Headlight Lens Replacement

From THE Corrado Forum Knowledge Base

This guide can be use to replace early & late model headlight lens. Nearside headlight is shown in the photos but it's the same procedure for the offside.

Tools / materials required

• Philips screw driver
• Flat blade screw driver
• Double sided tape (Halfords Trim Repair Tape is a good alternative to original)

1) Open the bonnet & remove radiator grill by unclipping 3 tabs at the top of the grill. Withdraw the grill from the front. To remove the headlight, remove 2 Philips screws (arrowed) on the top and a third screw (arrowed) can be accessed through a hole.

2) Ease the headlight away from the car and unclip the power connector by pulling the wire clip (arrowed) up and then pulling the plug away.

3) Two clips need to be removed before the plastic surround can be taken off. Lever the rear of the clip up (arrowed) & ease the surround away at that area. Do this for the other clip. The surround should come away from headlight. I suggest you clean away any dirt off the headlight lens before going any further to prevent any dirt entering the headlight whilst removing the lens.

4) Using a flat blade screwdriver insert it into the slot on the lens retaining clip. Do this on the lens side as the clips come away easier. Now lever the clip away from the lens, this can be a little tricky. Do this for the remaining clips. The lens should come away from the headlight case but take care as the seal maybe stuck to the case & lens.

Make sure that you DO NOT TOUCH THE LENS WITH ANYTHING as the reflective coating is very delicate and will come off and that will mean you need to buy a whole new headlight unit for £100!

5) The headlight should now be in 4 pieces – case, seal, lens & surround.

6) Before re-assembling the headlight it's a good idea to clean all the parts including the seal. Before fitting the lens apply a length of double sided tape about 100mm long to the bottom side of the lens but leave the backing tape on for now. This holds the bottom of the plastic surround in place otherwise it will sag in the middle.

7) Re-seat the seal on the headlight case. Note that the seal fits only one way. Now fit the lens to the seal.

8) Re-fit the lens retaining clips. This is best done by hooking one side over the lens first, then press the other end over the lip on the case. Repeat for the remaining clips.

9) Photo shows the clips correctly fitted.

10) Before re-fitting the plastic surround fit the 2 clips as shown arrowed. Remove the double-sided backing tape and re-fit the surround, paying attention slotting the tabs into the locating slots. Apply pressure to the bottom of the surround to ensure a good fix to the double-sided tape.

11) The headlight is now ready to re-fit to the car. To re-fit reverse the removal procedure. Re-fit the radiator grill.