High Intensity Discharge Headlamp Starter/Arc Tube Replacement TT6, TT7, TT8

Caution: The high intensity discharge system produces high voltage and current. To reduce the risk of severe shocks and burns:

Notice: When removing or replacing the arc tube, the arc tube must not contact the side of the headlamp housing or the bulb shield. Damage to the arc tube may result.

1. Remove the low beam headlamp relay in order to disable the HID (High Intensity Discharge) headlamp system. Refer to Headlamp Relay Replacement .
2. Remove the headlamp. Refer to Headlamp Replacement .
3. Remove the arc tube and starter cover (1), from the headlamp housing (2).



4. Disconnect the electrical connector (1) from the arc tube and starter assembly (2).



5. Remove the arc tube and starter assembly fasteners (1).
6. Remove the arc tube and starter assembly (2) from the headlamp housing (3).

Notice: Avoid touching the bulb or letting the bulb come in contact with anything damp. Oil from your skin or moisture on the bulb can cause the bulb to explode when the bulb is turned on. If either comes in contact with the bulb, clean the bulb with alcohol or a suitable degreaser and wipe the bulb dry.





Important: Ensure that the electrical connection is pointed towards the bottom of the headlamp housing.

1. Install the arc tube and starter assembly (2) to the headlamp housing (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the fasteners (1) in order to secure the arc tube and starter (2) to the headlamp housing (3).

Tighten
Tighten the starter/arc tube fasteners to 3.5 N·m (31 lb in).




3. Connect the electrical connection (1) to the arc tube and starter assembly (2).

Important: Ensure the arc tube and starter cover is properly installed and sealed to the headlamp assembly in order to avoid water intrusion in the headlamp assembly.




4. Install the arc tube and starter cover (1), to the headlamp housing (2).
5. Install the headlamp to the vehicle. Refer to Headlamp Replacement .
6. Install the low beam headlamp relay. Refer to Headlamp Relay Replacement .