Reworking Main Headlight Mounting

Information 

The headlights together with the mountings are fitted into the body at the factory.

If the mounting is replaced due to damage when re-using the headlight, it may have to be reworked.

This is necessary in order to ensure that the headlight can be fitted precisely.

1. Lock the new mounting to the headlight and install it.
   Fig 1: Checking Main Headlight Joint Line

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   1. 1.1. Check the joint line. If the joint line is OK, connect the headlight and install it fully.
   2. 1.2. If the joint line is not OK, the retainer plate must be reworked.

      The following options are available: 

2. Remove cross strut at the front fastening point. → Headlight can be adjusted forward in -Y-  direction.
   Fig 2: Adjusting Headlight Mounting

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3. Position mandrels underneath the mounting and/or mill it off. → Headlight can be adjusted forward in -Z-  direction.
   Fig 3: Adjusting Headlight Mounting

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4. Pull out the mounting by pulling it forward slightly and remove rear contact ribs -arrows-  . → Headlight can be adjusted in -X-  direction.
   Fig 4: Adjusting Headlight Mounting

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5. Remove the two pins at the back of the mounting and screw the mounting in further. → Headlight can be adjusted in X, Y and Z direction. → Tightening torque: 8 Nm (6 ftlb.) 

   Procedure for drilling the new fastening points.

   1. 5.1. Remove the two pins from the mounting.
      Fig 5: Removing Pins From Mounting

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   2. 5.2. Lock the mounting to the headlight.
   3. 5.3. Position the headlight in the wing so that there is a uniform gap around the headlight.

      The gap between the headlight and front apron must be at least 3 mm in order to ensure adequate ventilation of the headlight.

   4. 5.4. Secure the mounting to the headlight holder with the two front fastening nuts.
   5. 5.5. Release and remove the main headlight. The mounting remains on the vehicle.
   6. 5.6. The bores in the mounting now determine the position for the bores in the headlight holder.
      Fig 6: Drilling Headlight Holder Holes

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   7. 5.7. Mark the bores and remove the mounting.

      Information 

      When drilling, make sure that the components underneath are not damaged.

   8. 5.8. Drill holes using an 8-mm drill bit.
   9. 5.9. Carefully prime the bores to prevent corrosion.
   10. 5.10. The height (Z dimension) of the mounting must be adjusted using washers -arrow-  .

       Then secure with the fastening screws and fastening nuts. → Tightening torque: 8 Nm (6 ftlb.) 

       Fig 7: Adjusting Headlight Mounting

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