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HEADLIGHT ASSEMBLY(for LED Headlight) REASSEMBLY

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CAUTION / NOTICE / HINT

Note:

  • Handle components indoors as much as possible to prevent foreign matter from entering and adhering to headlight assembly components.

  • Do not reuse parts which have reduced fastening ability due to thread damage.

  • Do not touch the inner surface of the lens and metallic surfaces as much as possible, or they may become dirty.

  • Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wiped with a soft cloth.

  • When installing components, make sure that the wire harness is not pinched or pulled.

  • Do not use solvent to clean components. Only clean them with a dry cloth.

Tip:

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

  • The procedure listed below is for the LH side.

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PROCEDURE


  1. Click here

    INSTALL HEADLIGHT LEVELING MOTOR BASE PACKING


    1. Install a new headlight leveling motor base packing to the headlight leveling motor LH.

  2. Click here

    INSTALL HEADLIGHT LEVELING MOTOR LH


    1. B001XE5

      Insert and turn the headlight leveling motor LH clockwise to install it.

    2. Connect the connector.

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    INSTALL LIGHT CONTROL ECU


    1. Connect the connector.

    2. Install the light control ECU with the 2 screws.

  4. Click here

    INSTALL HEADLIGHT UNIT LH

    Note:

    • Prevention of static electricity is required during this procedure.

    • Use static electricity countermeasures SST (desktop anti-static mat set) and observe all precautions to prevent damage to the system by electrostatic discharge (ESD).

    • Perform work using clean rubber gloves.

    • Do not touch the headlight unit LH with bare hands.

    • Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wiped with a soft cloth.

    09890-47010 09891-04010 09891-04020 09891-04030 09891-04040

    1. B001YKN

      Set the headlight unit LH to the horizontal and vertical aiming screw.

    2. B001XUI

      While holding the headlight unit LH with one hand so that it does not fall over, tighten the horizontal and vertical aiming screw 10 rotations until the headlight unit LH is connected.

    3. B001XCU

      Lightly push the leveling motor joint to connect the leveling motor joint and headlight leveling motor LH.

    4. B001ZNNE01

      Tighten the horizontal and vertical aiming screw until the protrusion amount is the same as that recorded.

      Table 1. Text in Illustration
      *a Protrusion Amount Measurement Area - -

    5. Connect the 2 connectors.

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    INSTALL HEADLIGHT LENS GASKET


    1. B001YWQ

      Clean the headlight lens gasket installation groove.

      Table 2. Text in Illustration
      B001YA8 Area to Clean

    2. Prepare 2 screwdrivers, fold a piece of peeling paper over the tip of each screwdriver and fix the pieces of peeling paper in place with tape.

      Tip:

      Use the peeling paper that is supplied with the headlight lens gasket.

    3. B001WB5

      Using scissors, cut the headlight lens gasket at a 90°.

    4. B001YQ4

      Starting from the position shown in the illustration, set the headlight lens gasket into the straight groove counterclockwise until it meets the corner groove.

      Table 3. Text in Illustration
      B001YW3 Starting Point
      Note:

      Lightly set the gasket in place without pulling.

    5. B001WYB

      Set the headlight lens gasket into the corner groove and using 2 screwdrivers with their tips wrapped with peeling paper, push the gasket into the bottom of the groove.

      Table 4. Text in Illustration
      B001WGT Corner Groove
      B001YD9 Headlight Lens Gasket
      B001YA8 Peeling Paper
      Note:

      • Lightly set the gasket in place without pulling.

      • If the headlight lens gasket is set while pulled, the gasket will be pushed up at the corner groove.

    6. Repeat the following order while working in a circle back to the starting point.


      1. Set headlight lens gasket into straight groove.

      2. Push into bottom of groove.

      3. Set into corner groove.

      4. Push into bottom of groove.

    7. B001X0JE01

      Using scissors, cut the headlight lens gasket at a 45°angle at the starting point so that the gasket overlaps itself 20 mm (0.7874 in.) and set the gasket in place.

      Table 5. Text in Illustration
      *a 20 mm (0.7874 in.)
      B001WGT Corner Groove

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

      OK
      Gasket not pushed up or protruding.
      No gap where gasket overlaps.
      Note:

      Check the corners carefully since the gasket can easily become pushed up in those areas.

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    INSTALL HEADLIGHT LENS LH

    Note:

    • Perform work using clean rubber gloves.

    • Use static electricity countermeasures SST (desktop anti-static mat set) and observe all precautions to prevent damage to the system by electrostatic discharge (ESD).

    • Do not touch the inner surface of the lens with bare hands.

    • If dirty, lightly wipe with a soft cloth.

    • Prevention of static electricity is required during this procedure.

    09890-47010 09891-04010 09891-04020 09891-04030 09891-04040

    1. Clean the headlight lens gasket contact surface.

    2. B001YRH

      Set the headlight lens LH in place.

      Note:

      Set the headlight lens LH in the middle of the headlight lens gasket as shown in the illustration.

      Table 6. Text in Illustration
      B001YD9 Headlight Lens Gasket
      B001YVQ Head Light Housing
      B001YA8 Headlight Lens LH

    3. Check that the entire circumference of the headlight lens LH is positioned above the middle of the headlight lens gasket.

    4. B001X1IE01

      Attach the claws in the following order to install the headlight lens LH: The 2 claws D, 2 claws C, claw B, and then 2 claws A.

      Table 7. Text in Illustration
      *a Claw A *b Claw B
      *c Claw C *d Claw D
    5. B001XDME02

      Install the 7 screws.

      Table 8. Text in Illustration
      *A Headlight Assembly LH Backside *B Headlight Assembly LH Surface
    6. B001YLC

      Connect the connector.

    7. B001XT5E03

      Align the matchmark of the locking cap with the unlock position mark, and then rotate the locking cap clockwise until the lock position mark to install the locking cap.

      Table 9. Text in Illustration
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark

    8. Install the outer bracket with the 2 screws.

    9. Install the inner bracket with the 2 screws.

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    INSTALL FRONT BUMPER BAR REINFORCEMENT LH


    1. Attach the 2 guides to install the front bumper bar reinforcement LH.

    2. Install the 2 screws.

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    INSTALL HEADLIGHT BRACKET LH


    1. Install the headlight bracket LH with the 3 screws.

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    INSTALL HEADLIGHT BRACKET LH


    1. Install the headlight bracket LH with the 3 screws.

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    INSTALL FRONT TURN SIGNAL LIGHT SOCKET


    1. Connect the connector to install the front turn signal light socket.

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    INSTALL FRONT TURN SIGNAL LIGHT BULB


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

    2. B001XNUE01

      Align the matchmark of the front turn signal light socket with the unlock position mark, and then rotate the front turn signal light socket clockwise until the lock position mark to connect the front turn signal light socket.

      Table 10. Text in Illustration
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark