As I posted this weekend, I rebuilt both my front headlights. We had noticed that the light output was nominal
at best, and scary at worst. I had only driven the CSi once at night since purchasing it over a year ago. After
checking the lenses, both units exhibited a side to side movement within the buckets. After researching the
archives, I decided to rebuild the buckets with new adjusters, Jon Nelson’s brass modifications, new shock
absorbers, and place protective film on the face of the lenses. Tom Wuffer suggested completely removing the
assemblies from the car to make it easier, and I followed this suggestion – I’m glad I did.
Prior to starting, I turned the lights on in the garage and placed black tape on their pattern line which was
projected on the wall. As I knew that I wanted to aim them slightly higher, this would give me a reference point
when I replaced the assemblies.
Next came the headlight assembly removal.
First, I circled the 4 large nuts/washers on each side with a sharpie to make realigning them when finished
easier. Next, remove the one black 10mm bolt on the retaining strap next to the radiator. Finally, unhook the
two wiring harnesses on the outside of the air filter boxes. Then you can completely lift out the headlight
assembly.

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