Operation CHARM: Car repair manuals for everyone.

Halogen Headlamps, From 06.2008






Halogen Headlamps, from 06.2008

Observe notes on contact corrosion. Refer to => [ Contact Corrosion ] Service Precautions.

After any measures that could affect headlamp aim, headlamps must be readjusted. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.

=> [ Headlamp Housing ]

=> [ Headlamp Housing Mount ]

=> [ Low Beam Headlamp Bulb ]

=> [ Left and Right High Beam Headlamp ]

=> [ Daytime Running Lamp and Parking Lamp ]

=> [ Front Turn Signal Bulb ]

=> [ Headlamp Beam Adjustment Motors ]

=> [ Headlamp Housing Repair Set, Installing ]

Headlamp Housing

Removing

- Switch off ignition and remove ignition key.

- Turn light switch to 0 position.

- Remove front bumper cover.

- If equipped, remove the nozzle for the headlamp washer system => [ Headlamp Washer System Spray Nozzles ] Headlamp Washer System Spray Nozzles.






- Disconnect the electrical connector.

- Remove the bolts - 2, 3 and 5 -.

- Release the clamps on the back side of the fender - arrow - and then remove the headlamp housing - 4 - and mount - 1 - forward and out of the body.

Installing

Install in reverse order of removal, observing the following:

- Install the headlamp housing and mount to the lock carrier and fender and tighten the screws - 2, 3 and 5 - by hand.

- Install the front bumper cover.

- Align the headlamp housing gap dimensions according to the body contours.

- Tighten the bolts - 2, 3 and 5 -.

- Adjust headlamps. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.

Tightening Specifications






Headlamp Housing Mount

Removing






- Remove headlamp housings.

- Remove screws - 1 - and - 3 -.

- Remove the headlamp housing - 2 - from the mount - 4 - by moving the headlamp housing forward and up - arrow -.

Installing

Install in reverse order of removal, observing the following:

- Check adjustment nuts - 2 - on adjusters - 1 - and - 3 - for ease of movement - arrows -.






- Screw adjuster as far down as it will go, but do not tighten.

- Install the headlamp housing - 2 - into the mount - 1 -; the guide ridges on the headlamp housing must fit into the guides on the mount - arrows -.






- Install the mount and headlamp housing to the lock carrier and fender and tighten the screws by hand.






- Install the front bumper cover.

- Align the headlamp housing gap dimensions according to the body contours.

- Tighten the screws in sequence - 1 through 4 -.

When tightening the screws - 2 - and - 3 - the adjusting nut on the adjusting element will turn by itself against the mounting point of the headlamp housing and secure it.

- Adjust headlamps. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.

Tightening Specifications






Low Beam Headlamp Bulb

Removing

- Switch off ignition and remove ignition key.

- Turn light switch to 0 position.

- Remove the front wheel housing liner.

- Turn the housing cover - 1 - counter-clockwise - arrow - and remove it from the headlamp housing.






- Turn socket - 1 - counterclockwise - arrow - and remove from housing.






- Release the clamps - arrows - and disconnect the connector - 3 - from the socket - 1 - and bulb - 2 -.






Installing






Install in reverse order of removal, observing the following:

- Install the a new bulb - 1 - into the socket and connect the connector; when doing this, the tab - 2 - must be all the way - 3 - in the socket.

- Insert the new bulb into the housing without touching the bulb with bare hands.

Installation location is in the tab - 4 - must point downward.

- Close the housing cover clockwise.

The word TOP must be facing upward.

- Install the front wheel housing liner.

Left and Right High Beam Headlamp

Removing






- Switch off ignition and remove ignition key.

- Turn light switch to 0 position.

- Remove the air filter housing on the left headlamp.

- Remove the high beam housing cover - 1 - from the headlamp housing - arrow -.

- Turn socket - 1 - counterclockwise - arrow - and remove from housing.






- Release the clamps - arrows - and disconnect the connector - 3 - from the socket - 1 - and bulb - 2 -.






Installing






Install in reverse order of removal, observing the following:

- Install the a new bulb - 1 - into the socket and connect the connector; when doing this, the tab - 2 - must be all the way - 3 - in the socket.

- Insert the new bulb into the housing without touching the bulb with bare hands.

Installation position is in the tab - 4 - on the socket must point to the left and upward.

- Close the housing cover.

- Install the air filter housing on the left headlamp.

Daytime Running Lamp and Parking Lamp

Removing

- Switch off ignition and remove ignition key.

- Turn light switch to 0 position.

- Remove the front wheel housing liner.

- Turn the housing cover - 1 - counter-clockwise - arrow - and remove it from the headlamp housing.






- Turn socket - 1 - counterclockwise - arrow - and remove from housing.






- Press the release downward - arrow - and disconnect the connector - 2 - from the lamp - 1 -.






Installing

Install in reverse order of removal, observing the following:

- Insert the new bulb into the housing without touching the bulb with bare hands.

- Close the housing cover clockwise.

The word TOP must be facing upward.

- Install the front wheel housing liner.

Front Turn Signal Bulb

Removing






- Switch off ignition and remove ignition key.

- Turn light switch to 0 position.

- Remove the air filter housing on the left headlamp.

- Remove the high beam housing cover - 1 - from the headlamp housing - arrow -.

- Turn socket - 1 - counterclockwise - arrow - and remove from housing.






- Press the release downward - arrow - and disconnect the connector - 2 - from the lamp - 1 -.






Installing

Install in reverse order of removal, observing the following:

- Insert the new bulb into the housing without touching the bulb with bare hands.

- Close the housing cover.

- Install the air filter housing on the left headlamp.

Headlamp Beam Adjustment Motors

Removing

- Switch off ignition and remove ignition key.

- Turn light switch to 0 position.

- Remove the front wheel housing liner.

- Turn the housing cover - 1 - counter-clockwise - arrow - and remove it from the headlamp housing.






- Release the headlamp range control positioning motor - 1 -. On the left headlamp by turning it counter-clockwise - arrow -; on the right headlamp by turning it clockwise.






- Remove the ball head - 2 - by swiveling the control motor to the side and out of the ball head socket - 3 -.

- Remove headlamp beam adjustment motor out of headlamp housing.

- Disconnect the electrical connector - 4 -.

Installing

Install in reverse order of removal, observing the following:

- First, insert ball head of adjustment axle from the side into ball head mount of reflector, pull reflector toward rear to do so.

- Position the headlamp range adjustment positioning motor quick release on the headlamp housing.

- Engage the headlamp range adjustment positioning motor clockwise on the left headlamp and counter-clockwise on the right headlamp.

- Close the housing cover clockwise.

The word TOP must be facing upward.

- Install the front wheel housing liner.

- Adjust headlamps. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.

Headlamp Housing Repair Set, Installing

Headlamp mounting tabs that have broken off can be replaced by installing the repair set. Completely replacing the headlamp is not necessary.

There are different repair kits for left and right headlamps. Refer to the electronic parts catalog ETKA.

Procedure






- Remove headlamp with broken mounting tab.

- Remove remains of broken mounting tab at headlamp housing.

- Place mounting straps - 1 - and - 3 - from repair kit on headlamp housing and secure tabs with straps - 2 - and - 4 -.

Tightening Specifications