Headlamp: Service and Repair

REMOVAL

WARNING: THE REPLACEABLE HALOGEN HEADLAMP BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. GRASP BULB ONLY BY ITS PLASTIC BASE. AVOID TOUCHING GLASS ENVELOPE. KEEP BULB OUT OF REACH OF CHILDREN.

1. Disconnect the battery ground cable.







2. Remove the radiator upper sight shield.







3. Remove the retaining screw from headlamp.






4. Remove the mounting bolts from headlamp.







5. Remove headlamp assembly.
1 Pull headlamp assembly forward and disconnect high beam harness.
2 Disconnect turn signal harness.
3 Disconnect cornering lamp harness.
4 Disconnect the side marker lamp and harness.
5 Cut wire between burner assembly and ballast.
6 Remove headlamp assembly.







6. Remove the bolts from the ballast retaining bracket and remove the ballast and ballast harness.







INSTALLATION
1. Install the headlamp.
1 Connect high beam harness.
2 Connect turn signal harness.
3 Connect cornering lamp harness.
4 Connect the side marker lamp and harness.
5 Route low beam headlamp wiring through radiator grille opening panel and install headlamp assembly in place.







2. Install the headlamp mounting bolts.







3. Install the headlamp retaining screw.







4. Install the headlamp ballast on the mounting bracket and install the bolts.
5. Route the ballast and headlamp harness through the same location as previous harness was removed and connect permanent connector.







6. Install the radiator upper sight shield.