Headlamp Replacement

HEADLAMP REPLACEMENT

REMOVAL PROCEDURE




1. Remove the passenger side front floor kick up panel to access the IP electrical center.




2. Remove the cover from the IP electrical center.




3. Remove the HDLP Maxi circuit breaker #54, from the IP electrical center.
4. Raise the hood.




5. Disconnect the headlamp wiring harness electrical connector from the forward lamp wiring harness.




6. Remove the headlamp actuator knob cover.
7. Raise the headlamp by turning the headlamp motor/actuator manual control knob counterclockwise.




8. Remove the headlamp bezel.
9. Apply tape to the fender and hood edge to protect the paint.

NOTE: Refer to Notice - Apply Tape When Removing Body Panels in Service Precautions.

10. Remove the front fascia lower closeout panel.
11. Remove the brake caliper cooling duct.
12. Disconnect the electrical connectors from the headlamp automatic control module, RH side only.




13. Remove the headlamp bracket to the frame rail bolts.

IMPORTANT: Before removing the fasteners, support the headlamp assembly.




14. Remove the headlamp bracket nuts from the headlamp stud plate.

IMPORTANT: The headlamp assembly will have to clear the studs extending from the headlamp stud plate.

15. Lift the headlamp assembly out of the vehicle.
16. Remove the headlamp intermediate bracket from the headlamp.
17. Remove the headlamp motor/actuator from the headlamp.
18. Remove the headlamp capsule from the headlamp.

INSTALLATION PROCEDURE
1. Install the headlamp capsule to the headlamp.
2. Install the headlamp motor/actuator to the headlamp.
3. Install the headlamp intermediate bracket to the headlamp.
4. Position the headlamp assembly onto the studs extending from the headlamp stud plate.




5. Loosely install the headlamp bracket to the headlamp stud plate nuts.
6. Install the headlamp bracket to the frame rail bolts.




7. Beginning with the upper location, tighten the headlamp bracket to the frame rail bolts.

NOTE: Refer to Fastener Notice in Service Precautions.

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

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

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




9. Connect the electrical connectors to the headlamp automatic control module, RH side.
10. Install the brake caliper cooling duct.
11. Install the front fascia lower closeout panel.
12. Install the headlamp bezel.




13. Connect the headlamp wiring harness electrical connector to the forward lamp wiring harness.
14. Rotate the headlamp motor/actuator manual control knob clockwise to lower the headlamp.




15. Install the headlamp motor/actuator knob cover.
16. Remove the protective tape installed during removal of the headlamp.
17. Close the hood.




18. Install the HDLP Maxi circuit breaker #54 into the IP electrical center.




19. Install the cover to the IP electrical center.




20. Install the floor kick up panel.
21. Check the alignment of the headlamp opening door.
22. Check and adjust headlamp aim as necessary.