Mazda Trucks 1987-1993 Repair Guide

Headlights

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REMOVAL & INSTALLATION




CAUTION
On models using a halogen bulb: The halogen bulb contains gas under pressure. The bulb may shatter if the glass envelope is scratched or if the bulb is dropped. Handle the bulb carefully. Grasp the bulb only by its plastic base. Avoid touching the glass envelope. Keep the bulb out of the reach of children. Energize the bulb only when installed in the headlamp.

Pickups

See Figure 1



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Fig. Fig. 1: Front light assemblies

  1. Remove the radiator grille attaching screws and remove the grille.
  2.  
  3. Remove the headlight bulb trim ring, by removing the three screws and rotating the ring clockwise. Support the headlight bulb and remove the trim ring.
  4.  

Do not disturb the headlight aiming screws, which are installed in the housing next to the retaining screws.

  1. Pull the plug connector from the rear of the bulb and remove the bulb.
  2.  
  3. Connect the plug connector to the rear of a new headlight.
  4.  
  5. Install the headlight in the housing, and locate the bulb tabs in the slots and the housing.
  6.  
  7. Position the trim ring over the bulb and loosely install the retaining screws. Rotate the ring counterclockwise to lock it in position. Tighten the three attaching screws. Check the headlight operation.
  8.  
  9. Install the grille.
  10.  
  11. Have the headlight aim checked.
  12.  

MPV

See Figures 2, 3 and 4

  1. Make sure that the headlight switch is turned OFF .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Open the vehicle's hood and secure it in an upright position.
  6.  



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Fig. Fig. 2: Push down the upper retaining tab on the headlight bulb connector plug and pull straight off of the bulb

  1. Unfasten the locking ring which secures the bulb and wire harness plug assembly, then withdraw the assembly rearward.
  2.  
  3. Disconnect the electrical wire harness plug from the bulb and remove the locking ring as well.
  4.  



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Fig. Fig. 3: Turn the headlight bulb retaining ring counterclockwise and pull off of the back of the bulb



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Fig. Fig. 4: Pull the headlight bulb straight out of the headlight housing. Under any circumstance, never touch the glass of the light bulb with your fingers

To install:
  1. Before connecting a light bulb to the wire harness plug, ensure that all electrical contact surfaces are free of corrosion or dirt.
  2.  
  3. Install the locking ring onto the bulb, then line up the replacement headlight bulb with the harness plug. Firmly push the bulb onto the plug until the spring clip latches over the bulb's projection.
  4.  


WARNING
Do not touch the glass bulb with your fingers. Oil from your fingers can severely shorten the life of the bulb. If necessary, wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation.

  1. Position the headlight bulb and secure it with the locking ring.
  2.  
  3. Connect the negative battery cable.
  4.  
  5. To ensure that the replacement bulb functions properly, activate the applicable switch to illuminate the bulb which was just replaced. (If this is a combination low and high beam bulb, be sure to check both intensities.) If the replacement light bulb does not illuminate, either it too is faulty or there is a problem in the bulb circuit or switch. Correct if necessary.
  6.  
  7. Close the vehicle's hood.
  8.  

Navajo

See Figure 5



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Fig. Fig. 5: Halogen lamp replacement

Two aerodynamically styled headlamps are used. Each lamp uses a dual filament halogen bulb. A burned out bulb may be replaced without removing the headlamp.

  1. Check that the headlamp switch is turned OFF. Lift the hood and locate the bulb installed in the rear of the headlamp body.
  2.  
  3. Remove the electrical connector from the bulb by squeezing the connector tabs firmly and snapping the connector rearward.
  4.  
  5. Remove the bulb retaining ring by rotating counterclockwise. Slide the ring off the plastic base. Keep the ring for reinstallation.
  6.  
  7. Carefully remove the headlamp bulb from the socket by gently pulling straight backward out of the socket. Do not rotate the bulb during removal.
  8.  
  9. With the flat side of the bulb facing upward, insert the glass envelope of the bulb into the socket. Turn the base slightly, if necessary, to align the grooves in the forward part of the plastic base with the corresponding locating tabs inside the socket. When the grooves are aligned, push the bulb into the socket until the mounting flange contacts the rear face of the socket.
  10.  
  11. Install the plastic lock ring and connect the wiring. Turn the headlamps on and check for proper operation.
  12.  

