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post #1 of (permalink) Old 1st April 2007 Thread Starter
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Headlight removal on Lag 1 phase 2

When I was changing the discs and pads on my car at work the other day,I also had a look at the offside front headlamp aim.When parking up against our wall at home in the dark,the headlight didn't have the correct beam pattern,so I decided to have a look in our beam setter that we use for checking aims for the MOT.I discovered that some muppet had put the bulb in upside-down,and when they tried to force the holding clip in,they had broken the lower pivot for the lense..I sorted the pattern out by putting the bulb in the right way,but the aim was way too high due to the damage to the pivot and it was blinding people coming the other way at night.Rather than buy another light,I repaired the damage,and to do this I had to remove the headlight.

Firstly,open the bonnet and locate the five T30 torx headed bolts in the front grille.Three are easy to see and undo,but there are 2 hidden under the grille in the gap between it and the bumper(marked in yellow arrows in the picture).To undo these,you'll need a long T30 screwdriver or a socket with a long extension.

Now comes the tricky part!.There are two T20 headed screws in each corner of the grille where it meets the front wings.These are hidden under the painted part of the grille,which needs to unclipped to expose them.I only undid one side as I could pull the grille out far enough to get the headlight out without undoing the other side.

You need to be very careful when unclipping the two sections of the grille as the plastic is of a typical French quality....i.e very brittle and easy to snap.

Once the T20 screw is removed,the complete grille should be loose and you can then gently pull it out of the way of the lower headlight mounting nut.There is a 10mm bolt in the top of the headlight and a 10mm nut under the light.Remove these,unplug the two connectors and the light should be free....

In the picture below,you can see where the pivot had broken(marked in yellow).You can also see the headlamp aim adjuster(marked in yellow).This is what moves the lense up and down when you turn the dial in the dashboard.It has an electric motor in it which moves an arm in and out,and moves the lense inside the light to raise or lower the aim.To manually adjust them,you just turn the white plastic nut on the top of the adjuster.It's worth having the aims checked if you remove a headlight of change a bulb.Any MOT station can check the correct alignment and it should only take a matter of a couple of minutes to do.

All I did was apply some glue around the broken pivot,hold with a pair of pliers for a few minutes,allowed the glue to 'go off' and that was it,Roberts your mothers brother.

In the best Haynes manual tradition,re-fitting is the reverse procedure!.I'll adjust the aim to make sure it's spot on at work tomorrow,and thats one less thing it'll fail it's impending MOT test on..

The moral of this story is,no matter what headlight main or dipped beam bulbs your car has(H1,H4 or H7),they will only fit in one way!.If you have to force the clips that hold the bulb in at all,then the bulb is not fitted correctly.Not only will this effect the beam image,you risk damaging the headlight.

Hope this is usefull to someone.

I'd rather push my Alfa than drive a BMW....
Currently in Lagdti's garage:
2004 Saab 9-5 HOT Aero and a 2001 Audi A3 1.8 Turbo

Last edited by Lagdti; 1st April 2007 at 03:17 PM.
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