Headlights problems of the 2008 Saturn Outlook - part 2

On 8/26/2011, I replaced my drivers side headlight bulb and noticed a burnt wire smell but did not notice anything visually, approximately one month later I noticed that my light was out again the next day I bought a new bulb. I started the process of changing out the bulb but noticed it was back on so I stopped. A few days later the bulb was out again so I changed the bulb and noticed that the burnt smell was very bad and the plug on the wire harness and the wire insulation had melted. . Read more...

2008 Saturn Outlook headlamp wiring harness melted on drivers side (3rd time this has occurred). This is a safety issue!.

-2008 Saturn Outlook xr -passenger and driver side day-time running light and low-bean headlight stopped working entirely. Upon inspection wiring harness was melted. Have to take to dealership to re-wire harness and replace bulbs so I can drive at night.

Complete loss of low beam headlights under similar or identical circumstances as other voqs and various websites forums. Inspection revealed melted wiring harness connectors inside the headlamp assembly at the low beam headlamp bulb. Vehicle date of manufacture 10-2007. No known body work. Passenger low beam headlight connector is not melted as bad as the driver side low beam headlight connector. Appears to be coming predominantly from the black wire going into the connector. All insulation is melted away. Connector melted and brittle that it fell apart removing the bulb. Bulb part # appears to be h11, 12v 55w u 64211 l+dot. Osram. Germany e1 25s. W0 q3. Driver head light assembly casting date September 2007. Part number 25876413, which appears to have been superseded. Appears manufactured under automotive lighting with number lh hal 6143101907c2824. The inside connector area of the bulb itself also appears melted. The bulb is available for inspection. The headlamp assembly is still in use on the vehicle after receiving a pigtail splice repair and new bulb. The passenger side headlamp is now working and has received no repairs. Updated ivoq 11/29/11.

Right headlight low beam connection has melted. Was able to remove bulb, but badly burnt, can not replace lamp.

I have 130,000 miles on my 2008 Saturn Outlook and I have had to replace the headlight wire harnesses on both sides and multiple light bulbs. The most recent time I replaced the lightbulb ~30 days ago and it is burnt out already.

Passenger headlight not working on the 2008 Saturn Outlook xe. This vehicle only has 33,000 miles on it, so I'm quite surprised that it has already stopped working. I've read on other websites that there is a possible issue with the wiring harness being faulty and melting. This concerns me due to the fact that this lightbulb and wiring harness is not an easy part to replace.

The right front headlight of our 2008 Outlook went out. I replaced it. After a few months it went out again. This time when I looked at the socket into which the bulb was to sit, I noticed it was melted and burned.

Vehicle headlight bulb on passenger side blew out. Thought the bulb was just blown. Found the wire harness had melted also. Found on the internet this a well known issue, with the harnesses melting. . Fire could have occurred in my opinion. Vehicle out of warranty, so dealer wont cover. Service bulletin available but vehicle out of warranty.

Passenger side headlights have burnt out twice in the last several months. The second time we went to change it the wires are all melted. Need to have taken in for a new wire harness, this happened already twice to the drivers side of my vehicle. It is dangerous to have wires melting over and over. This is also a costly repair that should be recalled since it is not normal for this many cars to have this exact same problem, it is obviously a faulty design.

2008 Saturn Outlook. Replaced both front headlights in the past two months. Headlights burned out again. Headlight wiring has melted - have to replace wiring and wiring harness. This should be a recall - it's not due to wear and tear of vehicle. Is poor equipment used in manufacturing.

My headlight burned out on my 2008 Saturn Outlook. I tried to replace it and it still didn't work. I had a shop replace it thinking that I touched the bulb and was told that the socket/harness was melted and some of the wires beyond that were exposed. I called the dealer and this is not covered under extended warranty and was told that even if fixed, would happen over and over because the bulb is too hot and melts the wiring. I think this is a design issue and should be recalled. There are thousands of claims of this happening exactly the same way so it is a design flaw and should be dealt with by gm. I have since gotten pulled over and issued a citation for no headlight but don't have the outrageous amount of money to replace all components and pay labor charges of 1. 6 hours plus. This is dangerous due to loss of headlights for visibility, intermittent working of headlights, which if both went out could leave me stranded with four kids, and the exposed wire could cause an engine fire or short that could damage other components or the whole vehicle. So as of this message I still only have one working headlight (which may burn out soon too if its too hot for the wires) and am waiting for my next ticket. . . . . .

