Log #6 - Wiring Repair, OEM Lighting Return and Project Update

Restarting the Project After the Break

After Log #5, the plan was to continue the project as scheduled. However, an electrical fault occurred during bulb checks, so the work had to be paused temporarily. I did not continue the restoration work until the source of the fault was reliably identified and fixed.

After the repair process was completed, the project was restarted. This log records the electrical fault, the repair work, and the new decisions taken within the scope of the project.

First Signs of the Electrical Fault

During the bulb checks, both the left and right indicators and the hazard warning system stopped working. The first inspection of the fuse box showed that the hazard warning fuse had blown.

After replacing the fuse, the system worked only briefly before the same fuse blew again. Since the same thing happened after every fuse replacement, it became clear that the fuse itself was not the source of the problem.

The first assumption was that the hazard switch could be causing the fault. To rule this out, I installed a spare hazard switch and tested the system again. The fault continued unchanged and the fuse blew again.

Repairing the Wiring

Because the source of the fault could not be identified safely, the vehicle was taken to an auto electrician. During the checks, the system blew three more fuses. After that, the lighting wiring was inspected in more detail.

The inspection showed that the Hella headlight socket and the connected wiring had been seriously damaged by heat, with melted cable insulation. The damaged wiring was removed, the necessary cable repairs were carried out, and the system was rebuilt. Missing bulbs were also completed and the electrical system was checked again.

After the repair, the indicator system and hazard warning lights began working normally. The recurring fuse-blowing fault was fully eliminated.

Note: Photos of the actual wiring repair process could not be taken due to the rules of the workplace where the repair was carried out. The images below document the diagnosis stage, the removed LED setup, and the ordered replacement bulbs.

Likely Cause of the Fault

According to the electrician who carried out the repair, the main cause of the damage was the fan-cooled LED low beam bulbs installed by the previous owner.

Even though the LED conversion was not done by me, the damage clearly showed the long-term risk that non-OEM lighting systems can create for the electrical wiring.

Decision to Return to OEM Lighting

After the electrical system was made reliable again, I decided to completely abandon the fan-cooled LED bulbs used on the vehicle.

In line with the OEM+ direction of the project, the following products were ordered:

• Bosch Xenon Blue H1 halogen
• Bosch Xenon Blue H7 halogen
• Philips WhiteVision Ultra W5W

The installation and lighting performance of these bulbs will be evaluated in detail in the next log.

Rubber Seal Maintenance

After the electrical repair was completed, the door, trunk and other rubber seals were cleaned and lubricated with a suitable rubber seal care product.

The aim was to preserve the elasticity of the seals, reduce hardening and noise over time, and support longer service life.

Project Update

The Deerma BY200 upholstery and carpet cleaner ordered for detailed interior cleaning was cancelled by the seller due to lack of stock.

For this reason, the planned deep interior cleaning was postponed until a new device can be obtained.

Conclusion

With this work, the most serious electrical fault of the project so far was successfully repaired. The recurring fuse-blowing issue was completely eliminated and the reliability of the electrical system was restored.

At the same time, the non-OEM LED lighting setup was abandoned and the return to factory-character halogen lighting began. Restoring electrical reliability created a safer base for the next stages of the project, while the rubber seal maintenance continued the long-term preservation work on the vehicle.