LIGHTING

Headlights

REMOVAL & INSTALLATION

Composite

NOTE: This procedure only applies to replaceable halogen headlight bulbs (such as Nos. 9004 and 9005); it does not pertain to sealed beam units.

1. Open the vehicle's hood and secure it in an upright position.
2. Unfasten the locking ring which secures the bulb and socket assembly, then withdraw the assembly rearward.
3. If necessary, gently pry the socket's retaining clip over the projection on the bulb (use care not to break the clip.) Pull the bulb from the socket.

   To install:

4. Before installing a light bulb into the socket, ensure that all electrical contact surfaces are free of corrosion or dirt.
5. Line up the replacement headlight bulb with the socket. Firmly push the bulb onto the socket until the spring clip latches over the bulb's projection.

   WARNING
   Do not touch the glass bulb with your fingers. Oil from your fingers can severely shorten the life of the bulb. If necessary, wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation.

6. To ensure that the replacement bulb functions properly, activate the applicable switch to illuminate the bulb which was just replaced. (If this is a combination low and high beam bulb, be sure to check both intensities.) If the replacement light bulb does not illuminate, either it too is faulty or there is a problem in the bulb circuit or switch. Correct if necessary.
7. Position the headlight bulb and secure it with the locking ring.
8. Close the vehicle's hood.

Sealed Beams

EXCEPT XT

1. Disconnect the negative battery cable.
2. If necessary remove the grille.
3. Remove the retainer screws securing the bezel around the headlight assembly. Remove the bezel and place aside.
4. Pull the headlight out enough to access the wire harness at the rear of the light assembly.
5. Disconnect the electrical harness from the headlight assembly.
6. Installation is the reverse of removal. Test to make sure the headlight work correctly. Check the headlight alignment. Adjust if needed.

XT

The XT is equipped with pop-up headlamps. The headlamp motors are actuated by a switch on the left control wing. If the light fails to raise, it can be manually raised by means of a knob on top of the motor. The knob is covered by a rubber boot. Remove the boot and turn the knob in the direction of the arrow on top of the motor, this will raise the light.

NOTE: The XT is equipped with a sealed beam type headlight. If the light fails, the entire lens assembly must be replaced.

1. Disconnect the negative battery cable.
2. Disconnect the electrical harnesses from the light and the retractor motor.
3. Remove the front grille assembly.
4. Remove the screws that retain the lid on the light assembly and remove the lid.
5. Remove the headlight cover, by removing the retainer screws.
6. Remove the bolts that retain the headlight assembly and motor, and remove the assembly from the vehicle.
7. If needed, remove the motor from the assembly.
8. To remove the headlight, proceed as follows;
   1. Remove the retainer screws securing the bezel around the headlight assembly. Remove the bezel and place aside.
   2. Pull the headlight out enough to access the wire harness at the rear of the light assembly.
   3. Disconnect the electrical harness from the headlight assembly.
   4. To install, attach the wire harness to the rear of the headlight assembly.
   5. Position the headlight into the bracket assembly. Make sure the tabs on the headlight seat within the grooves in the bracket assembly.
   6. Install the bezel around the headlight, and secure in place with the retainer screws.
9. Install the headlight motor if removed.
10. Install the assembly in place on the vehicle and secure in place with the retainer bolts. Tighten the bolts to 17 ft. lbs. (23 Nm).
11. The remainder of installation is the reverse of removal. Test the operation of the headlights. Adjust the lights if needed.