Ford Fusion: Exterior Lighting / Headlamp Assembly. Removal and Installation

Removal

NOTE: The procedure for the LH headlamp assembly is shown, the RH headlamp assembly is similar.

NOTE: Removal steps in this procedure may contain installation details.

1. Remove the front bumper cover.
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   

1. 1. Remove the bolts.
      
   2. Remove the bolt.
      
   3. Disconnect the electrical connector.
      

1. 
   Remove the headlamp assembly.
   
   1. Separate the headlamp assembly from the ball stud.
      
   2. If equipped, separate the wiring harness guides from the headlamp assembly.
      

Installation

1. 
   Position the headlamp assembly.
   
   1. Install the headlamp assembly on the ball stud.
      
   2. If equipped, install the wiring harness guides to the headlamp assembly.
      

1. NOTE: When installing a new headlamp assembly, position the headlamp ballstud in the socket and align the headlamp assembly edge to the fender. If the headlamp assembly cannot be aligned adjust the ballstud socket.

   
   Install the headlamp assembly
   
   1. Install the bolts finger tight.
      
   2. Install the screw finger tight.
      
   3. Connect the electrical connector.
      

1. Align the headlamp assembly to the fender opening.
   

1. 
   
   • Tighten the bolt.
     
   • Tighten the screws.
     Torque: 32 lb.in (3.6 Nm)

1. Install the bumper cover.
   Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
   

1. Adjust the headlamp.
   Refer to: Headlamp Adjustment (417-01 Exterior Lighting, General Procedures).