How to Install 2006 Suzuki Forenza Headlamps

Forenza headlamp replacement

You can install new headlamps on the Forenza right at home with a few simple tools. Damage to the headlamps occurs most often during installation from unintentionally touching the halogen headlamp with bare hands. According to J.D. Power, under normal driving conditions, halogen headlamps will last for 60,000 miles. Excessively bumpy roads over time can lead to loose power connections that may short-out the headlamps. Continual running of the headlamps during the daytime also lessens their lifespan. Installing both left and right headlamps on the vehicle should take 30 minutes or less to complete successfully.

Things You'll Need

• Socket-wrench set
• Black electrical tape
• Latex gloves
• 2 headlamp bulbs
• Dielectric grease
• 1/4-inch drive torque wrench

Instructions

Removal

1. Raise the hood on the Forenza and locate the battery. Use a socket wrench to remove the negative cable from the battery. Completely wrap the cable's metal terminal end with electrical tape. Lay the cable down within the engine compartment, making sure that it's not near any other metal or the engine itself. The negative post on the battery will have a minus symbol identifying it on the battery case.

2. Remove the two securing bolts from the tabs on the top of the headlight assembly with a socket wrench. On the inner side of the headlight assembly, where the wiring harness plugs in on the left, is a small small retaining nut; remove it. Put the nut and two bolts aside for safekeeping.

3. Slowly pull the headlight assembly outward. Flip the headlight assembly down so that the back of it is visible and let it rest on the bumper. Remove the round cap that's covering the headlamp by turning it counterclockwise.

4. Remove the headlamp bulb's securing clip by lightly pushing down on it and popping it out of place. Remove the bulb from its position slowly. Use care so that you don't break the bulb off inside the headlight-assembly lens.

5. Disconnect the bulb from its wiring harness plug. Do not pull on the harness plug's wiring to remove it. Instead, hold the plastic harness plug itself during removal. Set the old bulb to the side of your work area.

Installation

1. Put on a pair of latex gloves and inspect the new headlamp bulb carefully. Look at it closely for any signs of damage. Inspect the filament within the bulb to assure connection to both sides of the contacts in the bulb. Compare the old bulb alongside the new one to also make certain the connecting prongs for the harness plug are the same.

2. Place a small dab of dielectric grease at the tip, on both sides, of each of the bulb's prongs. Gently plug the bulb back up to its harness connection securely. Insert the bulb back into its position on the headlight assembly and return the securing clip.

3. Flip the headlight assembly back up into its original position. Slowly slide the assembly back into its mounting position. Start the two securing bolts by hand as well as the retaining nut to insure proper threading. Set the 1/4-inch-drive torque wrench to 35 inch-pounds and completely secure both bolts and the nut in place.

4. Remove the tape from the negative battery cable and secure it back to its post on the battery. Turn the power on to the headlamps and check the repair. Follow this exact procedure to replace the passenger-side headlamp. The retaining nut on the passenger headlight assembly is located on the inner lower right side.

Tips & Warnings

• Never touch the headlamp bulb glass with bare hands because oils from your hands will deposit on the bulb and cause it to burn out quickly. Do not get any of the dielectric grease on the bulb glass for the same reason. If grease gets on the glass or it is touched with a bare hand, you must start over with a fresh bulb.

References

• "Chilton 2006 Asian Mechanical Service Manual, Lexus-Toyota Volume III"; Chilton; 2006
• "Automotive Wiring and Electrical Systems Workbench Series"; Tony Candela; 2009
• "Auto Upkeep: Basic Car Care, Maintenance, and Repair"; Michael E. Gray, Linda E. Gray; 2007
• YouTube: Forenza Headlamp Installation
• J.D. Power: Automotive Lighting