I have a 1994 FD RX7 and I just upgraded the headlight bulbs to LEDs. While reinstalling the headlight covers I noticed that the passenger side cover wont sit flush anymore with the bumper.
I've tried messing with the headlight motor adjuster but I cant tell if that is doing anything when I twist the red **** ontop. They dont seem to adjust much.

Any suggestions?

Passenger side wont sit flush with bumper anymore

 

I doubt it's the motor. Fit appears fine on the inside of the bumper. Same with the fender portion. It looks like just the front outside is high, and that's more likely just something not installed correctly. There is some 'play' in the covers, as the 'hole' the screw goes through on each corner is actually a "U"-shaped channel allowing the cover to be adjusted slightly on the vertical axis. You may have either not installed them correctly or, if you didn't remove them, may have knocked one side up a little when working on the lamps. They aren't as secure as one might think/hope. Having the attachment break off (30+ year old plastic strieks again) or screws coming loose and losing a cover at speed is, unfortunately, very common.

It is strange that you say you don't notice anything when turning the motor ****, That **** will move the assembly from fully-open to fully-closed. You should definitely be seeing movement if everything's installed correctly. Granted, it does take a fair bit of turning, but you should absolutely see movement.

 

Look like it's just the cover out of adjustment. Do what Sigma said and loosen the screws that hold the cover to the bucket and adjust it

 

Thank you very much for the advice! I just loosened all of the screws. shut the headlight and balanced it and it sat flush. It looks like when they get down the passenger side light is getting stuck on part of the front bumper and that is what is preventing it from closing all the way. Do either of you know if the headlights are able to be adjusted a bit left to right or should I dremel out a small notch to move them in slightly?

 

Your bumper is misaligned. The corner of the bumper and the corner of the fender should line up. I would suggest not doing anything to the buckets of the headlights themselves. If you do, you'll end up getting interference with the hood. Fix the bumper issue, then you can adjust the headlight covers correctly.

So many body panels interact with each other there, it can really be a pain to get everything to fit up well. Especially if the OEM bumper is warped at all, or the car has been bumped. All the metal is so thin, it is easy for things to get out of whack.