Service Procedure
1. Raise the vehicle on a hoist.2. Remove the front wheels.
3. Remove the bolts and screws shown in Figure 1 from the left and right front fender protectors.
NOTE:
The fender protectors will not be completely removed. Just take it loose at the front so you can get to bumper fascia fasteners.
4. Carefully snap loose the fillet molding--only at the front-from both front fenders as follows:
^ Refer to Figures 2 and 3.
CAUTION:
Don't use excessive force when working with the fillet molding. Excessive force may cause damage to clips. Excessive bending will cause white marks on the molding. If white marks are created the molding must be replaced.
^ Reach behind the front bumper fascia and release the first 8 clips (see Figure 3).
^ Release the clips in order - 1 through 8.
^ Press the clips in the direction indicated by the arrows.
NOTE:
Use special care with clips 2, 5, and 7. It may be necessary to use a plastic trim tool when releasing these clips. If any clip is damaged the molding must be replaced.
^ This will loosen the molding just past the parting line between the bumper fascia and fender.
5. Remove the 6 engine undercover bolts shown in Figure 4. Let the front of the under cover hang down.
6. Remove the bumper fascia bolt shown in Figure 4.
7. Remove the bumper fascia clips shown in Figure 5.
8. Remove the 4 fender to fascia bolts.
^ 2 bolts on each side.
9. If equipped disconnect both fog light harness connectors.
^ Left side shown right side not shown.
10. Release the bumper fascia clips under the headlamps as follows:
a. There are 2 clips under each headlamp in the locations shown in Figure 8.
b. Insert a plastic trim tool between the headlamp and the bumper fascia.
NOTE:
Plastic "Trim Tool Set" J-46534 (an "essential tool" is available from TECH-MATE.
c. Lift the front of the clip to release it. Release all 4 clips.
11. With 2 people carefully remove the bumper fascia.
CAUTION:
^ Use 2 people to remove the bumper fascia.
^ Don't let the fillet molding scratch the bumper fascia. Hold the fillet moldings out of the way as you remove the bumper fascia.
NOTE:
Be careful when moving / handling the fillet molding. Excessive bending will cause white marks on the molding. If white marks are created the molding must be replaced.
^ Do not drop or excessively bend the bumper fascia.
^ Set the fascia in a clean area.
12. Remove the headlamp bolts and nuts shown in Figure 11.
^ 3 bolts and 1 nut.
13. Release the plastic clip shown in Figure 12.
14. Pull the headlamp from its mounting position and disconnect the headlamp electrical connectors.
15. Remove both headlamps and place them in a clean working area.
16. Swap the HID control unit cover and the HID control unit from the old headlamp assemblies to the new headlamp assemblies as follows:
a. Remove the 2 screws for the HID control unit cover and remove the cover.
b. Disconnect the HID control unit connector shown in Figure 15.
c. Remove the 3 screws for the HID control unit.
d. Turn the HID control unit over and remove the harness screw shown in Figure 16.
e. Disconnect the HID control unit connector shown in Figure 16.
f. Replace the rubber 0-ring seal-shown in Figure 16-with the new one included with the headlamp kit.
g. Install the HID control unit and the HID control unit cover on the new headlamp assemblies in reverse order.
CAUTION:
^ The headlamp lenses can be permanently damaged (scratched) if not handled carefully.
^ It is recommended that a protective covering be used over the new headlamp lenses while swapping the above parts and when installing the bumper fascia.
^ A protective covering will prevent damage to the headlamp lenses while working with them and around them.
^ Make sure to remove any protective covering after installing the bumper fascia.
17. Install both of the new front headlamp assemblies on the vehicle.
18. Make sure the headlamps are working correctly.
19. Reassemble all parts removed in reverse order.
20. Make the old headlamp assemblies unusable by drilling a 3/8 inch hole in the headlamp lens.
NOTE:
^ There is a three day warranty parts hold before scrapping the headlamp assemblies.
^ The front headlamp xenon bulbs should be disposed of in accordance with local and state regulations.
CHECK HEADLAMP AIM
21. Check headlight adjustment (aim) as shown in Figure 18.
^ Make sure all tires are inflated to correct pressure.
^ Make sure there is no load in the vehicle other then the driver (or equivalent weight in the driver's seat) coolant and engine oil are filled to the correct level and the fuel tank is full.
^ Place vehicle on a flat level surface.
^ Make sure the headlamp aiming switch is set to "0".
Basic illuminating area for adjustment should be within the range shown in this aiming chart.