High Intensity Discharge Headlamp Ballast Replacement

High Intensity Discharge Headlamp Ballast Replacement

Removal Procedure

Warning

The high intensity discharge system produces high voltage and current. To reduce the risk of severe shocks and burns:

* Never open the high intensity discharge system ballast or the arc tube assembly starter.
* Never probe between the high intensity discharge system ballast output connector and the arc tube assembly.

1. Open the hood.
2. Remove the headlamp assembly. Refer to Headlamp Replacement (Service and Repair).




3. Remove the screws (1) attaching the arc tube and starter cover to the headlamp housing.
4. Remove the arc tube and starter cover.




5. Disconnect the arc tube and starter electrical connector (1).
6. Remove the ballast cable from the arc tube and starter cover.




7. Release the connector position assurance (CPA) (2) from the ballast electrical connector (1).
8. Disconnect the electrical connector (1) from the ballast.
9. Remove the screws (3) attaching the ballast to the headlamp.
10. Remove the ballast from the headlamp.

Installation Procedure

1. Install the ballast to the headlamp.





Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the screws (3) attaching the ballast to the headlamp and tighten to 2 Nm (18 lb in).
3. Connect the electrical connector (1) to the ballast.
4. Install the CPA (2) to the ballast electrical connector (1).





Note: Ensure the rubber grommet attached to the ballast cable is properly installed and sealed to the arc tube and starter cover, in order to avoid water intrusion in the headlamp.

5. Install the ballast cable to the arc tube and starter cover.
6. Connect the arc tube and starter electrical connector (1).





Note: Ensure the arc tube and starter cover are properly installed and sealed to the headlamp in order to avoid water intrusion in the headlamp assembly.

7. Install the arc tube and starter cover.
8. Install the screws (1) attaching the arc tube and starter cover to the headlamp and tighten to 2 Nm (18 lb in).
9. Install the headlamp. Refer to Headlamp Replacement (Service and Repair).
10. Close the hood.