I am asking these questions in my build thread, but it doesn't seem to generate much traffic. I figured this might get me a quicker response, as this is really getting at me.

The issue:
I installed my headlight assemblies. My PS went in without issue:



My DS, though, is not only popping-up fully, but also the corner is rubbing against the bumper cover:





Here's a shot of the headlight in the "fully-popped" position:



The way these mount, it's pretty fool-proof. You put the fasteners in, and the only adjustment seems to be on the headlight cover. If I can't get any answers here, I was planning on taking out both assemblies, and comparing for anything obvious (bends, etc.). There is no body damage, and all looks fine as far as bumper-to-fender fit is concerned. If there were any issues, I think the body shop would have noticed.
I appreciate any help here. Plus, if you care to visit my build thread and answer my other questions, that would be awesome also. Thanks in advance!!

 

The headlight bracket is held in alignment at the back with an adjustable strip that holds some alignment pins. It could be that this needs adjusting.

There are two bolts holding it in place, see photo below. So with the other bracket bolts undone you should be able to position the unit to suit.

 

Thanks!! I hope this works. I was wondering what that thing was for. I'll give it a shot soon and see.

 

I'm not seeing the pins you're talking about. Also, if I'm reading you post right, the bolted bracket you're talking about (under the two bolts at the very top of the assembly) doesn't seem to have any impact on assembly position. Actualy, I have no idea what that bracket does at all. I feel that they made it such that if you use all the bolts to mount it, there really isn't any adjusting you can do. I'm starting to feel this is a body issue. I took the assembly completely out, and it doesn't look like anything is "out of whack." On the other hand, there doesn't appear to be any body issues. If anyone has a spare assembly that I can borrow, I'd be willing to pay shipping both ways, unless you're local to 70002 I can pick up. Also, I would appreciate if anyone could post some detailed pictures of some properly installed any working assemblies, I would greatly appreciate it. Thanks!

 

Its a while since iv had my lights out - but you should still be able to shimmy the assembly around a little bit when the bolts arnt fully snugged down.

I would loosen the bolts on the headlight, the bolts on the front bumper and the bolts on the fender.
I would then shimmy the light where it need to be - snug it down. Then put the bumper / fender where they need to be and snug them down.

edit; these are the "pins" he speaks of. The other side of it is has a key on it. Loosen everything and use the available movement in all parts in proximity to get it how you need it.

 

My car didn't come with these pins, unfortunately. I did take that little bracket off completely, and I attempted to adjust the assemblies. No luck. The holes that bolt the assembly are fairly small, so there isn't much room for adjustment. In addition, the bolt that goes into the side (near the motor) and the bolts that connects the motor to the engine bay (via that small bracket), tighten-up the assembly even more.
As I've said before, the body shows absolutely no signs of prior damage, which makes this all the weirder. This is why I'm thinking I'd like to try to test-fit someone else's assembly. If not, I'll just skip this for now, and have a body shop address it later.

 

In one picture I'm seeing the black plastic light surround and I'm not sure it's tucked into the headlight cover properly. That would make it hang out wider. I'd fix that first.