Headlight Securing Lugs, Servicing

Headlight Securing Lugs From 10.00, Servicing

NOTE:
- If headlight securing lugs break due to application of excessive force, it may still be possible to service headlight in a cost effective manner (though headlight housing must not be damaged).
- Repairing headlight securing lugs on vehicles from 10.00 require the use of the applicable repair kit (where available).
- Repair kit can be used on both Halogen and HID headlight units.
- Observe the following WARNINGS when working on headlights with High Intensity Gas Discharge (HID) lamps:

WARNING:
- HIGH VOLTAGE.
- Always disconnect negative (-) battery terminal prior to servicing any parts of the HID lamp system marked with the yellow "HIGH VOLTAGE!" symbol.
- After disconnecting battery, briefly turn headlights on and off in order discharge any residual voltage.
- The control modules for HID lamps must never be operated (headlights turned on) without an HID lamp.
- HID bulbs operate at high voltages and temperatures and must only be operated (headlights turned on) when installed in the headlight housing.







Headlight securing lug repair kit, component overview

NOTE:
- When available, the repair kit contains parts to repair all headlight mounting positions.
- A right HID headlight unit is illustrated here. Components work for both right and left applications.

1. Top/inside mounting
- Reinforced
- With screw
- Use in repair.
2. Top/outside mounting
- Reinforced
- With screw
- Use in repair.
3. Headlight housing
4. Bottom/outside mounting
- Reinforced
- With screw
- Use in repair.
5. Bottom/inside mounting
- Reinforced
- With screw
- Use in repair.

Top/outside mounting, repairing
- Remove headlight.
- Remove all remnants of broken mounting.
- Sand breakage point smooth to housing.







- Press reinforcement -1- into replacement bracket -2- from repair kit.







- Fasten replacement bracket -1- onto headlight housing -3- with screw -2-.
- Install headlight.

NOTE: Check for even gaps between headlight assembly and front end trim. Adjust gaps as necessary prior to tightening screws.

- Check headlight operation.
- Check headlight aim.

Top/inside mounting, repairing
- Remove headlight.
- Remove all remnants of broken mounting.
- Sand breakage point smooth to housing.







- Press reinforcement -1- into replacement bracket -2- from repair kit.







- Fasten replacement bracket -2- onto headlight housing -1- with screw -3-.
- Install headlight.

NOTE: Check for even gaps between headlight assembly and front end trim. Adjust gaps as necessary prior to tightening screws.

- Check headlight operation.
- Check headlight aim.

Bottom/outside mounting, repairing
- Remove headlight.
- Remove all remnants of broken mounting.
- Sand breakage point smooth to housing.







- Press reinforcement -2- into replacement bracket -3- from repair kit.
- Screw adjustment bushing -1- into bracket -3- as necessary.







- Fasten replacement bracket -2- onto headlight housing -3- with screws -1-.
- Install headlight.

NOTE: Check for even gaps between headlight assembly and front end trim. Adjust gaps as necessary prior to tightening screws.

- Check headlight operation.
- Check headlight aim.

Bottom/inside mounting, repairing
- Remove headlight.
- Remove all remnants of broken mounting.
- Sand breakage point smooth to housing.







- Fasten replacement bracket -2- onto headlight housing -1- with screw -3-.
- Screw adjustment bushing into bracket as necessary.
- Install headlight.

NOTE: Check for even gaps between headlight assembly and front end trim. Adjust gaps as necessary prior to tightening screws.

- Check headlight operation.
- Check headlight aim.