I Can See Clearly Now

Story and Photos By: Mark Yanochko

Plastic headlamp lenses, on vehicles such as the PT Cruiser and LH models (300M, Concorde, LHS, Intrepid, New Yorker and Vision), are subject to hazing and scratching after years of fighting the elements. On vehicles driven extended periods of time, perhaps more than 75,000 miles, the effects of acid rain and UV radiation, as well as abrasive material takes its toll—so much, in fact, that the brightness of the headlight is severely diminished. An example of this damage is seen on the PT Cruiser headlamp, A, shown in Figure 1.

But all is not lost. These headlamp lenses can be restored to a like new, crystal clear look in pretty short order (less than one hour) using the Mopar® Headlight Restorer kit, part no. 68043526AA. The kit includes everything you need including wet/dry sandpaper, cleaner and sealer.

When you’re finished, headlamp performance and night vision illumination is improved, the resale value of the vehicle has increased and you have saved the cost of replacing headlight components. Here’s how it’s done.

TWO-STEP RESTORATION PROCESS

The first step involves sanding the headlight lens with wet/dry sandpaper to remove the damage, B, seen in Figure 2, from the headlight lens surface. The second step resurfaces the lens by sealing it to add gloss and protection.

Clean the headlight with water. Apply a large, pea-sized drop, C, of Product #1 on the #1000 grit sandpaper, D (Figure 3). Using moderate to heavy pressure, sand the entire plastic surface for at least 2 to 3 minutes (use circular and side-to-side motions, E, as shown in Figure 4). Add additional product or water to the headlight if the surface becomes too dry (slightly dry is good). Wipe the lens with a paper towel to remove the product and any residue from the headlight.

Next, apply a large, pea-sized drop of Product #1 on the #2500 grit sandpaper. Using moderate to heavy pressure, sand the entire plastic surface for at least 2 to 3 minutes (use circular and side-to-side motions) in the same manner as the #1000 grit sandpaper. Add additional product or water to the headlight if the surface becomes too dry (slightly dry is good). Wipe the lens with a paper towel to remove the product and any residue from the headlight.

Then, place a large, pea-sized drop of Product #1, F, on a folded square of the blue lint-free cloth, G, (Figure 5). Using moderate to heavy pressure, wipe the entire plastic surface, H, for at least 2 to 3 minutes (use circular and side-to-side motions) as shown in Figure 6. This time, use water and paper towels to remove all traces of the sanding process.

Clean and dry the headlight. If there are any obvious imperfections on the lens, repeat the sanding procedures with the #1000 grit and #2500 grit sandpapers and Product #1.

After you have finished sanding the headlight and the imperfections have been removed, apply Product #2. Spread four to five drops of Product #2 along the edge of the foam brush (this product is very watery and comes out of the pouch easily). Using very light pressure, apply a thin, smooth coating with the brush, J, to the headlight lens surface, K (Figure 7). Add more product to the brush as needed, but don’t overload it. Drips and streaks can result. If this occurs, simply apply another layer of Product #2.

Let the headlight dry for about 2 minutes, then examine the surface. If there are any obvious imperfections, re-apply Product #2.

After you have completed restoring the headlight on one side of the vehicle, repeat the procedure on the other lens. A sufficient amount of Product #1 and Product #2 are provided to restore both headlight lenses. When you’re all done, the headlamp lens, L, will look almost brand new, as shown in Figure 8.