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Replacing headlight assembly 200 1987

Here's a little more detail on the problem Tom pointed out...

1) The Light unit is mounted to a plastic/composite "Frame" by 3 rather tricky "safety pin latches", which can't be accessed with the frame mounted in the car.

2) The frame is mounted to the front end sheet metal by 3 or 4 bolts, whose heads are molded into the plastic frame. The nuts are on the engine side of the sheet metal.

Often at least 1 of the nuts is frozen to the bolt. Attempts to muscle it off usually spin the bolt head—leaving the frame and light still captive. Also, 1 nut on the right side is sort of blocked by the A/C Accumulator mount.

Assuming the frame & light come off OK, the "safety-pin" latches can be turned free with pliers. NOTE that 2 of the latch points are where the Aiming Screws attach. The 3rd latch point has a coil spring inside.

Be careful not to lose that spring. It keeps tension on the aiming screws. The light unit will not be secure without the spring.

To mount the new light unit, place it face down on a padded surface, then position the frame over it, guide the aiming screws into their latch points, and twist the safety-pins back in place. Do the same at the 3rd latch point while pressing down as needed to compress the spring inside.
AITROR (Assembly Is blah, blah, blah....)

The Left Frame P/N is 1312620 . The Right is 621 I think. Actually they are the same, except for bolt locations (which I was able to switch around once). Dealer price is about $65 each. Aftermarkets are cheaper, but I've never tried them.


--
Bruce Young,
'93 940-NA (current)
'80 GLE V8 (Sold 5/03)
'83 Turbo 245
'76 244 (lasted only 255,000 miles)
73 142 (98K)
'71 144 (track modified--crusher bound)
New 144 from '67 to '78
Used '62 122 from '63 to '67






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