Nissan Stanza/200SX/240SX 1982-1992 Repair Guide

Headlights

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REMOVAL & INSTALLATION



1982-83 200SXStanza (Regular Seal Beam Type)

See Figure 1

  1. Remove the headlight retaining ring screws. These are the three or four short screws in the assembly. There are also two longer screws at the top and side of the headlight which are used to aim the headlight. Do not tamper with these or the headlight will have to be reaimed.
  2.  



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Fig. Fig. 1: Exploded view of the standard headlight assembly

  1. Remove the ring on round headlights by turning it clockwise.
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  3. Pull the headlight bulb from its socket and disconnect the electrical plug.
  4.  

To install:
  1. Connect the plug to the new bulb.
  2.  
  3. Position the headlight in the shell. Make sure that the word TOP is, indeed, at the top and that the knobs in the headlight lens engage the slots in the mounting shell.
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  5. Place the retaining ring over the bulb and install the screws.
  6.  
  7. Check headlight system for proper operation--adjust headlight aim if necessary.
  8.  

1984-88 200SX240SX

See Figures 2, 3 and 4

If headlamps do not open on these models, first check the fusible link for the headlight motor. Also check the retract switch. If headlamps do not retract, check the retract control relay. Refer to the guide Operation Of Headlight Doors procedure.

  1. Open the headlamp. Disconnect the negative battery cable.
  2.  
  3. Unbolt and remove the finisher.
  4.  



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Fig. Fig. 2: Headlamp assembly - 1984 and later 200SX and 240SX



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Fig. Fig. 3: Adjust the lid to these dimensions at the joints, and so it is flush with the hood and fenders



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Fig. Fig. 4: Headlight lid adjustment

  1. Remove the headlamp lid.
  2.  
  3. Remove the bulb retaining ring. Unplug and remove the headlamp bulb.
  4.  
  5. Reverse the removal procedure to install. Install headlamp rubber cap with electrical connector firmly so that the lip makes contact with the headlamp body. Adjust the headlamp lid so it is flush with the hood and fender, and so the lid joint is as shown in the accompanying illustration. This is done by adjusting the lid mounting screws while open and close the headlamp by operating the manual knob on the headlamp motor. Make sure the lid is not interfering with the protector. Adjust the headlights if necessary.
  6.  

Stanza (Halogen Headlamp Type)

See Figures 5 and 6

The headlight is a semi-sealed beam type which uses a replaceable halogen bulb. A bulb can be replaced from the inside the engine compartment without removing the headlight assembly.

Use care and caution when working with this type bulb--high pressure halogen gas is sealed inside the halogen bulb.

  1. Disconnect the negative battery cable. On some late model vehicles, remove the Anti-lock brake system electrical connectors and bracket assembly to gain access to the bulb. Turn the bulb retaining ring counterclockwise until it is free of the headlight reflector, and remove it.
  2.  



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Fig. Fig. 5: Headlight (halogen type bulb) removal and installation



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Fig. Fig. 6: Headlight (halogen type bulb) removal and installation 1992 Stanza



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Fig. Fig. 7: Manual operation of power headlight doors

  1. Disconnect the electrical connector at the rear of the bulb. Then, remove the bulb carefully without rotating or shaking it.
  2.  
  3. Install in reverse order. Check headlight operation--adjust headlamp aim if necessary.
  4.  

Do not remove a headlight bulb and leave the reflector empty. If you do this, the reflector will become contaminated by dust and smoke. Do not remove one bulb until another is available for immediate replacement.

Do not touch the glass portion of the bulb. Handle it only by the plastic base!

MANUAL OPERATION OF HEADLIGHT DOORS



See Figure 7

  1. Turn OFF both headlight switch and retractable headlight switch.
  2.  
  3. Disconnect the battery negative terminal.
  4.  
  5. Remove the motor shaft cap.
  6.  
  7. Turn the motor shaft counterclockwise by hand until the headlights are opened or closed.
  8.  
  9. Reinstall the motor shaft cap and connect the battery cable.
  10.  

AIMING THE HEADLIGHTS



See Figures 8, 9, 10, 11 and 12

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 when any time front end work is performed on your vehicle, the headlights 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.

Headlight adjustment may be temporarily made using a wall 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 in front of you. These adjustments should always be fine-tuned by a repair shop equipped with aiming tools. Improper adjustments may be both dangerous and illegal.

For most of the vehicles covered by this guide, horizontal and vertical aiming of each headlamp assembly is provided by two adjusting screws which move the housing 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. 8: Location of the aiming screws on most vehicles with sealed beam headlights



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Fig. Fig. 9: Dual headlight adjustment screw locations-one side shown here (other side should be mirror image)



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Fig. Fig. 10: Example of headlight adjustment screw location for composite headlamps

  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.
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  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. 11: Low-beam headlight pattern alignment



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Fig. Fig. 12: 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.
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  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.
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  5. Have the headlight adjustment checked as soon as possible by a reputable repair shop.
  6.  

 
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