Headlamp: Service and Repair

LAMP

REMOVAL
1. Disconnect and isolate the battery negative cable.
2. Remove the grille panel from the grille opening reinforcement.

Headlamp Unit Remove/Install:

3. Remove the two screws that secure the mounting tabs on the inboard side of the headlamp unit housing to the grille opening reinforcement.

Headlamp Unit - North America:

Headlamp Unit - Export:

4. Pull the inboard side of the headlamp unit away from the grille opening reinforcement far enough to disengage the locator tab on the outboard side of the unit from the engagement slot in the outboard edge of the reinforcement.
5. Pull the headlamp unit away from the grille opening reinforcement far enough to disconnect the wire harness connectors from the headlamp bulb socket (North America), the headlamp bulb base (Export), the front position lamp socket (if equipped), and the headlamp leveling motor (if equipped).
6. Remove the headlamp from the grille opening reinforcement.

INSTALLATION
1. Position the headlamp unit to the grille opening reinforcement.
2. Reconnect the wire harness connectors to the headlamp bulb socket (North America), the headlamp bulb base (Export), the front position lamp socket (if equipped), and the headlamp leveling motor (if equipped).
3. Engage the locator tab on the outboard side of the headlamp unit into the engagement slot in the outboard edge of the grille opening reinforcement.
4. Align the two mounting tabs on the inboard side of the headlamp unit housing to the mounting holes in the grille opening reinforcement.
5. Install and tighten the two screws that secure the mounting tabs on the inboard side of the headlamp housing to the grille opening reinforcement. Tighten the screws to 3 N.m (30 in.lbs.).
6. Reinstall the grille panel onto the grille opening reinforcement.
7. Reconnect the battery negative cable.
8. Confirm proper headlamp unit alignment.

BULB - NORTH AMERICA

REMOVAL
1. Disconnect and isolate the battery negative cable.

Headlamp Bulb Lock Ring:

2. Reach behind the headlamp unit from the engine compartment side of the upper radiator cross-member to access the headlamp bulb lock ring.
3. Firmly grasp the lock ring on the back of the headlamp unit housing.
4. Rotate the lock ring on the back of the headlamp housing counterclockwise about 30 degrees to unlock it.

CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.

Headlamp Bulb Remove/Install:

5. Pull the lock ring, socket, and bulb straight out of the keyed opening in the headlamp housing and up from behind the upper radiator crossmember.
6. Disconnect the grille opening reinforcement wire harness connector from the headlamp bulb socket connector receptacle.
7. Remove the bulb and socket unit from the lock ring.

INSTALLATION

CAUTION:
- Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring.
- Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.

1. Position the headlamp bulb and socket into the lock ring.
2. Reconnect the grille opening reinforcement wire harness connector to the headlamp bulb socket connector receptacle.
3. Position the lock ring, socket, and bulb down behind the upper radiator crossmember and align them with the keyed opening on the back of the headlamp unit housing.
4. Push the socket and bulb unit straight into the headlamp housing until they are firmly seated.
5. Position the lock ring over the socket and engage it with the flange on the back of the headlamp housing.
6. Rotate the lock ring on the back of the headlamp housing clockwise about 30 degrees to lock it into place.
7. Reconnect the battery negative cable.

BULB - EXPORT

REMOVAL
1. Disconnect and isolate the battery negative cable.
2. Remove the headlamp unit from the grille opening reinforcement.

Headlamp Bulb Boot Seal Remove:

3. Firmly grasp the tab of the headlamp boot seal on the back of the headlamp unit housing.
4. Pull the tab away from the back of the headlamp unit housing to remove the boot seal from the housing and the bulb base.
5. Pinch the two hooked ends of the wire headlamp bulb retainer clip together and disengage them from the flange of the reflector.
6. Pivot the headlamp bulb retainer clip up off of the bulb flange and out of the way.

CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.

Headlamp Bulb Retainer Clip Engage/Disengage:

7. Pull the bulb straight out of the keyed opening in the headlamp reflector.

INSTALLATION

CAUTION:
- Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket and/or the lamp wiring.
- Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result.

Headlamp Bulb Remove/Install:

1. Position the bulb into the keyed opening in the headlamp reflector.
2. Pivot the headlamp bulb retainer clip back over the bulb flange.
3. Pinch the two hooked ends of the wire headlamp bulb retainer clip together and engage them into the slots in the flange of the reflector.
4. Position the center opening of the boot seal over the base of the headlamp bulb and pull it downward until the seal is fully engaged over the bulb base.
5. Position the outer circumference of the boot seal over the flange on the back of the headlamp unit housing and pull it downward until the seal is fully engaged over the flange.
6. Reinstall the headlamp unit onto the grille opening reinforcement.
7. Reconnect the battery negative cable.
8. Confirm proper headlamp unit alignment.