Headlamp 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.

The high intensity discharge system produces high voltage and current. In order 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.

Refer to Battery Disconnect Caution in Service Precautions.

NOTE: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry.




1. Remove the battery negative cable.
2. Remove the radiator grille from the vehicle.
3. Remove the front bumper assembly from the vehicle.
4. Remove the starter cable retaining screws and cover from the headlamp ballast.




5. Remove the retaining clip from the starter cable connector.
6. Remove the starter cable from the headlamp ballast.




7. Remove the headlamp retainers by pulling up and outward.




8. Disconnect the electrical connections and bulb(s) from the headlamp housing.




9. Remove the headlamp mounting bracket retainers.
10. Remove the headlamp mounting bracket from the headlamp housing.
11. On a bench, remove the arc tube with starter from the headlamp housing.

INSTALLATION PROCEDURE




1. On a bench assemble the arc tube with starter to the headlamp.
2. Install the headlamp mounting bracket to the headlamp housing.

NOTE: Refer to Fastener Notice in Service Precautions.

3. Install the headlamp mounting bracket retainers.

Tighten
^ Tighten the headlamp mounting bracket flange nut to 5 N.m (45 lb in).
^ Tighten the headlamp mounting bracket bolts to 1.24 N.m (11 lb in).




4. Connect the electrical connections and bulb(s) to the headlamp housing.

IMPORTANT: Ensure that the lower retaining tabs are seated for proper headlamp housing retention.




5. Install the headlamp to the vehicle.




6. Install the headlamp retainers by pushing down and inward.




7. Install the starter cable connector to the ballast.

IMPORTANT: The arc tube will not energize if the retaining clip is removed or improperly installed.

8. Install the retaining clip to the starter cable connector.




9. Install the starter cable retaining screws and cover 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.