For 1990-2009 cars

## Headlamp Bulb Replacement LWB

### Removal Procedure - Low Beam (Type C)

Caution: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury:

• | Turn off the lamp switch and allow the bulb to cool before changing the bulb.

• | Leave the lamp switch OFF until the bulb change is complete.

• | Always wear eye protection when changing a halogen bulb.

• | Handle the bulb only by its base. Avoid touching the glass.

• | Keep dirt and moisture off the bulb.

• | Properly dispose of the used bulb.

• | Keep halogen bulbs out of the reach of children.

1. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
2. For access to the left-hand headlight, detach and move the airbox upper cover rearward. Go to step 4.
3. For access to the right-hand headlight, remove the coolant reservoir fill neck by pulling up on the neck assembly and position aside. Note the orientation of the aligning tabs and keyway of the coolant reservoir fill neck for installation.
4. Remove the low beam headlamp dust cap (1) from the rear of the headlamp assembly by rotating the dust cap counter-clockwise. Note the orientation of the dust cap and tabs for installation.
5. Rotate the low beam headlight bulb socket assembly (2) counter-clockwise and remove the socket from the headlamp assembly.
6. Remove the low beam bulb (1) from the socket.

### Installation Procedure - Low Beam (Type C)

Important: Do not handle the quartz envelope of the headlight bulb. Wipe the quartz envelope immediately with methylated spirits if it is touched accidentally or the performance of the bulb will deteriorate.

1. Install the new low beam bulb (1) into the low beam socket assembly (2).

Important: The different-sized tabs on the bulb base and mating cut-outs in the headlamp assembly allow the bulb socket to seat correctly in one orientation position.

2. Install the low beam socket (2) into the headlamp assembly and lock the socket in place by rotating it clockwise.
3. Inspect the low beam dust cap seal and replace if necessary.
4. Install the low beam headlamp dust cap (1) to the rear of the headlamp assembly by aligning the tabs and rotating the dust cap clockwise to secure.

Important: For left-hand headlamp, go to step 5.

Important: For right-hand headlamp, go to step 6.

5. For the left-hand headlamp assembly, replace and secure the airbox upper cover. Go to step 7.
6. For the right-hand headlamp assembly, reinstall the coolant reservoir fill neck by aligning the tabs and keyway and pushing the neck into position.
7. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.

### Removal Procedure - Low Beam (High Intensity Discharge Headlamp Starter/Arc Tube Replacement)

Caution: Refer to Battery Disconnect Caution in the Preface section.

Caution: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury:

• | Turn off the lamp switch and allow the bulb to cool before changing the bulb.

• | Leave the lamp switch OFF until the bulb change is complete.

• | Always wear eye protection when changing a halogen bulb.

• | Handle the bulb only by its base. Avoid touching the glass.

• | Keep dirt and moisture off the bulb.

• | Properly dispose of the used bulb.

• | Keep halogen bulbs out of the reach of children.

1. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
3. Remove the headlamp assembly. Refer to Headlamp Replacement.
4. For access to the left-hand headlight, detach and move the airbox upper cover rearward. Go to step 4.
5. For access to the right-hand headlight, remove the coolant reservoir fill neck by pulling up on the neck assembly and position aside. Note the orientation of the aligning tabs and keyway of the coolant reservoir fill neck for installation.
6. Remove the low beam headlamp dust cap from the rear of the headlamp assembly by removing the six retaining torx screws (1).
7. Remove the high intensity discharge starter (1) from the headlamp assembly (2) by rotating it counter clockwise.
8. Disconnect the high intensity discharge starter (1) electrical connector (2), by firmly pressing down on the retaining tang (3).
9. Remove the high intensity discharge starter.

### Installation Procedure - Low Beam (Type D)

1. Connect the high intensity discharge starter (1) electrical connector (2), listen for an audible click from the retaining tang (3) to confirm fitting.
2. Install the high intensity discharge starter (1) and rotate it clockwise to secure it tot he headlamp assembly (2).
3. Install the headlamp dust cap from to the rear of the headlamp assembly.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the six retaining torx screws.

Tighten
Tighten the torx screws to 1.0 N·m (9.0 lb in).

5. Install the headlamp assembly. Refer to Headlamp Replacement.
6. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
7. Test headlamp for the correct operation.
8. For the left-hand headlamp assembly, replace and secure the airbox upper cover. Go to step 7.
9. For the right-hand headlamp assembly, reinstall the coolant reservoir fill neck by aligning the tabs and keyway and pushing the neck into position.
10. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.

### Removal Procedure - High Beam (Type C)

Caution: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury:

• | Turn off the lamp switch and allow the bulb to cool before changing the bulb.

• | Leave the lamp switch OFF until the bulb change is complete.

• | Always wear eye protection when changing a halogen bulb.

• | Handle the bulb only by its base. Avoid touching the glass.

• | Keep dirt and moisture off the bulb.

• | Properly dispose of the used bulb.

• | Keep halogen bulbs out of the reach of children.

1. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
2. Remove the Headlamp assembly. Refer to Headlamp Replacement.

Important: For left-hand headlamp access, go to step 2.

Important: For right-hand headlamp access, go to step 3.