In June of 2010, the right headlight went out on my 2008 Saturn Outlook. After taking to the dealer, it was discovered that the wiring harness had melted ! the harness was replaced at that time. While on vacation this July, 2011, and 800 miles from home, the left headlight is working when it wants to. After reading several other complaints, I am quite concerned about this problem and fearful of a fire. My vehicle has approx. 45,000 miles on it at this time. Of course, the bumper to bumper warranty has expired. I feel that this matter should be checked into and repairs should be done at no cost to the customer. A recall is needed immediately !.

My right headlight burned out and we replaced it after a huge struggle as it is very difficult to get to. Then about a month later, my left headlight burned out, so we replaced it with the same degree of difficulty. However, when I replaced this one, the harness (?) or component you put the bulb in appeared black and "burnt". My headlight worked fine for about a week and it burned out again. I hate to keep replacing headlights if there is a problem with the harness, which is evident by searching on the internet for information about replacing the headlights in the Saturn Outlooks. It takes a great deal of time and effort just to get to the bulb changed only to have it continue to burn out after a very short period of time. I really believe there should be a recall on these headlight harnesses as the company should fix the problem. I have contacted Saturn and was told I would have to pay to take it to a GMC dealer and have an evaluation done on the vehicle. I am very upset with gm about this.

Headlight keeps burning out. I believe it is the wiring harness.

Headlights go out due to a faulty wire harness. Has happened many times and I fix it just to have them go out again. This is a clear safety issue and many people have had the same problem. Time to step up and fix this obvious safety problem.

Passenger low beam headlight went out, and wiring was found to be melted, repaired and now 4 months later the passenger low beam headlight is now again out. Gm has not issued a recall after multiple failures,, and now wondering if driving this vehicle is safe as it could catch fire( wires getting hot enough to mel in to) ='s not safe ,, thanks gm.

On my 2008 Saturn Outlook the passenger side headlight went out then after being replaced went out again about a month later come to find out the wiring burned out and had to be replaced. A few months later I was driving and pulled over for the driver side headlight being out. I had the light replaced only for it to go out a few months later and also at this time told the wiring melted and I had to get the whole thing replaced. This is a safety issue I drive with kids in my car and if this ever happened to both lights at night I don't want to think of what could have happened.

Low beam driver's side headlamp on Saturn Outlook. Bulb appeared to fail but on further inspection of the wiring harness it was melted at the connector. This happened in Jan/Feb of 2011 and now (Jul) the passenger side is out. Replaced the light bulb initially on both only to have it continuously go out. Inspecting wiring harness on the passenger side later today. This clearly appears to be a fire hazard.

I own a 2008 Saturn Outlook and the passenger side headlight has gone out. The vehicle has 47,000 miles on it and the wiring harness is most likely burned out and melted as many other 08' Saturn Outlook's have been known to do. This is a significant safety issue because there have been many documented cases where faulty electrical wiring have been know to cause vehicle fires. This issue should not have to create fire, property damage or injury in order to initiate a recall given the history of known problems with faulty electrical wiring.

The failure that occurred in my 2008 Saturn Outlook was a faulty driver's side wiring harness for the headlight, which resulted in the lowbeam headlight being inoperable. This occurred on may 8th, 2011 and was continuous. I had the wiring harness replaced at my cost due to the safety issue of only driving with one working headlight at night as well as the fact it's against the law in the state of ohio. Additionally, I was traveling to canada and did not want to risk the possibility of a crash or collision with an animal due to the faulty light. I paid out of pocket over $270 for the necessary repairs including parts and labor (the old part is not available). Gm published a bulletin regarding this issue: (#09-08-42-004: low beam headlamp bulb inoperative - replace harness and fill connector cavity for low beam bulb connector with nyogel grease may 29, 2009) this is most definitely a safety issue and should be recalled immediately. Thank you for your time and consideration with this matter.

2008 Saturn Outlook - headlight wiring harness melted.

Melting / electrical fire in headlight wiring harness and pre-mature headlight bulb failure.

