January 2005

This first thing to do is raise the headlight. You can twist the black knob at the back of the headlight motor to raise or lower the headlight. Next remove the black plastic covering on the side of the headlight.

Next, remove the 3 screws that hold the back surround, remove the surround.

Remove the 3 bolts that hold the chrome ring, remove the chrome ring.

Pull the headlight out, unplug the wires, remove the headlight. Next, remove the 'eyebrow' plate. This plate is attached with rubber plugs. There are 2 on the wide side and 1 on the narrow side.

Remove the 3 allen-head screws, that hold the inside pivot bar, on the side of the housing

Remove the 5 screws that hold the headlight cover. Note, on the driver's side, I didn't remove the cover.

Remove the circlip and washer on the end of the pivot are. Then slide the arm from the headlight bucket.

Position the inside pivot bar bracket up, then carefully slide the headlight bucket towards the center of the car to remove for the car. This will remove it leaving the outside pivot bar attached to the inside of the fender well.

Carefully remove the rubber covering from the back of the headlight box.

Remove the 3 allen-head bolts. Next, remove the nut that holds the pivot arm. Carefully remove this bracket. Note that this bracket is splined and will need to be 'convinced' off.

Remove the nut that holds the ground wires.

Carefully push the rubber cover wires that hold the headlight motor relay back through the headlight box. Now, remove the headlight motor.

This shows the front view of the headlight box with everything removed.

This shows the side view.

I drilled out spot-welds and used a cutting wheel and sawzall to cut the metal around the box. I would recommend in the future that the fender be removed before attempting to remove the headlight box. I removed the box from the passenger side, with the fender attached, and it took several hours. I removed the box from the driver side, without the fender, and it took 20-30 minutes.

Here's the side shot with the box removed.

This shows the headlight box removed from the car. You'll notice the drain pipe still attached. The pipe is tack-welded to the bottom of car, which I just ground down before removing.

Here's the side shot. This is the passenger side, which has the VIN pop-riveted on it.