3. For access to the left-hand headlight, detach and move the airbox upper cover rearward. Go to step 4.
4. For access to the right-hand headlight, remove the coolant reservoir fill neck by pulling up on the neck assembly and position aside. Note the orientation of the aligning tabs and keyway of the coolant reservoir fill neck for installation.
5. Remove the high beam headlamp dust cap (1) from the rear of the headlamp assembly by rotating the dust cap counterclockwise. Note the orientation of the dust cap and tabs for installation.
6. Rotate the high beam headlight bulb socket assembly (2) counterclockwise and remove the socket from the headlamp assembly.
7. Remove the high beam bulb (1) from the socket.

### Installation Procedure - High Beam (Type C)

Important: Do not handle the quartz envelope of the headlight bulb. Wipe the quartz envelope immediately with methylated spirits if it is touched accidentally or the performance of the bulb will deteriorate.

1. Install the new high beam bulb into the high beam socket assembly.

Important: The different-sized tabs on the bulb socket base and mating cut-outs in the headlamp assembly allow the bulb socket to seat correctly in one orientation position.

2. Install the high beam socket (2) into the headlamp assembly and lock the bulb in place by rotating it clockwise.
3. Install the headlamp dust cap (1) to the rear of the headlamp assembly by rotating clockwise.

Important: For left-hand headlamp, go to step 5.

Important: For right-hand headlamp, go to step 6.

4. For the left-hand headlamp assembly, replace and secure the airbox upper cover. Go to step 7.
5. For the right-hand headlamp assembly, reinstall the coolant reservoir fill neck by aligning the tabs and keyway and pushing the neck into position.
6. Inspect the headlamp aim. Refer to Headlamp Aiming.
7. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
8. Check all vehicle lights for correct operation.

### Removal Procedure - High Beam (Type D)

Caution: Refer to Battery Disconnect Caution in the Preface section.

Caution: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury:

• | Turn off the lamp switch and allow the bulb to cool before changing the bulb.

• | Leave the lamp switch OFF until the bulb change is complete.

• | Always wear eye protection when changing a halogen bulb.

• | Handle the bulb only by its base. Avoid touching the glass.

• | Keep dirt and moisture off the bulb.

• | Properly dispose of the used bulb.

• | Keep halogen bulbs out of the reach of children.

1. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
3. Remove the Headlamp assembly. Refer to Headlamp Replacement.

Important: For left-hand headlamp access, go to step 2.

Important: For right-hand headlamp access, go to step 3.

4. For access to the left-hand headlight, detach and move the airbox upper cover rearward. Go to step 4.
5. For access to the right-hand headlight, remove the coolant reservoir fill neck by pulling up on the neck assembly and position aside. Note the orientation of the aligning tabs and keyway of the coolant reservoir fill neck for installation.
6. Remove the high beam headlamp dust cap from the rear of the headlamp assembly by removing the six retaining torx screws (1).
7. Rotate the high beam headlight bulb socket assembly (2) counter clockwise and remove the socket from the headlamp assembly.
8. Remove the high beam bulb from the socket.

### Installation Procedure - High Beam (Type D)

Important: Do not handle the quartz envelope of the headlight bulb. Wipe the quartz envelope immediately with methylated spirits if it is touched accidentally or the performance of the bulb will deteriorate.

1. Install the high beam socket assembly (2) into the headlamp assembly and lock the bulb in place by rotating it clockwise.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the headlamp dust cap (1) to the rear of the headlamp assembly by installing the six retaining torx screws.

Tighten
Tighten the screws (1) to 1.0 N·m (9.0 lb in).

Important: For left-hand headlamp, go to step 5.

Important: For right-hand headlamp, go to step 6.

3. For the left-hand headlamp assembly, replace and secure the airbox upper cover. Go to step 7.
4. For the right-hand headlamp assembly, reinstall the coolant reservoir fill neck by aligning the tabs and keyway and pushing the neck into position.
5. Inspect the headlamp aim. Refer to Headlamp Aiming.
6. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.
7. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
8. Check all vehicle lights for correct operation.

### Removal Procedure - Front Park (Type C and D)

Caution: Refer to Battery Disconnect Caution in the Preface section.

1. Disconnect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.

Important: For left-hand headlamp access, go to step 2.

Important: For right-hand headlamp access, go to step 3.

3. For access to the left-hand headlight, detach and move the airbox upper cover rearward. Go to step 4.
4. For access to the right-hand headlight, remove the coolant reservoir fill neck by pulling up on the neck assembly and position aside. Note the orientation of the aligning tabs and keyway of the coolant reservoir fill neck for installation.
5. Rotate the front park bulb and socket (1) counter clockwise and remove the bulb and socket from the headlamp assembly.
6. Remove the front park bulb (2) from socket.

### Installation Procedure - Front Park (Type C)

1. Insert a new front park bulb (2) into the front park bulb socket.

Important: There are tabs on the bulb base and mating cut-outs in the headlamp assembly allow the bulb to seat correctly.

2. Install the front park bulb and socket (1) into the headlight assembly and rotate clockwise to secure.

Important: For left-hand headlamp, go to step 3.

Important: For right-hand headlamp, go to step 4.

3. For the left-hand headlamp assembly, replace and secure the airbox upper cover. Go to step 5.
4. For the right-hand headlamp assembly, reinstall the coolant reservoir fill neck by aligning the tabs and keyway and pushing the neck into position.
5. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.

Caution: Refer to Battery Disconnect Caution in the Preface section.

6. Connect the battery ground cable. Refer to Battery Negative Cable Disconnection and Connection.
7. Check all vehicle lights for correct operation.