HEADLIGHT ASSEMBLY(for LED Headlight) REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


  • Use the same procedure for the RH side and LH side.

  • The following procedure is for the LH side.

PROCEDURE


  1. INSTALL HEADLIGHT UNIT

    Note


    • Make sure to wear clean rubber gloves when performing this procedure.

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

    • If there are any fingerprints or foreign matter on the headlight unit or other components, wipe them off with a soft cloth.


    1. Temporarily install the headlight unit to the housing.

    2. B001MFV

      While holding the headlight unit by hand, turn the aiming screw as shown in the illustration to install the headlight unit.

      Tech Tips

      Turn the aiming screw the same number of times as it was turned during removal.

    3. B001N31

      Engage the pivot collar.

    4. Connect the connector.

  2. INSTALL HEADLIGHT LENS GASKET


    1. Completely remove the old headlight lens gasket.

    2. B001KS6C01
      B001MUK Cleaning Area

      Clean the installation groove of the headlight lens.

    3. B001LVIC09
      *a Release Paper
      *b Tape
      *c 45°

      Partially remove the release paper from a new headlight lens gasket, and cut off a piece of it.

    4. Fold the release paper over the tip of a screwdriver and secure it in place with tape as indicated by the arrows, in the order shown in the illustration.

    5. Using scissors, cut the end of the headlight lens gasket at a 45° angle.

    6. B001N0JC01
      B001LAT Starting Position

      Starting from the position shown in the illustration and moving counterclockwise, temporarily install the headlight lens gasket as shown in the illustration.

      Note

      Gently install the headlight lens gasket without pulling it.

    7. B001LDHC01
      B001KHV Corner Groove

      Set the headlight lens gasket into the corner groove.

      Note


      • Gently install the headlight lens gasket without pulling it.

      • If the headlight lens gasket is pulled while it is installed, it will not be installed properly in the corner groove.

    8. B001NAYC01
      B001MUK Release Paper

      Using 2 screwdrivers with their tips wrapped with release paper, completely press the headlight lens gasket into the groove to install it.

      Note


      • Gently install the headlight lens gasket without pulling it.

      • If the headlight lens gasket is pulled while it is installed, it will not be installed properly in the corner groove.

    9. B001MG5C01
      B001KHV Corner Groove

      Repeat the following until the headlight lens gasket reaches the starting position: Temporarily install the headlight lens gasket to the straight groove and completely press it into the groove, and then temporarily install it to the corner groove and completely press it into the groove.

    10. After installing the headlight lens gasket completely, check that the ends overlap for 10 mm (0.394 in.) or more.

      Standard Dimension
      Area Dimension
      A 10 mm (0.394 in.) or more

    11. Check the installation condition of the headlight lens gasket.

      Note


      • Make sure the headlight lens gasket is not protruding and is installed properly.

      • Make sure there is no gap between the ends of the headlight lens gasket.

      • Make sure to thoroughly check the corners as the headlight lens gasket is likely to be improperly installed in the corners.

  3. INSTALL HEADLIGHT LENS

    Note


    • Make sure to wear clean rubber gloves when performing this procedure.

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

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


    1. Clean the sealing surface of the headlight lens.

    2. B001MPI

      Engage the 7 claws to install the headlight lens to the housing.

      Note

      Make sure all of the claws are engaged.

    3. B001KVEC01
      B001KHV Screw
      B001NB3 "TORX" screw

      Using a T20H "TORX" driver, install the "TORX" screw.

    4. Install the 8 screws.

    5. Check the installation condition of the headlight lens gasket.

      Note

      Make sure the headlight lens gasket is not protruding and completely contacts the headlight lens.

    6. B001MMU

      Connect the connector.

    7. B001K8F

      Turn the headlight back cover as shown in the illustration to install it.

  4. INSTALL FRONT TURN SIGNAL LIGHT SOCKET AND WIRE


    1. B001KDN

      Engage the 2 clamps and claw to install the front turn signal light socket and wire.

  5. INSTALL HEADLIGHT LEVELING MOTOR BASE PACKING


    1. Install a new headlight leveling motor base packing.

  6. INSTALL HEADLIGHT LEVELING MOTOR


    1. B001MLDC01
      *a Aiming screw

      Insert the headlight leveling motor in the direction indicated by the arrow (1) shown in the illustration.

    2. Turn the aiming screw of the headlight leveling motor in the direction indicated by the arrow (2) shown in the illustration to engage the shaft.

      Tech Tips

      Turn the aiming screw the same number of times as it was turned during removal.

    3. B001MHZC01
      *a Aiming screw

      Turn the headlight leveling motor in the direction indicated by the arrow (3) shown in the illustration.

      Tech Tips

      When installing the headlight leveling motor of the headlight assembly RH, turn the headlight leveling motor in the opposite direction of the arrow (3) shown in the illustration.

    4. Turn the aiming screw of the headlight leveling motor in the direction indicated by the arrow (4) shown in the illustration.

      Tech Tips

      Turn the aiming screw the same number of times as it was turned during removal.

    5. B001N3L

      Connect the connector.

  7. INSTALL FRONT TURN SIGNAL LIGHT BULB


    1. Install the front turn signal light bulb to the front turn signal light socket and wire.

    2. B001N13

      Turn the front turn signal light socket and wire with the front turn signal light bulb as shown in the illustration to install them as a unit.