I take no responsibility for any damage or injury caused by following these instructions. Do so at your own risk.
The first thing is to remove the headlamp, just one bolt holds it in accessed from behind and the lamps out
You can see the crap in the bottom of the light from the water
Looking at the back of the light you can see where someone has tried to seal it before, plus the gap which is letting in all the water.
Now comes the removal of the plastic cover. Before you start removing the cover note how far it protrudes
past the edge of the lamp all the way round as mounting it to far one way or the other you will end up with a gap between the headlight and the ar bodywork.
The way I removed the plastic cover was to get a long sharp knife, insert it in the gap between the lamp and the cover and carefully slide it along to remove the seal. this can be quite difficult to do. you will find that as the sealant comes away it will make a cracking sound, It almost gave me a heart atttack the first time it happened at I thought I had cracked the plastic.
Once removed give the lamp a clean, you will also notice in the photo above that the black painted edge of the cover has come away in places leaving it see through. I used Black gloss paint (As thats all I had to hand) and a small brush to repaint the black edge back on.
Once the paint is dry you then need to reseal the cover back onto the lamp, For this I used black instant gasket. from somewhere like halfords. It comes in a small squeezy tube. Only squeeze a small thin continuous bead all the way round the lamp, try to keep the bead to the outer edge of the lamp otherwise the gasket may enter the lamp when you push on the cover (if you know what i mean)
Once dry which will only be a couple of hours you can refit the lamp. which should now be leak free.
Dan.
Edited by danuk, 22 October 2006 - 03:44 PM.
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