Low beam headlight wiring harness and bulb connection melted causing loss of headlights.

The low beam headlight went out on the vehicle. I went to autozone to purchase the headlight replacement when I was told that it could possibly be two different headlights that I would need to bring the broken one so they can sell me a replacement. I found out that it is not very easy to replace the headlight on this vehicle as several other parts have to be removed in order to get to the headlight connector. I found instructions and several complaints from owners indicating they have replaced the headlight several times during the year only to be told by dealers that the harness/connector are burned and that is the cause of the problem. I proceeded to remove the underliner of the tire to get to the headlight on my vehicle. As suspected, the connector and wire harness were burned. I found several service bulletins instructing dealers to "check and replace" the harness and headlight on these vehicles. When I called Saturn I was informed that the dealership had replaced the headlight in my vehicle on April 2011. . . However they never informed me of this change. Right now my wife is driving this vehicle without a headlight as Saturn is refusing to replace the burned harness that I found on the car. This is not only a safety issue, but a fire hazard on the vehicle. This should be a mandatory recall by now. . . . It is not just happening on Saturn Outlooks, it is also happening on GMC acadias which is exactly the same car. . . . .

Passenger side headlight is out on Saturn Outlook. Wiring harness is melted. This happened on the drivers side about a year ago. Very expensive to replace and is obviously a design flaw and a huge danger as we are without low beams until we can get it fixed and parts are on backorder. Probably because everyone is having a problem.

My 2008 Saturn Outlook (recently purchased used) has intermittent headlight issues. The headlights go in and out with no warning. The service center quoted me over $600 to fix the issue. They say it's a faulty wiring harness common with the Saturn Outlook model. Not a bulb burnout, but a structural problem that Saturn knew about. I've done some research online and this seems to be fairly widespread. I can't help but feel like gm has taken advantage of a lot of people.

We bought our 2008 Saturn Outlook xr in Dec. 2010 from carmax. It had ~35,000 miles on it. At ~38,500 miles the passenger side low beam headlight went out. I removed the bulb and found the connector was melted. I tried replacing the bulb, but the light did not work. The cable must be ruined.

We have a 2008 Saturn Outlook. Headlight on driver's side went out; paid $117 to have fixed; same light went out and dealer fixed it n/c, and replaced harness. Now passenger side has gone out twice. . On our way to dealer to look at the situation.

Wiring harness providing power to headlight shorted out.

Headlight wire harness failure. Headlamps were burning out frequently and finally determined that gm installed faulty low gauge wiring. Harness in my vehicle was burned and melted causing a fire risk. The dealer replaced one harness while still under warranty. I am having to replace the other harness now at 64k miles.

Drivers side low beam headlight went out. I have 30,000 miles on my 2008 Saturn Outlook. Replaced the bulb. Light went out again during 20 hour drive home. Turns out harness is melted and the bulb is fine.

In March, 2011, my cars left headlight burned out. When I changed the light, I discovered that the wiring harness had melted. I replaced the harness with a gm part bought at a dealership. Last week, the right headlight burned out. Again, when I changed the light, I discovered that the wiring harness also had melted. The wires seem small to me, and are smaller than the wires on the replacement harness.

The contact owns a 2008 Saturn Outlook. While driving approximately 60-65 mph, the driver side headlight failed. The contact then smelled an abnormal burning odor and he continued driving using the low beams. The contact attempted to replace the bulb and discovered that the headlight wiring had melted. The vehicle was taken to a local mechanic where the contact was referred to an authorized dealer. The dealer advised that the headlight would need a replacement wiring harness assembly however, the part needed for repairs was on back order and not readily available. The vehicle was not repaired. The VIN was unavailable. The failure mileage was 46,605 and the current mileage was 46,635. Updated 03/22/lj.

The drivers side headlight went out around 24,000 miles in which the dealer replaced the whole assembly. 20,000 miles later the same headlight went out for which I had to pay the dealer $40 to install it. 5,000 miles later the passenger headlight stop working and paid the dealer $40 to replace it. Two hours later it stop working and had to bring it back to the dealership for which they told me I needed a new assembly. If gm doesn't fix this problem then they lost a buyer for life.