Headlamp Unit Replacement

REMOVAL

NOTE: Some moisture accumulation inside a vented headlamp unit is normal. Moisture will vent from tubes or vents located on the back of the unit. This normal condition will appear as a fogging on the inside of the headlamp lens (similar to the fog that sometimes appears on the inside of the windshield). This moisture may be removed by activating the headlamps on high beam for 15 minutes. If water droplets larger than I mm in size have accumulated on the inside of the headlamp lens, the headlamp unit should be replaced.

1. Release hood latch and open hood.
2. Disconnect and isolate the battery negative remote cable.
3. Remove the one bolt retaining the washer bottle filler neck and move aside.
4. Remove the two bolts retaining the speed control servo and move aside.
5. Remove fasteners to upper radiator crossmember:
- Two jack screws on each side.
- Three crossmember retaining bolts on each side.
- Three push pin fasteners across top of grille.
- Gently pry back grille and remove the two bolts to front crossmember. This will allow you to move the crossmember forward, pivoting at the radiator grille, to access the headlamp unit.

NOTE: Once the crossmember is loose, take care not to scratch the fenders.

6. Maneuver the headlamp unit to remove from behind fascia. Gentle prying of fascia may be needed to clear it enough to remove the headlamp unit.
7. Disconnect the lamp connectors and transfer lamps if replacing unit.

INSTALLATION

CAUTION: Do not touch the glass of halogen lamps with fingers or other possibly oily surface, reduced bulb life will result.

NOTE: If replacing complete headlamp unit, transfer lamps to new unit.

1. Connect the lamp connectors.
2. Maneuver the headlamp unit to under the crossmember and behind fascia. Gentle prying of fascia may be needed to clear it enough to install the headlamp unit.

NOTE: Be careful not to scratch the fenders while the crossmember is loose.

3. Install fasteners to upper radiator crossmember:
- Gently pry back grille and install the two bolts to front crossmember.
- Two jack screws on each side.
- Three push pin fasteners across top of grille.
- Three crossmember retaining bolts on each side.

4. Install the two bolts retaining the speed control servo.
5. Install the one bolt retaining the washer bottle filler neck.
6. Connect and the battery negative remote cable.
7. Verify headlamp operation and alignment.
8. Close hood and check alignment of hood that it is flush with the fenders.