Headlamp Replacement

REMOVAL PROCEDURE

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




1. Remove the passenger side front floor kick up panel to access the Instrument Panel (I/P) electrical center.




2. Remove the HDLP Maxi circuit breaker #54, from the I/P electrical center.
3. Raise the hood.




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




6. Remove the headlamp bezel.
7. Remove the front fascia lower closeout panel.
8. Remove the brake caliper cooling duct.
9. 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.




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




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

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

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.




3. Loosely install the two bolts mounting the headlamp bracket to the frame rail.

NOTE: Refer to Fastener Notice in Cautions and Notices.

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).




6. Connect the electrical 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.




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. Install the floor kick up panel.
14. Close the hood.
15. Check the alignment of the headlamp opening door. For adjustment procedures, refer to Headlamp Opening Door Adjustment. Headlamp Opening Door Adjustment
16. Check headlamp aim.
^ To check the aim of the headlamps using the screen method, refer to Headlamp Aiming (Screen Method). Headlamp Aiming (Screen Method)
^ To check the aim of the headlamps using the mechanical method, refer to Headlamp Aiming (Mechanical Method). Headlamp Aiming (Mechanical Method)
17. Remove any protective tape installed during removal of the headlamp.