Friday, November 16, 2007

Replacing an XJ40 Headlight

How hard could it be to replace a Jaguar's sealed beam headlight? Well, let me tell you that it was a bit harder than anticipated. The school bus headlight bezel's screws were readily available. But luxury cars are made with hidden screws and bolts. So, the service manual was essential. Here are the instructions modified and translated into the American dialect:

  1. Open the hood and disconnect the negative battery cable.
  2. Remove the two radiator grille pieces. Two upward pointing screws hold the grille pieces to the grille frame.
  3. Remove the grille frame (the rectangular piece with the jaguar emblem on it).
  4. Move the rubber cover to access the bolts and nuts.
  5. Remove the nuts and washers which secure the rear of the headlight assembly to the car.
  6. Remove the lower bolt securing the headlight assembly.
  7. If necessary, disconnect any electrical connectors and remove the headlamp assembly.
  8. Loosen the four screws which hold the rim finisher in place.
  9. Loosen the three screws which hold the chrome rim around the headlight. Rotate the rim and pull headlight and rim straight out.
It sounded fairly simple until I got to #6. Which bolt is "the lower bolt"? After wiggling the assembly around for a while, I eventually spotted a 10m bolt head which turned out to be what they were talking about. I think "central bolt" would have made more sense. From there it was easy. Total project time was about two hours. Now that I know how to do it, I imagine the next time will go much quicker.

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