Attachment III - Technical Information
OVERVIEWSome of the affected vehicles may not conform to the requirements specified by Federal Motor Vehicle Safety Standard (FMVSS) 108: Lamps, Reflective Devices, and Associated Equipment. The low beam headlamp assemblies may exhibit some level of dimming after exposure to heat from operating the headlamps. Dim low beam headlamps may decrease driver visibility, increasing the risk of a crash.
Before delivering any of the vehicles involved in this recall, dealers are to replace the headlamp assemblies.
SERVICE PROCEDURE
Removal
1. Remove both front wheels. For additional information, refer to Workshop Manual (WSM), Section 204-04.
2. Remove the four fender splash shield retainers and the two nuts from the RH and LH side of the vehicle. See Figure 1.
3. Remove the two lower front bumper cover screw-type retainers from the RH and LH side of the vehicle. See Figure 2.
4. Remove the three fender splash shield screws from the RH and LH side of the vehicle. See Figure 3.
5. Position the fender splash shield aside in order to access the front bumper cover to fender attachment bracket. See Figure 4.
6. Inspect the attachment bracket to see if a screw-type retainer is installed. If present, remove and discard. If not present, proceed to step 7. See Figure 5.
7. Using a nonpermanent marking tool (such as a grease pen), make alignment marks on the front bumper cover for reinstallation. See Figure 6.
8. Remove the two outer front bumper cover pin-type retainers. See Figure 7.
9. Remove the shim(s) located under the bumper cover at the previously removed pin-type retainer locations. See Figure 8.
10. Remove the three torx screws and four pin-type retainers from the front bumper cover. See Figure 9.
11. Release the front bumper cover from the RH and LH fenders by pulling outward. Position the front bumper cover forward to allow for removal of the headlamp assemblies. See Figure 10.
12. Remove the three mounting screws from the RH and LH headlamp assemblies. See Figure 11.
13. Release the three clips holding the wiring to the LH headlamp mounting bracket. See Figure 12.
14. Remove the headlamp assemblies:
a. Release the headlamp assemblies from the ballstud by pulling them straight forward.
b. Disconnect the headlamp electrical connector and remove the headlamps.
15. Remove the two screws attaching the old headlamp assemblies to the mounting brackets and remove the brackets. See Figure 13.
Installation
1. Install the new headlamp assemblies:
a. Transfer the mounting brackets to the new headlamp assemblies. Tighten mounting bracket screws to 2 Nm (18 lb-in).
b. Connect the electrical connector and engage the headlamp into the ballstud by pushing the assembly rearward.
c. Attach the three wiring retaining clips to the LH headlamp mounting bracket. See Figure 12.
d. Loosely install the three RH and LH headlamp assembly mounting screws. See Figure 11.
2. Lift up the front bumper cover and engage cover into the fender by pushing inward until it is seated. See Figure 10. Position the front bumper cover back to the previously made alignment marks. See Figure 6.
3. Align the headlamp assemblies:
a. Position the headlamp assemblies so there is an even gap around them. See Figure 14a.
b. Position the headlamps so they are flush with the fender contour. See Figure 14b.
c. Tighten the headlamp mounting screws to 3.6 Nm (32 lb-in). See Figure 11.
4. Install the three torx screws and four pin-type retainers into the front bumper cover. See Figure 9.
5. Install the bumper cover shim(s). See Figure 8.
6. Install the two outer front bumper cover pin-type retainers. See Figure 7.
7. Reposition the fender splash shield and install the three fender splash shield screws to the RH and LH side of the vehicle. See Figure 3.
8. Install the lower bumper cover screw-type retainers to the RH and LH side of the vehicle. See Figure 2.
9. Install the fender splash shield retainers and nuts to the RH and LH side of the vehicle. See Figure 1.
10. Install both front wheels. For additional information, refer to WSM, Section 204-04.
11. Close the hood and check the gap between the bumper cover and hood. See Figure 15. If necessary, loosen the three bumper cover torx screws (See Figure 9), adjust the bumper cover to obtain a tight and even gap, and retighten the screws. If bumper cover is not flush with the hood, check to make sure the bumper cover shim(s) were reinstalled. See Figure 8.
12. Clean the previously made alignment marks from the front bumper cover.
Headlamp Aiming
NOTE:
The 2013 Fusion vehicles are equipped with VOR (Visual Optical Right) type headlamps. After installing new headlamp assemblies, headlamp aiming must be checked and, if necessary, adjusted.
NOTE:
Horizontal aim is not adjustable for VOR headlamps.
NOTE:
Consult your state vehicle inspection manual for recommended tolerance ranges for visual aiming.
NOTE:
Before starting headlamp adjustment:
^ check the tire inflation.
^ check that no other load is in the vehicle other than a half tank of fuel.
^ check that the headlamps are clean.
^ check that the vehicle is on level ground.
NOTE:
The vertical wall or screen must be a minimum of 2.4 m (8 ft) wide.
1. Park the vehicle on a level surface approximately 7.6 m (25 ft) from the vertical wall or screen directly in front of it.
NOTE:
The center of the lamp is marked on the lens (circle, crosshair or other mark).
2. Mark a horizontal reference line on the vertical wall or screen.
3. Measure the center of the headlamp height to ground and record the measurement.
4. Make a 2.4 m (8 ft) horizontal mark (using masking tape) on the vertical wall or screen at the same distance from the ground as previously recorded.
NOTE:
This procedure should be done in a dark environment to effectively see the headlamp beam pattern.
5. Turn on the low beam headlamps to illuminate the wall or screen and open the hood.
6. On the wall or screen, locate the high intensity area of the beam pattern. Adjust the top edge of the high intensity zone to be even with the horizontal reference line.
7. Return the vehicle to the customer.