HEADLIGHT ASSEMBLY(for Single Beam Headlight) DISASSEMBLY

PROCEDURE


  1. REMOVE FRONT TURN SIGNAL LIGHT BULB


    1. A01OB6H

      Turn the headlight cord with the front turn signal light bulb as shown in the illustration to disconnect them as a unit.

    2. A01ODJX

      Remove the front turn signal light bulb from the headlight cord.

  2. REMOVE HEADLIGHT CORD


    1. A01OAUA

      Disconnect the connector.

    2. Disengage each clamp to remove the headlight cord.

  3. REMOVE HEADLIGHT LEVELING MOTOR


    1. A01OAXKC01
      *a Aiming Screw

      Turn the aiming screw of the headlight leveling motor in the direction indicated by the arrow (1) shown in the illustration.

      Tech Tips


      • Turn the aiming screw until the headlight leveling motor can be moved in the direction indicated by the arrow (2) shown in the illustration.

      • Make sure to remember the number of aiming screw rotations.

    2. Turn the headlight leveling motor in the direction indicated by the arrow (2) shown in the illustration to disengage the pin.

      Tech Tips

      When removing the headlight leveling motor of the headlight assembly RH, turn the headlight leveling motor in the opposite direction of the arrow (2) shown in the illustration.

    3. A01ODL4C01
      *a Aiming Screw

      Turn the aiming screw of the headlight leveling motor in the direction indicated by the arrow (3) shown in the illustration to disengage the shaft.

      Tech Tips

      Make sure to remember the number of aiming screw rotations.

    4. Pull out the headlight leveling motor in the direction indicated by the arrow (4) shown in the illustration to remove it.

  4. REMOVE HEADLIGHT LEVELING MOTOR BASE PACKING


    1. Remove the headlight leveling motor base packing.

      Note

      After the headlight leveling motor base packing is removed, be sure to replace it with a new one. Failure to do so may cause water ingress.

  5. REMOVE HEADLIGHT LENS


    1. A01O9XUC01
      *a Screw
      *b "TORX" Screw

      Remove the 4 screws.

    2. Using a T20H "TORX" driver, remove the "TORX" screw.

    3. A01O9RI

      Using a dryer, heat the backside of the headlight assembly.

      Note

      If the headlight assembly is heated unevenly, it will deform or melt.

    4. A01OBSW

      Disengage the 6 claws.

    5. Remove the headlight lens.

      Note


      • Be sure to wear clean rubber gloves.

      • Do not allow dirt or foreign matter to get on the headlight lens.

      • If there are any fingerprints on the back of the headlight lens, wipe them off with a soft cloth.

      Tech Tips

      If the headlight lens cannot be removed even after heating, using a screwdriver with its tip wrapped with protective tape, lift the headlight lens. Be careful not to damage the headlight lens and housing.

  6. REMOVE HEADLIGHT LENS GASKET


    1. A01O9LD

      Remove the headlight lens gasket.

      Note

      After the headlight lens is removed, be sure to replace headlight lens gasket with a new one. Failure to do so may cause water ingress.

  7. REMOVE LIGHT CONTROL ECU


    1. A01OBET

      Disconnect the 2 connectors.

    2. A01OAOC

      Remove the 4 screws and 2 light control ECUs.

  8. REMOVE HEADLIGHT UNIT

    Note


    • Do not allow dirt or foreign matter to get on the headlight unit assembly.

    • If there are fingerprints on the headlight unit assembly, wipe them off with a soft cloth.


    1. A01OAQQ

      Remove the 3 screws and reflector.

    2. A01OCQZ

      Remove the 3 screws.

    3. Disengage the 2 guides to remove the cover.

    4. A01ODV2

      Disconnect the connector.

    5. Disengage the 2 clamps.

    6. Remove the 3 screws and remove the projector unit assembly.

    7. A01OBZ5

      While holding the bracket by hand, turn the horizontal aiming screw as shown in the illustration until the bracket can be removed.

      Tech Tips

      Make sure to remember the number of aiming screw rotations.

    8. A01OD62

      Disengage the 2 claws to remove the bracket.

    9. A01ODKK

      Using a clip remover, disengage the clamp to remove the pivot collar.