How do I remove & then realign headlight assembly (W124)?
 

Did the search on this forum and it did not address all of my concerns. CD service manual does not either.

My 1993 - W124 right (passenger) headlight assembly is not properly installed from the previous owner. It is pushed in a little from the side and does not fit even with the fender like the drivers side. The top next to the hood protrudes foward more than the assembly on the drivers side. Questions:

1. How do I remove the yellow side marker?

2. How do I remove the painted metal strip under the assembly?
(I see the one next to the grill, but how to accsess the one next to the fender?)

3. (hex bolts I have located) I see the two adjustment bolts next to the grill. one holds the metal trim strip and the other is a hole in the frame. I see the big plastic one on top of the assembly. How many more bolts hold the assembly? How do I get to them without bending anything?

4. On reinstallation, which bolts do I adjust to align and get the proper fit?


As always .....THANKS FOR THE EXPERT HELP!!

Your side marker has a large clip that you squeeze in the horizontal plane...look back there with a flashlight & you'll see. That side marker has to slide straight forward when its released, as it clips into the side of the headlight cluster.

Removing the marker, you'll see 2 bolts up high that hold that side of the headlight cluster, and down low you'll see a bolt installed vertically that holds that end of the metal fascia. The other end is held by the screw you've described.

If you remove the 8mm bolt near the grill that goes into the inner side of the headlight cluster, the only remaining fastener is the large plastic one up top.

How I adjusted mine recently: I started by aligning the outer edge of the cluster with the fender lines/creases...the 2 mounting screws on the outer side allow some positioning. I next installed the 8mm hex bolt on the inner side of the cluster, paying attention to align the cluster comparably to the other side, as relative to the grille assembly (you may have to close the hood a few times to check). That done, I simply installed the big plastic nut-thing without disturbing the cluster location. That done, re-install the side marker, button things up and go find a wall you can aim your headlights on!

As an aside...when you re-install the side marker be sure to push it back in firmly until it clicks. There have been numerous cases of side markers coming loose because of not doing this.