Headlamp: Service and Repair

Headlamp Bulb, E-150, E-250, E-350 with Aerodynamic Lamps

Removal

WARNING: THE HALOGEN HEADLAMP BULB (13007) CONTAINS GAS UNDER PRESSURE. THE HEADLAMP BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR THE HEADLAMP BULB IS DROPPED. HANDLE HEADLAMP BULB CAREFULLY. GRASP HEADLAMP BULB ONLY BY ITS PLASTIC BASE. AVOID TOUCHING THE GLASS ENVELOPE. KEEP HEADLAMP BULB OUT OF REACH OF CHILDREN. ENERGIZE THE HEADLAMP BULB ONLY WHEN INSTALLED IN THE HEADLAMP (13008).

1. Check that headlamp switch (11654) is in OFF position.
2. Lift hood (16612) and locate headlamp bulb installed in rear of headlamp body.
3. Bend back and lift upon two black tabs to release the headlamp.
4. Remove electrical connector from headlamp bulb by grasping connector firmly and pulling connector rearward.
5. Remove headlamp bulb retainer (13N019) by rotating counterclockwise (when viewed from rear) about one-eighth turn and sliding headlamp bulb retainer oft plastic base. Keep headlamp bulb retainer to be used again to retain new headlamp bulb.
6. Carefully remove headlamp bulb from socket in reflector by gently pulling straight backward out of socket. Do not rotate headlamp bulb during removal.

Installation











1. CAUTION: Bulbs No.9004 and No.9007 look similar but are not interchangeable. With flat side of plastic base of headlamp bulb facing upward insert glass envelope into socket Turn base slightly to left or right if necessary to align grooves in forward part of plastic base with corresponding locating tabs inside socket.

2. When grooves are aligned push headlamp bulb firmly into socket until mounting flange on base contacts rear face of socket
3. Slip headlamp bulb retaining ring (13015) over rear of plastic base against mounting flange. Lock headlamp bulb retaining ring into socket by rotating headlamp bulb retaining ring clockwise. A stop will be felt when headlamp bulb retaining ring is fully engaged.
4. Push electrical connector into rear of plastic base until it snaps and locks into position.
5. For E-15O E-250 E-350 High Series position headlamp into opening and hold while pushing the two black tabs downward to engage the ends of the adjuster screws. A snap must be heard to make sure tabs are engaged.
6. Check lamp to make sure it is seated securely. If loose install again and make sure the three adjuster screws are engaged.

7. NOTE: A properly aimed headlamp normally need not be re-aimed after installation of this headlamp bulb. A burned-out headlamp bulb should not be removed from the headlamp reflector until just before a replacement headlamp bulb is to be installed. Removal of a bulb for an extended period of time may allow contaminants (dust, moisture, smoke) to enter the headlamp body and affect the performance of the headlamp. When servicing the headlamp bulb, energize the headlamp bulb only while it is contained within the headlamp body.

Check headlamps for proper operation.