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.

- 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