Headlamp: Service and Repair

Headlamp Assembly

Service Repair No - 86.40.49

Removal

WARNING: Vehicles fitted with Xenon headlamps, the following precautions must be observed. Failure to comply may result in exposure to ultra violet rays, severe electric shock, burns or the risk of explosion. Ensure the headlamps are switched off at all times. Eye and hand protection must be worn. Never switch on the lamps or test the bulbs with the lamp holder released from the headlamp.

1. Disconnect the battery ground cable.
2. Remove the front radiator grille.

WARNING: Vehicles fitted with Xenon headlamps, the following precautions must be observed. Failure to comply may result in exposure to ultra violet rays, severe electric shock, burns or the risk of explosion. Ensure the headlamps are switched off at all times. Eye and hand protection must be worn. Never switch on the lamps or test the bulbs with the lamp holder released from the headlamp.

CAUTION: Always protect paintwork and glass when removing exterior components.

3. Remove the headlamp assembly.
^ Release the headlamp assembly clips.
^ Disconnect the electrical connector.





NOTE:
^ Do not disassemble further if the component is removed for access only.
^ High intensity discharge lamp bulb illustrated.
^ If installed, leave the Silica Gel sachet in place.

4. Remove the headlamp bulb.
^ Remove the cover.
^ Disconnect the electrical connector.
^ Release the clip.





5. Remove the headlamp inner bulb.
^ Remove the cover.
^ Disconnect the electrical connector.
^ Release the clip.





6. Remove the headlamp outer bulb.
^ Remove the headlamp outer retaining clip.
^ Remove the cover.
^ Release the electrical connector.





7. Remove the side lamp bulb.
^ Release the bulb holder.





8. Remove the side marker bulb.
^ Release the bulb holder.





9. Remove the turn signal indicator bulb.
^ Remove the cover.
^ Release the bulb holder.





10. Remove the gas discharge modules.
^ Remove the 6 screws.





Installation

1. Install the gas discharge modules.
^ Install the screws.
2. Install the turn signal indicator bulb.
^ Secure the bulb holder.
^ Install the cover.
3. Install the side marker bulb.
^ Install the bulb holder.
4. Install the side lamp bulb.
^ Install the bulb holder.
5. Install the headlamp outer bulb.
^ Connect the electrical connector.
^ Install the cover.
^ Install the headlamp outer retaining clip.

CAUTION: Make sure the seal is installed correctly.

6. Install the headlamp inner bulb.
^ Secure with the clip.
^ Connect the electrical connector.
^ Install the cover.

CAUTION: Make sure the seal is installed correctly.

7. Install the headlamp bulb.
^ Secure with the clip.
^ Connect the electrical connector.
^ Install the cover.
8. Install the headlamp assembly.
^ Connect the electrical connector.
^ Secure with the 2 clips.
9. Install the front radiator grille.
10. Connect the battery ground cable.

NOTE: The headlamp setting is 1.2 % below horizontal and parallel.

11. Check the headlamp beam alignment.