Found headlight defect in Sunfire and Cavalier.

[Crustpunk]

Please advise on this issue. I have a 2003 Sunfire that for the entire time I had it I thought it was a lemon/had been wrecked. Mechanics went over it again because headlights and turn signals have been failing repeatedly. I was told I need a new wiring harness which will set me back $770 or so plus the $165 they are charging for coming up with that diagnosis. Some of these solutions sound more appealing as I only have temp jobs. But I'm not sure if I should try them or look for a used wiring harness. Thanks all.

[Kurt V65]

My problem was low beam headlights quit for no apparent reason. The problem was not the headlight bulbs (9007) or the 2 fuses (left and right headlights, 15amp) in the interior fusebox..Or the 40amp fuse under the hood. Try the method stated here, it worked for me. The problem was in the wiring which runs between the 2 headlights. It is located between the radiator and the bumper. For some reason the wiring had become broken and I repaired it with a butt connecter. Good luck on your repair, mine was quick and easy.

[Crustpunk]

Thanks, I will look into the solutions offered in this forum.

[Tech II]

There was a recall for this......

[Crustpunk]

I didn't hear of a recall. When was that?

[Tech II]

Not sure of the years......but it was something like 2000-2003 Cavaliers and Sunfires......most of the joints were replaced and taped.....

It was a definite recall for the headlight harness......

Go to any GM shop and they can look up the recall for you.......only thing I don't remember was, the time limit for the recall....

[roydion78]

Cool car and a very nice build!

[Crustpunk]

Well, I got my lemon (I mean Sunfire) back from the garage and issue still needs resolved. Mechanic said all the wires at the connector are corroded and need replaced, which would mean probably a replacement wiring harness for the headlights. Two questions if anyone can help. Would it be easy for a non-mechanically/electrically inclined person such as myself to put another wiring harness in, and would getting a wiring harness from a salvage yard be an acceptable alternative to paying almost $800 for a new wiring harness? Thanks.

[Tech II]

Why not get a copy of the recall(if it is out on time)? It will explain to you where the connections are and how to repair them......

[Crustpunk]

I called a dealer and they said there was no recall for it.

[Captaincanadian]

I have a similar problem except mine is the driver side low beams are dim. (Yes I replaced the low beams. Same effect) turn signals are great and high beams are dim aswell but they aren't off. I took a quick look while replacing the headlights and see absolutely no corrosion, unless I take the entire circuitry apart and check I can't seem to find a solution. I drive a lot at night and the car runs beautifully except that one issue. Any ideas 2003 sunfire

[Stealthee]

If lights are dim it sounds like poor grounding. I had a similar issue at one time with another car with the taillights. After poking and prodding and getting no where I finally used a test light to determine which wire was the ground wire on the taillight harness and simply added a ground wire attached to the chassis. Problem was fixed.

[dmmackay]

I have a 2000 cavalier- NO LOWS OR DRL's .. just high beams.

Another Common issue with the wiring, is under the battery tray.
There is a Pin Out Connector for the Wiring Harness - which gets corroded from the battery acid falling on it.
On mine, it actually ate a hole complete through it. I cut all the wires to it and spliced in new ones, but it did not correct the problem-
I still haven't fixed it- but the PIN OUT CONNECTOR under the Batter Tray on the Wiring Harness, can definitely be a Problem!
I called the Chevy Dealer and got a Bunch of BS.. NO recall- then recall was done, and Time was up on recall, . etc. etc.