Vauxhall Insignia 2011, Water In Headlamp Unit & Ballast/Driver. Repair and Sealing. Xenon HID D1S

This video is an amateur job documenting my fix for the drying out of the headlamp unit, replacement of the ballast/driver and sealing the headlamp unit to prevent further water ingress.

It's based on my 2011 Vauxhall Insignia Elite 2.0 Eco Turbo Diesel with Adaptive Front Lighting and Auto Leveling, also the factory fitted Xenon HID headlamps.

It shows bolt locations, bolt sizes, locator positioning, testing method and illustrations of damage in the ballast unit.

This is the second of two videos, this one showing the passenger side light after water ingress. The first video    • Replacing Xenon HID Headlight Ballast...   shows the RH (Drivers side in UK) and the mistakes I made with missed bolt locations.

This second video shows successful removal of the unit, replacement of the ballast and sealing. It also shows the original lamp from the first vid with water in it again as I didn't seal that one up. I would have taken it out and sealed it if I hadn't been part exchanging it for another newer insignia. I just dried it out with a hair dryer.

I got the Ballast/Driver from eBay, part number in video, but check the part number you take out of the unit before you purchase one, there are some subtle differences in the units available. Mine cost around £40.

To replace it with a Ballast / Driver from the local Vauxhall dealer would have been £250 without fitting. The cost of a headlamp unit from the same dealer was £1000+ without fitting.

I dried the headlamp unit out with a hair dryer on a medium heat as I didn't want it too hot and melt some of the AFL equipment in the unit. Remove both covers off the unit to allow warm humid air to disperse.

The bulbs were tried first to see if it was the bulb that needed replacing, before I decided that the ballast needed replacing.

Serious Note: This type of work can be dangerous, especially as the Headlamp bulb is driven by very high voltages that could give you a big shock. Disconnect the battery negative terminal to ensure the power won't be restored while your holding a wire and lean on the remote key fob button...
If you're at all unsure as to the next step, stop and consult a trained mechanic or auto electrician. I am neither. Any advice you follow from this video is at your own risk.

If it wasn't likely to save many Insignia Owners some money from repairing this defect, rather than going to the dealer, I probably wouldn't have posted the video. The dangers and risks are worth taking very very seriously.

Good luck and I wish you many happy years of motoring!!