A properly aimed headlamp need not be reaimed after installation of the bulb.

  1. To remove the headlamp assembly: Disconnect the headlamp bulb connector. Remove the screw retaining the side marker assembly to the vehicle and remove the assembly.
  2.  
  3. Remove the fasteners retaining the grille to the grille reinforcement and remove the grille. Remove the spring clips retaining the headlamp assembly to the grille reinforcement and remove the assembly. Install in reverse order.
  4.  

AIMING THE HEADLIGHTS



See Figures 6 through 11

The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made.


CAUTION
About once a year, when the headlights are replaced or any time front end work is performed on your vehicle, the headlight should be accurately aimed by a reputable repair shop using the proper equipment. Headlights not properly aimed can make it virtually impossible to see and may blind other drivers on the road, possibly causing an accident. Note that the following procedure is a temporary fix, until you can take your vehicle to a repair shop for a proper adjustment.



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Fig. Fig. 6: Headlamp aiming-MPV shown

Headlight adjustment may be temporarily made using a wall, as described below, or on the rear of another vehicle. When adjusted, the lights should not glare in oncoming car or truck windshields, nor should they illuminate the passenger compartment of vehicles driving in front of you. These adjustments are rough and should always be fine-tuned by a repair shop which is equipped with headlight aiming tools. Improper adjustments may be both dangerous and illegal.

For most of the vehicles covered by this manual, horizontal and vertical aiming of each sealed beam unit is provided by two adjusting screws which move the retaining ring and adjusting plate against the tension of a coil spring. There is no adjustment for focus; this is done during headlight manufacturing.

Because the composite headlight assembly is bolted into position, no adjustment should be necessary or possible. Some applications, however, may be bolted to an adjuster plate or may be retained by adjusting screws. If so, follow this procedure when adjusting the lights, BUT always have the adjustment checked by a reputable shop.

Before removing the headlight bulb or disturbing the headlamp in any way, note the current settings in order to ease headlight adjustment upon reassembly. If the high or low beam setting of the old lamp still works, this can be done using the wall of a garage or a building:

  1. Park the vehicle on a level surface, with the fuel tank about 1 / 2 full and with the vehicle empty of all extra cargo (unless normally carried). The vehicle should be facing a wall which is no less than 6 feet (1.8m) high and 12 feet (3.7m) wide. The front of the vehicle should be about 25 feet from the wall.
  2.  



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Fig. Fig. 7: Location of the aiming adjustment screws on most vehicles with sealed beam headlights-Pickup shown



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Fig. Fig. 8: Example of headlight rear adjustment screw location for composite headlamps-MPV shown



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Fig. Fig. 9: Example of front facing headlight adjustment screw location for composite headlamps-MPV shown

  1. If aiming is to be performed outdoors, it is advisable to wait until dusk in order to properly see the headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible by closing shades or hanging cloth over the windows.
  2.  
  3. Turn the headlights ON and mark the wall at the center of each light's low beam, then switch on the brights and mark the center of each light's high beam. A short length of masking tape which is visible from the front of the vehicle may be used. Although marking all four positions is advisable, marking one position from each light should be sufficient.
  4.  



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Fig. Fig. 10: Low-beam headlight pattern alignment



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Fig. Fig. 11: High-beam headlight pattern alignment

  1. If neither beam on one side is working, and if another like-sized vehicle is available, park the second one in the exact spot where the vehicle was and mark the beams using the same-side light. Then switch the vehicles so the one to be aimed is back in the original spot. It must be parked no closer to or farther away from the wall than the second vehicle.
  2.  
  3. Perform any necessary repairs, but make sure the vehicle is not moved, or is returned to the exact spot from which the lights were marked. Turn the headlights ON and adjust the beams to match the marks on the wall.
  4.  
  5. Have the headlight adjustment checked as soon as possible by a reputable repair shop.
  6.  

 
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