High Intensity Discharge Headlamp Ballast Replacement Early Design

Caution: The high intensity discharge system produces high voltage and current. To reduce the risk of severe shocks and burns:

Caution: The high intensity discharge system produces high voltage and current. In order to reduce the risk of severe shocks and burns, the battery negative cable must be disconnected any time service work is being performed on or around the high intensity discharge system.

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connectionin Engine Electrical.
2. Remove the headlamp. Refer to Headlamp Assembly or Headlamp Bulb Replacement.
3. Remove all rubber covers from the headlamp housing.



4. Press the retaining clip (2) downward to release the clip and disconnect the electrical connector (1) from the bulb.
5. Remove all bulbs to prevent damage and to allow easy removal of ballast harness.
6. Attach a suitable length of wire to the ballast harness electrical connector (1).
7. If necessary, turn the headlamp adjuster counterclockwise to allow ample space to release the electrical connector.



8. Pull the ballast harness (1) from the opposite end to allow the wire (2) to flow through the inside of the headlamp (3).
9. Disconnect the wire (2) from the ballast harness (1).

1. Attach the wire (2) to the ballast harness electrical connector (1).
2. Pull the wire from the opposite end to allow ballast harness to flow through the headlamp.
3. Connect the ballast harness electrical connector to the bulb and install the bulb to the headlamp.



4. Press down on the retaining clip (2) to lock the bulb in place.
5. Install the remaining bulbs onto the headlamp.
6. Install all rubber covers to the headlamp housing.
7. Install the headlamp to the vehicle. Refer to Headlamp Assembly or Headlamp Bulb Replacement.
8. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connectionin Engine Electrical.