This is a work in progress. I will update it when I can.
Always wear the proper safety gear!
Removal of the Main Outer Lens
1) Remove headlights from car.
2) Clean any debris from the main lens with a soft sponge and warm, soapy water.
3) Pre-heat oven to 225f degrees.
4) Remove
main rear cover,
fog lamp cover, all
5 bulbs (low, high, fog, turn and park),
corner trim and
headlight gasket (held in by 2 screws and 3 flares).
5) Place wooden planks in the oven to rest the headlight on, then bake each headlight for 15 minutes at 225f degrees and open them. Don't let the headlight touch anything metal inside the oven as the hot metal will deform the plastic.
VIDEO: How to open a sealed headlight.
6) Using a
short razor blade, carefully remove any large pieces of excess silicone from the tongue of the main lens.
Use caution. If you scratch the silver perimeter paint from the back side, it will show through.
Never touch the inside of the lens! This will cause scratches that will be visible in the completed headlight.
If the inside of the lens is dirty and compressed air won't remove the dirt or debris, wash it gently with very soft finger tips, warm water and Dawn dish soap, then blow it dry with compressed air.
7) Wrap the main lens carefully in plastic wrap and store in a safe place until it is needed for re-installation.