HEADLIGHT ASSEMBLY REPAIR

Tech Tips

Use the same procedure for both the RH and LH sides.
The procedure listed below is for the LH side.
If the area where the headlight unit is installed is damaged, the repairs listed below can be performed inexpensively by using brackets for the repair. This may only be done if the headlight unit itself is not damaged.

REMOVE FRONT SPOILER (w/ Front Spoiler)

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REMOVE FRONT BUMPER COVER
1. Apply protective tape to the outer circumference of the front bumper cover, as shown in the illustration.
  
  Text in Illustration
  
  *1 Protective Tape
2. Using a clip remover, remove the clip.
3. Remove the 3 bolts, 5 screws and 2 clips.
4. Disengage the 10 claws and remove the front bumper cover.
5. Disconnect the connectors.
  
  Tech Tips
  
  If the vehicle is equipped with fog light and daytime running lights, disconnect the connectors.
6. Remove the 2 clips.
REMOVE HEADLIGHT UNIT
1. Remove the 3 screws.
2. Disconnect the connectors and remove the headlight unit.
INSTALL HEADLIGHT PROTECTOR RETAINER UPPER
Tech Tips
- If the installation area of the headlight unit is damaged, use a bracket for low-cost repair.
- Ensure that the headlight unit is not damaged.
1. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.
  
  Note
  
  After cutting off the shaded portion, place the headlight protector retainer upper against the bosses and gradually file away the shaded portion until installation is possible.
2. Install the headlight protector retainer upper with the 2 screws.
INSTALL HEADLIGHT PROTECTOR RETAINER LOWER
Tech Tips
- If the installation area of the headlight unit is damaged, use a bracket for low-cost repair.
- Ensure that the headlight unit is not damaged.
1. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.
  
  Note
  
  After cutting off the shaded portion, place the headlight protector retainer lower against the bosses and gradually file away the shaded portion until installation is possible.
2. Install the headlight protector retainer lower with the 2 screws.
INSTALL HEADLIGHT UNIT
1. Connect the connectors and install the headlight unit.
2. Install the 3 screws.
INSTALL FRONT BUMPER COVER
1. Install the 2 clips.
2. Connect the connectors.
  
  Tech Tips
  
  If the vehicle is equipped with fog light and daytime running lights, connect the connectors.
3. Engage the 10 claws and install the front bumper cover.
4. Tighten the 3 bolts and 5 screws.
5. Install the 3 clips.
6. Remove the protective tape.
REMOVE FRONT SPOILER (w/ Front Spoiler)

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PREPARE VEHICLE FOR HEADLIGHT AIMING ADJUSTMENT
1. Prepare the vehicle:
  - Ensure that there is no damage or deformation of the body around the headlights.
  - Fill the fuel tank.
  - Make sure that the oil is filled to the specified level.
  - Make sure that the coolant is filled to the specified level.
  - Inflate the tires to the appropriate pressure.
  - Place the spare tire, tools, and jack in their original positions.
  - Unlock the trunk.
  - Sit a person of average weight (75 kg, 165 lb) in the drivers seat.
PREPARE FOR HEADLIGHT AIMING (Using a screen)
1. Prepare the vehicle in accordance with the following:
  - Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot.
  - Place the vehicle at a 90° angle to the wall.
  - Keep a 25 m (82 ft) distance between the center of the headlight bulb and the wall.
  - Place the vehicle on a level surface.
  - Bounce the vehicle up and down to settle the suspension.
    
    Note
    
    A distance of 25 m (82 ft) between the vehicle (the center of the headlight bulb) and the wall is necessary for proper aim adjustment. If unable to secure a distance of 25 m (82 ft), set a distance of exactly 3 m (9.84 ft) to check and adjust the headlight aim. (Since the target zone changes depending on the distance, follow the instructions shown in the illustration.)
2. Prepare a piece of thick white paper (approximately 2 m (6.6 ft) high x 4 m (13.1 ft) wide) to use as a screen.
3. Draw a vertical line down the center of the screen (V line).
4. Set the screen, as shown in the illustration.
  Tech Tips
  
  Stand the screen perpendicular to the ground.
  
  Align the V line on the screen with the center of the vehicle.
5. Draw base lines (H line, V LH and V RH lines) on the screen, as shown in the illustration.
  Tech Tips
  
  The base lines differ for low-beam inspection and high-beam inspection.
  
  Mark the headlight bulb center marks on the screen. If the center mark cannot be observed on the headlight, use the center of the headlight bulb.
  1. H Line (Headlight height):
    
    Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlight bulb center marks of the low-beam headlights.
  2. V LH Line and V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights):
    
    Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low-beam headlight bulbs).
INSPECT HEADLIGHT AIMING
1. Cover the headlight on the opposite side or disconnect its connector, to prevent light from the headlight not being inspected from affecting the headlight aiming inspection.
  
