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Join Date: Sep 2014
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1985.5 944 headlight problem

My son's 944 passenger side headlight went out this past weekend. I figured it would be an easy headlight bulb change. Changed the bulb, still no light so I checked the fuses. The fuse was blown, but apparently there is something not quite right. Someone had replaced the 7.5A fuse with a 20A. I replaced it with a new 7.5A and it immediately blew.
Any ideas?

Old 12-12-2014, 02:04 PM
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Ornery Bastard
 
Join Date: Sep 2001
Location: South Sound
Posts: 2,879
Quote:
Originally Posted by Barristan View Post
My son's 944 passenger side headlight went out this past weekend. I figured it would be an easy headlight bulb change. Changed the bulb, still no light so I checked the fuses. The fuse was blown, but apparently there is something not quite right. Someone had replaced the 7.5A fuse with a 20A. I replaced it with a new 7.5A and it immediately blew.
Any ideas?
All I can think to say is to trace all the wiring from the fuse to the headlight and find out where the short is.

The bigger problem is that, with wiring designed for 7.5 amps delivering well above that, you're likely going to need to replace it as there's decent chances of melted insulation, etc.
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Old 12-12-2014, 02:32 PM
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Yeah, it was the wiring. I traced it back to where it went into the larger wiring harness. The insulation was missing on all three lines and one was broken.

So.... How hard is it to replace the wiring for the headlight? I fixed it as best I could for now, but it's definitely a temporary fix.
Old 12-12-2014, 02:56 PM
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Garage
Download this manual and look at pages 106-107 for an electrical diagram.

cannell2.co.uk

Good Luck
Old 12-12-2014, 04:06 PM
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Perfect opportunity to go with a new wiring harness, which obviously should have been done when the headlights were upgraded by the PO.

Old 12-12-2014, 09:11 PM
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