The Log of maintenance, modification and ownership

Renew crumbling headlamp wires

Alfa 156s without doubt suffer from the “environmental-friendly” material used for electrical wire wrapping. 2 main areas afflicted needing attention are seat belt pretensionors wires and headlamp wires

Alfa 156 crumbling headlamp wires

I own 2 sets of the Xeon headlamp and have seen 3 sets of it. All have the crumbling wires. At that time, I don’t see any malfunction of the headlamp due to the deteriorated wire wrapping. I just felt very uncomfortable by merely looking at it. So I decided to do some preventive maintenance.

Step 1

To renew the internal wires, I took the harness out by unplugging the connector inside the headlamp housing and the connector to the ballast.

Alfa 156 headlamp internal wire plug

Headlamp wire plug inside the housing

Alfa 156 headlamp wire connector to ballast

Headlamp wire connector to ballast

Step 2 – Remove the old headlamp wires wrapping

Used only my finger nails, I easily remove the old wrapping of the wires.

Removing old wire wrapping

Step 3 – Re wrap the wire

Open the plug cell to access the individual wires.

I use heat shrink tubes to re warp the wire. Luckily I manage to source shrink tubes that match the original colours. The diameter of the tube I used is 1mm.

Step 4 – Install the headlamp wires back

It is quite an enjoyable process by just looking at the renewed wire with tidy and clean appearance of the wires

Feb 2023

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