Lighting and Horns: Service and Repair

REMOVAL




1. Disconnect and isolate the battery negative cable.
2. Remove the oval-shaped rubber access hole plug from the forward upper outboard surface of the front fender wheel liner (4).
3. Reach through the wheel liner access hole to remove the nut (5) that secures the stud on the lower outboard corner of the front lamp unit (3) housing to the fender headlamp mounting panel.
4. With the hood panel opened, remove the two screws (2) that secure the inboard side of the lamp housing to the mounting panel.
5. Grasp the lamp firmly and pull straight forward to disengage the ball stud on the upper outboard corner of the lamp from the plastic grommet (1) in the mounting panel.




6. Pull the lamp away from the fender far enough to access and disconnect the three wire harness connections (4) from the headlamp bulb (2), the park/turn signal bulb socket (3) and the side marker bulb socket (5) on the back of the lamp housing.
7. Remove the front lamp unit (1) from the fender.

INSTALLATION




1. Check to be certain that the two front lamp unit U-nuts (1) and the plastic headlamp mounting grommet are in good condition and properly positioned on the front sheet metal (1).




2. Position the front lamp unit (1) close enough to the front fender to access and reconnect the three wire harness connections (4) to the headlamp bulb (2), the park/turn signal bulb socket (3) and the side marker bulb socket (5) on the back of the lamp housing.
3. Rearrange the wire harnesses as necessary to prevent them from becoming pinched between the back of the lamp housing and the fender.




4. Align and insert the two alignment pins on the back of the lamp housing (3) with the two alignment holes in the fender headlamp mounting panel.
5. Using hand pressure, push the lamp firmly and evenly rearward until the ball stud on the back of the upper outboard corner of the lamp snaps into the plastic grommet (1) in the mounting panel.
6. Install and tighten the two screws (2) that secure the inboard side of the lamp housing to the U-nuts on the front sheet metal. Tighten the screws to 7 N.m (65 in. lbs.).
7. Reach through the front fender wheel liner (4) access hole to install and tighten the nut (5) that secures the stud on the lower outboard corner of the lamp housing to the mounting panel. Tighten the nut to 7 N.m (65 in. lbs.).
8. Reinstall the rubber plug into the front fender wheel liner access hole.
9. Reconnect the battery negative cable.
10. Confirm proper headlamp alignment.