Hid Headlamp Ballast Replacement

REMOVAL PROCEDURE




CAUTION: 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.

CAUTION: The high intensity discharge system produces high voltage and current. To reduce the risk of severe shocks and burns. The battery negative cable must be disconnected any time service work is being performed on or around the high intensity discharge system.

CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.

1. Remove the battery negative cable.
2. Remove the radiator grille from the vehicle.
3. Disconnect the front bumper assembly from the vehicle.
4. Remove the starter cable fasteners from the starter cable.
5. Remove the starter cable from the headlamp ballast.




6. Remove the body wiring harness from the ballast.




7. Remove the ballast support bracket fastener from the vehicle.
8. Remove the ballast and ballast support bracket from the vehicle.




9. Remove the ballast and ballast subplate fastener from the support bracket.
10. Remove the ballast and ballast subplate from the ballast support bracket.
11. Remove the ballast subplate fasteners from the ballast.
12. Remove the ballast from the ballast subplate.

INSTALLATION PROCEDURE




IMPORTANT: Ensure that the ballast subplate is oriented with the ring on the starter cable side of the ballast.

1. Install the ballast to the ballast subplate.
2. Install the ballast subplate fasteners to the ballast.

Tighten
Tighten the ballast subplate fasteners to 5 N.m (45 lb in).

3. Install the ballast and ballast subplate to the ballast support bracket.
4. Install the ballast and ballast subplate fastener to the ballast support bracket.

Tighten
Tighten the ballast support bracket fastener to 8.5 N.m (75 lb in).




5. Install the ballast and ballast support bracket to the vehicle.
6. Install the ballast support bracket fastener to the vehicle.

Tighten
Tighten the ballast support bracket to the vehicle fastener to 10 N.m (88 lb in).




7. Install the body wiring harness to the ballast.




8. Install the starter cable to the headlamp ballast.
9. Install the starter cable retainers to the headlamp ballast.

Tighten
Tighten the starter cable screws to 0.7 N.m (6 lb in).

10. Install the front bumper assembly to the vehicle.
11. Install the radiator grille to the vehicle.
12. Install the battery negative cable.