ls973800 said:
come to find out the connector and wiring were melted
Yes, that is a well known documented concern with GM and many owner's have had the connectors replaced under warranty. There might have even been a recall on them, but I'm not sure.
No known recalls have been put out for this issue, but there was a current TSB released concerning this issue:
#10-08-42-001A: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector) - (Aug 6, 2010)
Subject: Low Beam Headlamp Bulb Diagnosis/Replacement (Inspect Bulb and Connector)
Models: 2008-2011 Buick Enclave
2007-2011 Cadillac Escalade, Escalade ESV, Escalade EXT
2008-2011 Cadillac CTS, CTS-V
2010-2011 Cadillac CTS Sport Wagon, SRX
2007-2011 Chevrolet Avalanche, Silverado, Suburban, Tahoe
2008-2011 Chevrolet Malibu
2009-2011 Chevrolet Traverse
2010-2011 Chevrolet Equinox
2007-2011 GMC Acadia, Sierra, Yukon, Yukon XL, Yukon Denali, Yukon Denali XL
2010-2011 GMC Terrain
2006-2010 Pontiac G6
2007-2010 Saturn AURA, OUTLOOK
Attention: This bulletin DOES NOT apply to vehicles equipped with High Intensity Discharge (HID) lamps.
This bulletin is being revised to include the 2011 model year and add models. Please discard Corporate Bulletin Number 10-08-42-001 (Section 08 - Body and Accessories).
Condition
Some customers may comment that the low beam headlamp is inoperative.
Correction
DO NOT replace the entire headlamp assembly for this condition.
Replace the bulb and inspect the connector following the procedure below.
Remove the headlamp bulb. Refer to Headlamp Bulb Replacement procedure in SI.
Inspect the connector. • If the connector is NOT discolored or damaged, replace the bulb only. For bulb part numbers, see Headlamp Bulb (Low Beam) in Group 02.727 of the appropriate Parts Catalog.
• If the connector is discolored at the bulb interface, replace the connector (service pigtail listed below) and bulb.
Important: Use only Duraseal splice sleeves (salmon, P/N 12089189). Other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Refer to Splicing Copper Wire Using Splice Sleeves in SI for splicing procedures.
1. Cut the wires of the connector approximately 45 mm (1¾ in) from the connector and splice in the service pigtail connector. Ensure that the splices are not above the connector when re-installing.
2. Replace the bulb.
Verify that the headlamp is fully functional.
Parts Information
Usage
Part Number
Description
CTS, SRX, Malibu, AURA, G6, Full-Size Trucks, Acadia, Enclave, Traverse, OUTLOOK
20939657
Cable (Connector) Assembly, Headlamp (Service Pigtail)
Equinox/Terrain
20938905
Connector Assembly, Headlamp Wiring Harness
OUTLOOK
20858015
Harness Assembly, Headlamp Wiring
Warranty Information
For vehicles repaired under warranty, use:
Model
Labor Operation
Description
Labor Time
CTS
N9526*
Wiring Harness, Headlamp - Replace (One Side)
1.5 hrs
Add
To Replace Other Side
0.4 hr
SRX
N9526*
Wiring Harness, Headlamp - Replace (One Side)
0.5 hr
Add
To Replace Other Side
0.4 hr
Malibu/AURA
N9526*
Wiring Harness, Headlamp - Replace (One Side)
0.8 hr
Add
To Replace Other Side
0.8 hr
G6
N9526*
Wiring Harness, Headlamp - Replace (One Side)
0.5 hr
Add
To Replace Other Side
0.5 hr
C/K Pickup
N9526*
Wiring Harness, Headlamp - Replace (One Side)
0.5 hr
Add
To Replace Other Side
0.4 hr
C/K Utility
(Chev/GMC)
N9526*
Wiring Harness, Headlamp - Replace (One Side)
0.8 hr
Add
To Replace Other Side
0.8 hr
C/K Utility
(Cadillac)
N9526*
Wiring Harness, Headlamp - Replace (One Side)
1.0 hr
Add
To Replace Other Side
1.0 hr
Acadia/Enclave/Traverse/OUTLOOK
N9526*
Wiring Harness, Headlamp - Replace (One Side)
0.8 hr
Add
To Replace Other Side
0.8 hr
Equinox/Terrain
N9526*
Wiring Harness, Headlamp - Replace (One Side)
0.5 hr
Add
To Replace Other Side
0.5 hr
*This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.
Note: If only bulbs are replaced, use labor operation N0440 or N0441.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.