This 2007 Suzuki Grand Vitara came in with the complaint of no low beam headlights. I checked the wiring at the passenger side low beam head light first and this is what I found. A burnt harness connector and bulb adapter.
I wired in a new harness connector. I had some NOS (New Old Stock) two wire connectors in my shop, so I used those, to get rid of them. Notice that the original connector had three cavities. The replacements will as well. The third wire in the perpendicular position can easily be removed with a pocket screwdriver. Locate the locking tab on the terminal end of the connector. Insert the screwdriver blade into the slot (notched), depress the locking tab and pull the wire from the connector body. You now have a connector similar to the original. Three slots and two wires. if you do not feel comfortable removing the terminal and wire, you can simply tape off the extra wire end.
To order a repair kit that includes; 4169 harness, 34175-33E50 adapter and Flösser® H7 bulb (high quality 55W bulb made in Germany), please click here.
Installed a new bulb onto a new adapter. Yes, it is fully assembled. I think an engineer really goofed this one up. There is not enough contact area between the bulb terminals and the adapter terminals. Also keep in mind that at no time should anything touch the glass on the new bulb. Even the oil from your finger print will damage the bulb. What happens is the oil or any other substance causes uneven heating of the glass when the light is turned on. The glass may shatter or at least crack. this will result in the loss of the inert gas that protects the bulb element and it will quickly burn out. Never power up one of these bulbs outside of it’s housing assembly. You could be hurt by shattering glass or badly burnt.
Placed the bulb and bulb adapter into the rear of the light assembly and secured using the wire hinge lock.
Installed the rubber boot for the assembly. The boot seals on the outer housing and it also seals on the bulb adapter.
Then connected the new harness to the two terminal bulb adapter.
Notice, that I back filled the harness connector with white lithium grease. I repeated the process on the driver’s side and this car was fixed.
Thanks for the help. I have the same exact problem but the dealer told me I have to replace the whole headlight assembly and it costs 1,300 dollars. They dont tell u that u can just rewire the harness and buy a new socket adapter!