High Intensity Discharge Headlamp Ballast Replacement Philips

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.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Remove the battery negative cable.
2. Remove the radiator grille from the vehicle. Refer to Grille Replacement in Exterior Trim.
3. Remove the front bumper assembly from the vehicle. Refer to Front Bumper Impact Bar Replacement in Bumpers.



4. Remove the starter cable retaining screws and cover from the headlamp ballast.



5. Remove the retaining clip from the starter cable connector.
6. Remove the starter cable from the headlamp ballast.



7. Remove the body wiring harness from the ballast.



8. Remove the ballast and ballast subplate fastener from the support bracket.
9. Remove the ballast and ballast subplate from the ballast support bracket.
10. Remove the ballast subplate fasteners from the ballast.
11. Remove the ballast from the ballast subplate.

Important: Ensure that the ballast subplate is oriented with the ring on the starter cable side of the ballast.

1. Install the ballast to the ballast subplate.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the ballast subplate fasteners to the ballast.

Tighten
Tighten the ballast subplate fasteners to 5 N·m (45 lb in).

3. Install the ballast and ballast subplate to the ballast support bracket.
4. Install the ballast and ballast subplate fastener to the ballast support bracket.

Tighten
Tighten the ballast support bracket fastener to 8.5 N·m (75 lb in).




5. Install the body wiring harness to the ballast.
6. Install the starter cable to the headlamp ballast.




Important: The arc tube will not energize with the retaining clip removed or improperly installed.

7. Install the retaining clip to the starter cable connector.



8. Install the starter cable cover and screws to the headlamp ballast.

Tighten
Tighten the starter cable screws to 0.7 N·m (6 lb in).

9. Install the front bumper assembly to the vehicle. Refer to Front Bumper Impact Bar Replacement in Bumpers.
10. Install the radiator grille to the vehicle. Refer to Grille Replacement in Exterior Trim.
11. Install the battery negative cable.