How to fix hydraulic headlight adjustment

[Jev88]

Well I finally tackled the Ducato (230, MK2) "stupid" headlamp adjuster mechanism. Replacement part from Opie Oils is slightly different part number and lots of retailers say it is Left hand drive only.... That is nonsense!

It is a bit fiddley and requires some blind work pushing parts through the bulk head hole but got there in the end. I hear this might be a future MOT failure do take note my friends.

In brief.
Battery out.
Driver's lower dash out.
Old switch on upper dash out.
Loosen off some pipes near headlights to allow better access if needed.
Old units have ball attachment onto mechanism, spray with lubricant and pop off in situ. Twist mechanism and push away from front of van to line up three plastic protrusions and pull mechanism free.
Both adjusters have to fed through engine bay and pushed pulled through bulk head to driver's lower dash.
Same in reverse BUT in order for dashboard switch to line up correctly you need to feed adjusters up and over a white cross member directly behind dash and not underneath it or you will have to start again.
Round pins pop back into plastic arms on headlamps and require lining up so the one grooved protrusion is to the right... Push and twist to lock.

Hope that helps some others.

I removed headlamp as I wasn't sure how to release the ball end of the hydraulics but not needed. I could also see where the old units crack and leak all the fluid out where pipe meets unit.

 

[SteveJ]

Thanks for this, now I know that the lights don't need to come out which I was suspecting. Looks fairly straightforward if a bit of a pain to do, thanks for beating me to it . I'll be doing mine in the next couple of weeks now we're back from an exceedingly sunny Scotland so you've saved me from a fair bit of head scratching.

 

[pappajohn]

Or they could have fitted electric adjusters like everyone else.

 

[Jev88]

Or they could have fitted electric adjusters like everyone else.

I did contemplate attaching two bike cables and machining something on the dashboard a little like old gear levers used to be as there is a reasonably healthy spring on the mechanism. Who in their right mind runs flimsy hydraulic pipes round corners in a hot engine bay? Apart from old Citroen's and I'll forgive them as the old models had hydraulic Everything!

 

[_Sid]

Jev - I tried opie oils for some replacement actuators for my year 2000 Boxer 270 based campervan but no joy.

Do you know of any other suppliers?

Thanks

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[Jev88]

All I can say is Google the part number? Do you have it?

 

[Jev88]

.

looks the same?

 

[_Sid]

Thanks for the quick reply. No, I don't have the part no. The Peugeot agent didn't list it.

 

[Jev88]

And this guy managed to build an electric version....

Electric height

 

[_Sid]

I've just seen the image that you posted. Price seems excessive. I'm going to see if Peugeot so a blanking piece for the adjuster in the photo and do away with it completely

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[_Sid]

I'll watch the u-tube in a moment. Thank you

 

[Jev88]

And..... Foreign eBay sites can help.

<Broken link removed>

 

[Jev88]

And last one (quite good fun trying to seek out these old parts).
Electric version

 

[_Sid]

Thanks. If I can't get a blanking piece I'll go down the electric route like the guy on u-Tube and source some electric motors

 

[Woody5900]

Headlamp adjusters DO NOT have to work on motorcaravans! See last line below (copied from the link below)

MOT inspection manual: cars and passenger vehicles - 4. Lamps, reflectors and electrical equipment - Guidance - GOV.UK

Headlamp, position lamps, daytime running lamps, stop lamps, indicators, hazard warning lamps, fog lamps, reversing lamps, lighting ‘tell-tales’, trailer electrical socket, electrical wiring and battery rules and inspection for car and passenger vehicle MOT tests.

www.gov.uk

4.1.5. Levelling devices​

Make sure any manual headlamp levelling devices (driver controls) work by:

• switching on the dipped beam headlamps
• operating the manual levelling device
• checking that the headlamp beams move up and down
• returning the levelling device control to its original position

Vehicles with high intensity discharge (HID) or LED dipped beam headlamps may be fitted with a suspension or headlamp self-levelling system. If these systems have been fitted, they must work.

Sometimes it is not easy to determine if the self-levelling systems work. In such cases you should give the benefit of the doubt.

You can identify HID headlamps from:

• ‘DCR’ mark on the headlamp lens or body
• an igniter module or inverter behind the headlamp
• taking a few seconds to reach full intensity
• a bluish tinge to the light

HID headlamps use high voltage. You should take care when inspecting these headlamps.

The check of headlamp levelling devices does not apply to motor caravans.

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[ChrisAndEmma]

Headlamp adjusters DO NOT have to work on motorcaravans! See last line below (copied from the link below)

MOT inspection manual: cars and passenger vehicles - 4. Lamps, reflectors and electrical equipment - Guidance - GOV.UK

Headlamp, position lamps, daytime running lamps, stop lamps, indicators, hazard warning lamps, fog lamps, reversing lamps, lighting ‘tell-tales’, trailer electrical socket, electrical wiring and battery rules and inspection for car and passenger vehicle MOT tests.

www.gov.uk

4.1.5. Levelling devices​

Make sure any manual headlamp levelling devices (driver controls) work by:

• switching on the dipped beam headlamps
• operating the manual levelling device
• checking that the headlamp beams move up and down
• returning the levelling device control to its original position

Vehicles with high intensity discharge (HID) or LED dipped beam headlamps may be fitted with a suspension or headlamp self-levelling system. If these systems have been fitted, they must work.

Sometimes it is not easy to determine if the self-levelling systems work. In such cases you should give the benefit of the doubt.

You can identify HID headlamps from:

• ‘DCR’ mark on the headlamp lens or body
• an igniter module or inverter behind the headlamp
• taking a few seconds to reach full intensity
• a bluish tinge to the light

HID headlamps use high voltage. You should take care when inspecting these headlamps.

The check of headlamp levelling devices does not apply to motor caravans.

Thanks for sharing this - I can cross that job off the list now!