Headlamp Assembly Replacement

REMOVAL PROCEDURE

NOTE: When removing body panels, apply tape to corners of panel and adjacent surfaces to help prevent damage.

Headlamp Assembly Replacement: Removal Procedure:

1. Remove the HDLP Maxi circuit breaker #54, from the instrument panel (I/P) electrical center.
2. Raise the hood.

Headlamp Assembly Replacement: Removal Procedure:

3. Disconnect the headlamp wiring harness electrical connector from the forward lamp wiring harness.
4. Raise the headlamp by turning the headlamp motor/actuator manual control knob counterclockwise.

Headlamp Assembly Replacement: Removal Procedure:

5. Remove the headlamp bezel.
6. Remove the front fascia lower closeout panel.
7. Remove the brake caliper cooling duct.
8. Disconnect the electrical connectors from the headlamp automatic control module (RH side only).

Important: Before removing the fasteners be sure to support the headlamp assembly.

Headlamp Assembly Replacement: Removal Procedure:

9. Remove the two bolts mounting the headlamp bracket to the frame rail.

Headlamp Assembly Replacement: Removal Procedure:

10. Remove the three nuts mounting the headlamp bracket to the headlamp stud plate.
11. Carefully lift the headlamp assembly out of the vehicle.

The headlamp assembly will have to clear the studs extending from headlamp stud plate.
12. Transfer parts as necessary.

INSTALLATION PROCEDURE

Headlamp Assembly Replacement: Installation Procedure:

1. Use care in positioning the headlamp assembly into the vehicle.

Mount the headlamp assembly onto the studs extending from the headlamp stud plate.
2. Loosely install the three nuts mounting the headlamp bracket to the headlamp stud plate.

Headlamp Assembly Replacement: Installation Procedure:

3. Loosely install the two bolts mounting the headlamp bracket to the frame rail.
4. Beginning with the upper location, tighten the two bolts mounting the headlamp bracket to the frame rail.

Tighten
Tighten the headlamp mounting bolts to 20 N.m (15 lb ft).

5. Beginning with the upper inner location, tighten the nuts mounting the headlamp to the headlamp stud plate.

Tighten
Tighten the headlamp mounting nuts to 10 N.m (89 lb in).

Headlamp Assembly Replacement: Installation Procedure:

6. Connect the electri6al connectors to the headlamp automatic control module (RH side).
7. Install the brake caliper cooling duct.
8. Install the front fascia lower closeout panel.
9. Install the headlamp bezel.

Headlamp Assembly Replacement: Installation Procedure:

10. Connect the headlamp wiring harness electrical connector to the forward lamp wiring harness.
11. Lower the headlamps manually to ensure no binding exists.

Rotate the headlamp motor/actuator manual control knob clockwise to lower the headlamp.
12. Install the HDLP Maxi circuit breaker #54 into the I/P electrical center.
13. Close the hood.
14. Check the alignment of the headlamp opening door. For adjustment procedures, refer to Headlamp Opening Door Adjustment.

Headlamp Bulb Replacement: Removal Procedure:

15. Check headlamp aim.
^ To check the aim of the headlamps using the screen method, refer to Headlamp Aiming (Screen Method).
^ To check the aim of the headlamps using the mechanical method, refer to Headlamp Aiming (Mechanical Method).
^ Remove any protective tape installed during removal of the headlamp.