My passenger side headlight wont come on. It looks like the plastic plug has melted. (The drivers side headlight words fine). Ive replaced the headlight unit. And the plug. But still fails. I have the Halogen lights. When you wiggle the plug wires the light will flash. When you force the wires into the plug the light comes on til you let go of the wires. I believe there is a short somewhere.. But not sure where.
The car runs great. And I have no plans to get rid of it. But really need to find a solution. Otherwise I cant drive at night or in the rain.
Thanks.

 

About a year ago I replaced my early/pre-facelift (04 R53) headlights with '05 Xenon projectors I had scored from a salvage yard.
A few nights later the the passenger side headlamp was out. I tried changing the bulb and ballast to no avail.
After removing and inspecting the internal wires connection to the plug; I discovered the wire sheathing had totally crumbled and disintegrated causing a short between them.
I painstakingly replaced/re-wired the bad section of wires which fixed the problem. It may possibly be your problem as well?

Good luck