HEADLIGHT ASSEMBLY(for Halogen Headlight and LED Headlight) DISASSEMBLY

CAUTION / NOTICE / HINT

Note


  • Be sure to read Precaution thoroughly before servicing.

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  • 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.

Tech Tips


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

  • The procedure listed below is for the LH side.

PROCEDURE


  1. REMOVE HEADLIGHT SOCKET COVER


    1. B001ZPOE01
      Text in Illustration
      *a Matchmark
      *b Unlock Position Mark

      Turn the headlight socket cover counterclockwise until the matchmark is aligned with the unlock position mark to remove the headlight socket cover.

  2. REMOVE NO. 2 HEADLIGHT BULB


    1. B001ZAX

      Disconnect the connector.

    2. B001VL4

      Turn the No. 2 headlight bulb counterclockwise until the bulb stops.

    3. Remove the the No. 2 headlight bulb.

      Note

      Do not touch the glass part of the No. 2 headlight bulb.

  3. REMOVE FRONT TURN SIGNAL LIGHT BULB


    1. B001ZX9E01
      Text in Illustration
      *a Matchmark
      *b Unlock Position Mark

      Turn the front turn signal light socket counterclockwise until the matchmark is aligned with the unlock position mark to disconnect the front turn signal light socket.

    2. B001ZDV

      Remove the front turn signal light bulb from the front turn signal light socket.

  4. REMOVE FRONT TURN SIGNAL LIGHT SOCKET


    1. B001VUE

      Disconnect the connector and remove the front turn signal light socket.

  5. REMOVE HEADLIGHT BRACKET LH (for Outside)


    1. B001WOH

      Remove the 3 screws and headlight bracket LH.

  6. REMOVE HEADLIGHT BRACKET LH (for Inside)


    1. B001W3J

      Remove the 3 screws and headlight bracket LH.

  7. REMOVE FRONT BUMPER BAR REINFORCEMENT LH


    1. B001YVE

      Remove the 2 screws.

    2. B00204K

      Detach the 2 guides and remove the front bumper reinforcement LH.

  8. REMOVE HEADLIGHT LENS 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 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.

    SST
    09890-47010   ( 09891-04010, 09891-04020, 09891-04030, 09891-04040 )

    1. B001Y6W

      Remove the 2 screws and inner bracket.

    2. B001X6A

      Remove the 2 screws and outer bracket.

    3. B001Y6TE01
      Text in Illustration
      *a Matchmark
      *b Unlock Position Mark

      Turn the locking cap counterclockwise until the matchmark is aligned with the unlock position mark to remove the locking cap.

    4. B001YLC

      Disconnect the connector.

    5. Remove the 7 screws.

      B001XKUE01
      Text in Illustration
      *A Headlight Assembly LH Backside *B Headlight Assembly LH Surface

    6. Remove the headlight lens LH:

      Note


      • Perform work using clean rubber gloves.

      • 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.

      Tech Tips


      • The connection between the headlight lens LH and headlight housing is extremely tight. Therefore, make sure to use the following method of using a dryer to warm and soften the headlight lens gasket to separate the headlight lens LH and headlight housing.

      • With the headlight lens LH slightly lifted, cut the headlight lens gasket and separate the headlight lens LH.


      1. Using a dryer, warm the headlight lens gasket from the backside of the headlight assembly LH at the separation starting point of the headlight lens LH and headlight housing.

        Note

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

        B001WK2E02
        Text in Illustration
        *A Headlight Assembly LH Surface *B Headlight Assembly LH Backside
        *a Separation Starting Point - -

        Tech Tips


        • If the headlight lens LH cannot be lifted, even after heating, using a screwdriver, lift the headlight lens LH.

        • Tape the screwdriver tip before use.

      2. Detach the 2 claws A and slightly lift the headlight lens LH.

      3. Heat the headlight lens gasket starting from the backside of the headlight assembly LH and finishing at the area around claw B.

      4. Detach the claw B and slightly lift the headlight lens LH.

      5. Heat the headlight lens gasket starting from the backside of the headlight assembly LH and finishing at the area around claw C.

      6. Detach the 2 claws C and slightly lift the headlight lens LH.

      7. Heat the headlight lens gasket starting from the backside of the headlight assembly LH and finishing at the area around claw D.

      8. Detach the 2 claws D and remove the headlight lens LH.

        B001X1IE01
        Text in Illustration
        *a Claw A *b Claw B
        *c Claw C *d Claw D

  9. REMOVE HEADLIGHT LENS GASKET

    Note


    • Perform work using clean rubber gloves.

    • 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.

    • The gasket must not be reused.


    1. Remove the headlight lens gasket from the headlight lens and headlight housing.

      Tech Tips

      Using a dryer, heat the headlight lens gasket. While softening the headlight lens gasket, remove it from the headlight lens LH and headlight housing.

  10. REMOVE 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.

    SST
    09890-47010   ( 09891-04010, 09891-04020, 09891-04030, 09891-04040 )

    1. Using a vernier caliper, measure and record the protrusion amount of the horizontal and vertical aiming screw.

      B001VP8E01
      Text in Illustration
      *a Protrusion Amount Measurement Area - -
    2. B001ZVP

      Disconnect the connector.

    3. Using a screwdriver, detach the 6 claws and remove the headlight unit LH.

      B001W0M
      Text in Illustration
      B001YA8 Protective Tape - -
    4. B001XL1

      Remove the leveling motor joint.

      Tech Tips

      Install the removed leveling motor joint to the headlight unit LH.

    5. B001WUS

      Turn the aiming screw joint counterclockwise and remove it.

      Tech Tips


      • Use the same procedure to remove the aiming screw joint on the other side.

      • Install the removed aiming screw joint to the headlight unit LH.

  11. REMOVE HEADLIGHT LEVELING MOTOR LH


    1. B001WR8

      Disconnect the connector.

    2. Turn the headlight leveling motor LH counter clockwise and remove it.

      B001VRL

  12. REMOVE HEADLIGHT LEVELING MOTOR BASE PACKING


    1. Remove the headlight leveling motor base packing from the headlight leveling motor LH.

      Note

      The packing must not be reused.