The rest of the car is not nice enough for new headlights, especially at the cost of HIDsIMO, by the time you disassemble the headlight enough to properly fix the wiring, the lens is off. At that point you can also replace the reflector bowl. Might as well send the lens off the be professionally polished and UV re-coated. The little project has became a big project.
TLDR: These headlights are (imo) an obvious manf. defect that leads to a safety issue, but the responsibility has been dumped onto the owner.
Second Change of Plan:Change of plan.
I am going to clip the wires off each plug one at a time leaving enough pigtail to solder to and use heat0shrink over each pigtail.
Shouldn't take me more than an house or so a side.
Not as neat as a full rewire, but a lot safer than using liquid tape.
I thought about that.Sorry I did not see this sooner. The lack of experience of some of our constant posters really shows with their lack of personal experience.
You will cause more damage by trying to rewire the harness when all you need is to do is recover the good wire and insulation. I have done this on several of my cars. If you need some of this split loom let me know and I will send you all you need for $7 shipped. View attachment 244691
If the first one does not go as well as I expect, I'll take you up on the loom.The loom I have works, but it’s your car and choice. Sounds like you have made your choice. Not what I would do (I have reworked a V10tdi into a Corvette) but you may know better. Just sharing my experience. Good luck
How did you get the rear plug out?
I have the bi-xenon headlights. As I recall I did not have any problem separating the components.I assume the hard part was getting the rear plug and the ballast connector?
I have the dual projects (HID and Halogen).I have the bi-xenon headlights. As I recall I did not have any problem separating the components.
The hard part was getting the harness unclipped inside the assembly.