Service Procedure

1. To assist reassembly, mark the position of the left headlamp on the body and note the position of the headlamp level bubble. Apply masking tape to the fascia just below the headlamp to prevent scratching the fascia.

2. For vehicles equipped with a 2.0L DOHC non-turbocharged engine, remove the engine compartment relay box attaching bolts.





3. Remove the top and two rear headlamp assembly attachment bolts (Figure 1).

4. Insert a trim stick between fascia and the lower edge of the headlamp assembly and turn the trim stick 90° to allow access to the bottom headlamp bolt.

5. Remove the bottom headlamp bolt and remove the trim stick

NOTE:
Use care to prevent scratching the fascia.


6. Disconnect the two headlamp assembly wiring connectors. The hole cover must be removed to disconnect the side marker light connector.

NOTE:
On vehicles equipped with the 2.0L turbocharged engine and automatic transmission, the bottom connector should be disconnected after headlamp removal.

7. Slide the headlamp assembly outboard until the tab on the bottom is under the unsupported fascia section. Depress the fascia to clear the tab and remove the headlamp assembly.





8. Remove the front ABS hydraulic unit bracket bolt (Figure 2).





9. Position the upper hole in the provided reinforcement bracket 1-7/16" (36 mm) from the headlamp attaching hole in the headlamp support panel. Align the lower bracket hole with the front ABS hydraulic unit bolt hole. Insert the provided bolt in the lower bracket hole and tighten to 120 in-lbs (14 N.m) (Figure 3).

10. Center punch and drill a 5/16" (8 mm) hole through the upper bracket hole and through the headlamp support panel.

NOTE:
Tape the drill bit about 1/2" from the end to prevent contact with the brake lines.

11. Remove any burrs and use primer, Mopar PN 4443636 or equivalent, to cover the edges of the hole.





12. Attach the provided back plate by inserting the front bracket bolt removed in step 8 through the new hole and into the back plate weld nut. Align the remaining two back plate holes with the existing headlamp attachment holes. Tighten the bolt to 120 in-lbs (14 N.m) (Figure 4).

13. Reinstall the headlamp assembly and connect the two wiring connectors. Insert the top of the headlamp assembly under the headlamp support then depress the fascia to allow the tab on the bottom of the headlamp to pass without scratching the fascia.

14. Insert a trim stick between the fascia and the lower edge of the headlamp and turn the trim stick 900 to allow access to the bottom headlamp bolt.

15. Install the bottom headlamp bolt, tighten to 43 in-lbs (5 N.m) and remove the trim stick.

NOTE:
Use care to prevent scratching the fascia.

16. Align the headlamp in its original position, using the marks made in Step 1, and return the level bubble to its original position. Install the remaining three headlamp bolts and tighten to 43 in-lbs (5 N.m).

17. For vehicles equipped with a 2.0L DOHC non-turbocharged engine, install the engine compartment relay box attaching bolts.

18. Remove the masking tape from the fascia.

NOTE:
Headlamp alignment is not necessary if this procedure is followed properly.