Complete Headlamp Replacement

A2
COMPLETE HEADLAMP, REPLACEMENT

- Turn off ignition.
- Make sure radio is off.
- Disconnect battery ground lead.
- Left-hand headlamp: Remove battery for improved access.
- Right-hand headlamp: Remove control module box ventilation pipe. Lift and remove washer reservoir filler tube. Unhook diagnostic unit and place to one side.
- Undo headlamp electrical connector at center bottom (rear) of headlamp housing.




- Unhook and withdraw side lamp fitting towards front. Allow assembly to hang from wiring.
- If bumper is painted, take care to avoid scratching paintwork.




- Use sliding calipers to measure vertical position of hood catch as illustrated.
- Catch has elongated holes and is adjusted by means of rubber stop to ensure correct vertical position of hood.
- Remove hood catch bolts (2). Move catch to one side to expose headlamp housing outer retaining screws (2).
- Remove headlamp housing retainer bolts (3) and withdraw headlamp unit towards front.
- Reinstall headlamp in reverse order. Ensure that connector beside inner screw on left-hand unit is positioned correctly by means of locating pin.

Torque:
3 headlamp housing retaining bolts: 8.5 Nm (75 inch lbs.) (max 10 Nm/90 inch lbs.)




- Reinstall side lamp

Adjust height of hood catch to same setting as measured prior to removal.

2 hood catch bolts: 25 Nm (18.5 ft. lbs.)

Note:
headlamp washer hose location.

Torque:

- Reconnect headlamp housing connector.
- Right-hand headlamp:
- Reinstall washer reservoir filler tube, diagnostic unit and ventilation pipe
- Reconnect battery. Reset radio code and clock.
- Close hood and check fit.
- If alarm is installed, check hood opening alarm function.
- Check headlamp adjustment.

A3
Headlamp adjustment




Headlamp adjustment is carried out using the adjusting screws (arrows in illustration).

Use a 8 mm Allen key for adjustment.

A = vertical adjustment using a bubble level
B = horizontal adjustment

For headlamp adjustment see instructions in TP 31875/1S.