[RandalJ]

My symptoms were front turn signal out and headlight intermittent on the passenger side. Cornering light was OK. I tested all contacts, and nothing appeared wrong with the headlight assembly or components.

In my case it was the harness connection at the back of the headlight assembly. The plug on the wiring harness must be completely engaged into the socket at the bottom of the assembly for everything to work. There is a plastic bracket, part of the headlight assembly mounting bracket, that is supposed to hold that wiring plug firmly in place, enough that re-installation of the headlight assembly causes the plug to go all the way into the socket. Apparently the holding bracket can wear out of be damaged with careless re-installation of the headlight assembly. Not the greatest quality of design.

If you've eliminated burned out bulbs or bulb socket connection problems, run this test:

Remove the headlight assembly, and unsnap the harness plug from the holding bracket so that the plug can reach further. Slide the headlight assembly back in, like you are going to re-install it, but just far enough in so that you can connect the socket into the back of it by hand. Be sure to get the headlight assembly in far enough that it will rest on the mounting bracket and not fall, or you'll have a bigger problem. Note that it takes some pressure to get the harness plug all the way in, because there are 16 or so electrical contacts that you are engaging. You should feel it "give" as it goes all the way in. Now test your lights to see if that was it.

If it was, then your bracket is not holding the wiring harness socket as securely as it should. If you don't want to buy the whole plastic headlight assembly holding bracket, which the harness plug clip is part of, then an alternative is to manually push the plug in from the engine bay, with the headlight assembly installed.

Snap the wiring harness plug back into its clip. You'll need to do this so that the plug is at least close to being all the way home when you re-install the headlight assembly. When re-installing the headlight assembly, look at the guides (two on each side if I remember right)and the shark fin along the bottom of the assembly. Make sure they go in their respective channels on the mounting bracket, otherwise the guides ca be damaged. Then make sure you hear a resounding snap when you lock down your headlight assembly.

Once everything's in, go to the engine compartment, and find the back of the headlight. The back of the headlight assembly protrudes over the plug location, and there's lots of other stuff in the way, making it a chore to get to the plug. It's that way for both headlights. You may have to take off the air cleaner "top" covers. I ended up using a 12" ratchet extension for reach and leverage, pushing on the back of the plug until I felt it give. Make sure you feel it give because you can be pretty sure then that it's all the way in. You might get everything working again with the plug not all the way in, but the problems may return. Once the plug is fully in, it won't shake out again. The bracket should at least put tension on to help keep it in, and with 16 pins, I don't think it would come out due to vibration or temperature cycling anyway.

All the lights should now work, same as when you ran the test.

Avoid removing your headlights again unless absolutely necessary.

Hope this helps.