Service Procedure
NOTE:Most of the photos in this procedure are for the right side headlamp. Make sure to perform this Service Procedure for both the left and right side headlamps.
1. Make sure the headlight switch is OFF.
2. Write down the radio station presets.
3. Disconnect the negative battery cable.
4. Remove the 4 bumper fascia clips shown in Figure 2.
5. Raise the vehicle and loosen the inner fenders (fender skirts) for both the left and right side.
^ Remove screws and clips shown in Figure 3 for both the left and right side.
^ Remove clips shown in Figure 4 for both the left and right side.
6. Pull the inner fenders (fender skirts) out of the way; hook them over the brake rotors.
7. Look up into the area behind the bumper fascia locate and remove the bumper fascia mounting bolts-2 on each side.
NOTE:
Figure 6 shows the bolts for the right side. Make sure to remove the left side bolts also.
8. Pull the bumper fascia forward and then down enough to expose the headlamp side mounting bolt (see Figure 7).
9. Remove the headlamp side mounting bolt (see Figure 7).
10. Remove headlamp assembly top mounting bolts (see Figure 8).
11. Pull the headlamp assembly from its mounting position.
^ First pull it forward then
^ Move it toward the center of the car.
12. Disconnect the 4 harness connectors.
13. Remove the High Intensity Discharge (HID) ballast-3 nuts (see Figure 11).
^ Save the nuts they'll be reused.
CAUTION:
Be careful not to scratch the headlamp lens while you're working on the headlamp assembly.
14. Remove the HID ballast mounting bracket-3 nuts (see Figure 12).
^ Save the nuts they'll be reused.
15. Install the new HID ballast mounting and headlamp support bracket (see Figure 13).
^ Mount the bracket using only 2 of the original bracket mounting studs as shown in Figure 13.
^ Reuse 2 of the nuts you removed in step 14 Figure 12.
NOTE:
The third mounting stud (not used) is behind the bracket and cannot be seen in Figure 13.
16. Install the HID ballast onto its new mounting bracket as shown in Figure 14.
^ Reuse the nuts you removed in step 13 Figure 11.
^ Make sure the HID ballast is installed with the label facing out (so you can see it) as shown in Figure 14.
17. Look down into the readjust behind the bumper and under the headlamp mounting position. Remove the 2 transporter tie-down bracket bolts shown in Figure 15.
18. Place the headlamp assembly back into its mounting position.
^ Slide the new bracket into the area just behind the bumper.
^ Connect the headlamp harness connectors.
^ Carefully maneuver the headlamp assembly back into its original mounting position.
NOTE:
Pay attention to the lower part of the headlamp bracket. Make sure it doesn't catch on any of the wire harnesses.
19. Loosely install (don't tighten) the top and side headlamp mounting bolts (see Figures 7 and 8).
20. Look up into the area behind the lower bumper.
21. Locate the upper and lower bolt holes for the tie-down bracket bolts that were removed in step 17.
^ The mounting holes for the headlamp mounting bracket should be lined up with the tie-down bracket bolt holes.
22. Reinstall (reuse) the transporter tie-down bracket bolts to secure the headlight mounting bracket.
CAUTION:
Make sure the washer motor, side marker lamp, and fog lamp harnesses are not pinched by the new headlamp bracket.
^ A 14-mm box end wrench can be used to tighten the lower bolt inside the boxed cover (see Figure 19).
NOTE:
A 14-mm boxed end ratchet, such as GearWrench(R) (or equivalent) can be used to make the installation of this bolt faster. GearWrench(R) set (8 mm to 19 mm), Part No. 285-KD-9620 is available from TECH MATE at 1-800 662-2001-option 4.
23. Tighten the top and side headlamp mounting bolts (see Figures 7 and 8).
24. Reinstall the bumper fascia and inner fenders (fender skirts) in reverse order.
25. Reconnect the negative battery cable.
26. Check the headlamps for correct operation.
27. Reprogram the radio station presets.