  Note
  
  Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, and may easily melt or be damaged due to heat.
2. Start the engine.
  
  Note
  
  Engine rpm must be 1,500 or more.
3. Set the headlight leveling switch to 0 (zero).
4. Turn on the headlight and make sure that the cutoff line falls within the specified area, as shown in the illustration.
  Tech Tips
  
  Alignment distance is 25 m (82 ft):
  
  The cutoff line is 48 mm (1.88 in.) to 698 mm (27.48 in.) below the H line with low-beam (ECE Regulation No. 48).
  
  Alignment distance is 3 m (9.84 ft):
  
  The cutoff line is 6 mm (0.23 in.) to 84 mm (3.3 in.) below the H line with low-beam (ECE Regulation No. 48).
  
  Alignment distance is 25 m (82 ft):
  
  The cutoff line is 249mm (9.8 in.) below the H line with low-beam.
  
  Alignment distance is 3 m (9.84 ft):
  
  The cutoff line is 30 mm (1.18 in.) below the H line with low-beam.
  
  Since the low-beam light and the high-beam light are a unit, if the aiming on one is correct, the other should also be correct. However, check both beams just to make sure.
ADJUST HEADLIGHT AIMING
1. Adjust the aiming vertically:
  
  Adjust the headlight aim into the specified range by turning aiming screw A with a screwdriver.
  
  Note
  
  The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.
2. Perform low-beam aim adjustment.
  
  Tech Tips
  
  The headlight aim moves down when the aiming screw is turned clockwise, and moves up when the aiming screw is turned counterclockwise.
3. Adjust the aim horizontally:
  
  Adjust the headlight aim into the specified range by turning aiming screw B with a screwdriver.
  
  Note
  
  The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.
PREPARE VEHICLE FOR FOG LIGHT AIMING ADJUSTMENT
1. Prepare the vehicle:
  - Ensure that there is no damage or deformation of the body around the fog lights.
  - Fill the fuel tank.
  - Fill the oil to the specified level.
  - Fill the coolant to the specified level.
  - Inflate the tires to the appropriate pressure.
  - Place the spare tire, tools and jack in their original positions.
  - Unload the trunk.
  - Sit a person of average weight (75 kg, 165 lb) in the driver seat.

Text in Illustration
*1	Protective Tape

PREPARE FOR FOG LIGHT AIMING

Prepare the vehicle in accordance with the following conditions:
- Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot.
- Place the vehicle at a 90° angle to the wall.
- Keep a 25 m (82 ft.) distance between the center of the fog light bulb and the wall.
- Place the vehicle on a level surface.
- Bounce the vehicle up and down to settle the suspension.
Tech Tips

A distance of 25 m (82 ft.) between the vehicle (center of the fog light bulb) and the wall is necessary for proper aim adjustment. If unable to secure a distance of 25 m (82 ft.), secure a distance of exactly 3 m (9.84 ft.) to check and adjust the fog light aim (Since the target zone will change with the distance, follow the instructions shown in the illustration.).
Prepare a piece of thick white paper (approximately 2 m (6.6 ft.) (high) x 4 m (13.1 ft.) (wide)), to use as a screen.
Draw a vertical line down the center of the screen (V line).
Set the screen as shown in the illustration.
Tech Tips
- Stand the screen perpendicular to the ground.
- Align the V line on the screen with the center of the vehicle.

Text in Illustration
*a	V LH Line
*b	V Line
*c	V RH Line
*d	H Line
*e	Ground

Draw base lines (H line, V LH, V RH lines) on the screen as shown in the illustration.

Tech Tips

Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark.

H Line (Fog light height):

Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the fog light bulb center marks of the fog lights.
V LH Line and V RH Line (Center mark positions of left-hand (LH) and right-hand (RH) fog lights):

Draw 2 vertical lines so that they intersect the H line at each center mark.

INSPECT FOG LIGHT AIMING
1. Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light not being inspected from affecting fog light aiming inspection.
  
  Note
  
  Do not keep the fog light covered for more than 3 minutes. The fog light is made with plastic components, which may melt or be damaged due to excessive heat.
2. Start the engine.
  
  Tech Tips
  
  Engine speed must be 1500 rpm or more.
3. Turn on the fog light and make sure that the cutoff line falls within the specified area, as shown in the illustration.
  Tech Tips
  
  If the alignment distance is 25 m (82 ft.): The upper edge of the hot zone for the fog light should be 433 mm (17.06 in.) below the H line.
  
  If the alignment distance is 3 m (9.84 ft.): The upper edge of the hot zone for the fog light should be 52 mm (2.04 in.) below the H line.
ADJUST FOG LIGHT AIMING
1. Adjust the fog light aim to within the specified range by turning the aiming screw with a screwdriver.
  
  Note
  
  The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.