		12 Rotate lamp unit housing cover clockwise into place. The fastening screw must be at the top (picture 5).
		13 Tighten fastening screw.
		14 Connect headlamp plug.
		15 Test operation of lamp unit.
		16 Install in the reverse order.

Picture 1

Fig 1: Identifying Lamp Unit With Manufacturing Date Label

Figure 2

Fig 2: Identifying Ignition Module

Figure 3

Fig 3: Identifying Ignition Module

Figure 4

Fig 4: Locating Supply Lines

Figure 5

Fig 5: Identifying Fastening Screw

PARTS ORDERING NOTES

Part no.	Designation	Quantity
A 002 546 13 41	Solder connector	3
A 203 820 11 12 05	Xenon headlamp repair kit	1