Technical Instructions
1995 Mark VIII LSC Headlamp Modification ProcedureIMPORTANT:
This procedure must be followed step-by-step to ensure that the headlamp system operates correctly. All necessary parts are included in the kit. All removed parts are to be re-packaged and returned using the pre-paid shipper included in the kit.
A. WIRING HARNESS MODIFICATION
1) Open glovebox door.
2) Remove damper from RH side of glovebox door.
3) Lower the glovebox door.
4) Locate wire harness 14401 in the dash. The harness is located on the left side of the glovebox door opening, between the dash panel support bracket and heater plenum.
5) Locate the 2 Red with Yellow wires in the harness.
6) Turn headlamps ON, ignition switch OFF.
7) With a test light, check for voltage in the 2 wires. Mark the wire which is Battery Positive (B+).
8) Turn headlamps OFF.
9) Cut the R/Y wire that was identified and marked in step 7.
10) Insulate both ends of the wire by crimping one butt connector over each end of the wire.
11) Tape the wire harness closed with the supplied tape.
12) Reattach the damper to the RH side of the glovebox door.
13) Close glovebox door.
B. HEADLAMP REPLACEMENT
1) Remove the warning sticker from the radiator upper sight shield and remove any adhesive residue with an alcohol pad. The sticker is located next to the hood latch.
2) Remove the 5 screws that secure the sight shield to the radiator support, detach the secondary hood release and remove the sight shield.
3) Locate the left ballast output connector. The connector is a 2 wire connector (wire colors are: Red/Black and Black) that is secured to the radiator support behind the left low beam headlamp. Unplug the connector.
4) Locate the right ballast output connector. The connector is a 2 wire connector (wire colors are: Red/Black and Black) that is secured to the radiator support behind the right low beam headlamp. Unplug the connector.
5) Locate the 2 headlamp wire harness connectors that connect the ballasts to the headlamps. The connectors are secured to the grille opening panel just inboard of the headlamps. The wire colors in the connectors are: Gray and Yellow.
6) Remove the connectors from the grille opening panel and cut the wires on the headlamp side of the connector close to the connector.
7) Remove the 2 screws (11 mm hex) which secure the ballasts to the ballast bracket. The headlamp ballasts are located on the RH side of the radiator opening in the grille opening panel. The screws that secure the ballast to the bracket are located at the top of the ballasts.
8) Remove both ballasts from the bracket and set aside.
9) Disconnect the high beam and marker lamp connectors from the headlamp assemblies.
10) Remove the 3 clips that secure each headlamp assembly and discard clips. NOTE: To remove clips, use snap ring pliers to spread the clips and then pull straight up.
11) Remove both headlamps and set aside.
12) Install both left and right replacement headlamp assemblies provided in the kit using the new clips provided in the kit.
13) Install the wiring jumper harness between the headlamp assemblies low beam headlamp (outboard lamp) and ballast connector that was unplugged in Steps 3 and 4.
14) Connect high beam and marker lamp connectors to the headlamp assemblies.
15) Reinstall the radiator upper sight shield and secondary hood release.
18) Turn headlamps ON.
19) Verify low beam function.
20) Verify high beam function. NOTE: The low beam lamps do not come ON with the high beams.
21) Remove the Owners Guide Package from the trunk and set aside.
22) Place new Owners Guide Package (with orange seal on flap) into the trunk.
23) Align headlamps per the following procedure.
C. HEADLAMP ALIGNMENT PROCEDURE
To align the headlamps, the vehicle must be positioned on a level surface and the vehicle air suspension system must be "normalized" using the following procedures.
Air Suspension "Normalization" Procedure
1) Make sure the air suspension switch on the LH side of the trunk is ON.
2) Place vehicle in PARK, set the parking brake and start the engine.
3) Open the drivers door (leave passenger door closed).
4) Sit on front bumper to lower the front of the vehicle.
5) Have assistant close the driver1 5 door.
6) Stay seated on the front bumper until the air compressor stops raising the front of the vehicle.
7) Sit on the rear bumper of the vehicle to lower the rear of the vehicle.
8) Have assistant open and close the driver's door.
9) Stay seated on the rear bumper until the air compressor stops raising the rear of the vehicle.
10) Open and close the driver's door. The suspension will vent and will now be at the proper ride height.
11) Turn engine OFF.
NOTE:
Do Not lean on the vehicle until the headlamp alignment has been set.
Headlamp Alignment
Tools required: 4mm hex wrench or 4 mm hex socket.
1) Open the hood and open the headlamp access panel. Locate the horizontal indicator and adjusting screw; they are located closest to the center of the vehicle.
2) Use a 4 mm wrench to turn the horizontal adjusting screw until the knurled portion of the screw is aligned with the "0" reference mark on the gray (RH) or blue (LH) plastic retainer.
3) Locate the vertical aim spirit level.
4) With the vehicle on a level surface, use a 4 mm wrench to turn the vertical aim adjusting screw until the bubble in the spirit level is centered.
5) Close the headlamp access panel and close the hood.