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