HEADLIGHT ASSEMBLY(for Halogen Headlight and LED Headlight) REASSEMBLY

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.

Tech Tips


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

  • The procedure listed below is for the LH side.

PROCEDURE


  1. INSTALL HEADLIGHT LEVELING MOTOR BASE PACKING


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

  2. INSTALL HEADLIGHT LEVELING MOTOR LH


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

      B001YMK

    2. Connect the connector.

  3. 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.

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

    1. B001WB7

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

    2. B001XY1E02
      Text in Illustration
      *a Vertical Aiming Screw
      *b Horizontal Aiming Screw

      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.

      Tech Tips

      When tightening the aiming screws, make sure to turn the horizontal aiming screw clockwise and use the inserted screwdriver to turn the vertical aiming screw counterclockwise.

    3. B001VUY

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

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

      B001VP8E01
      Text in Illustration
      *a Protrusion Amount Measurement Area - -

    5. Connect the connector.

  4. INSTALL HEADLIGHT LENS GASKET


    1. B001ZMU

      Clean the headlight lens gasket installation groove.

      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.

      Tech Tips

      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. B001XOW

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

      Text in Illustration
      B001YW3 Starting Point

      Note

      Lightly set the gasket in place without pulling.

    5. B001ZUF

      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.

      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. B001ZJZE01
      Text in Illustration
      *a 20 mm (0.7874 in.)
      B001WGT Corner Groove

      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.

    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.

  5. INSTALL 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 with bare hands.

    • If dirty, lightly wipe with a soft cloth.

    SST
    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.

      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. 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.

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

    5. Install the 7 screws.

      B001XKUE01
      Text in Illustration
      *A Headlight Assembly LH Backside *B Headlight Assembly LH Surface
    6. B001YLC

      Connect the connector.

    7. B001XT5E03
      Text in Illustration
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark

      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.

    8. Install the outer bracket with the 2 screws.

    9. Install the inner bracket with the 2 screws.

  6. INSTALL FRONT BUMPER BAR REINFORCEMENT LH


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

    2. Install the 2 screws.

  7. INSTALL HEADLIGHT BRACKET LH (for Inside)


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

  8. INSTALL HEADLIGHT BRACKET LH (for Outside)


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

  9. INSTALL FRONT TURN SIGNAL LIGHT SOCKET


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

  10. INSTALL FRONT TURN SIGNAL LIGHT BULB


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

    2. B001XNUE01
      Text in Illustration
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark

      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.

  11. INSTALL NO. 2 HEADLIGHT BULB


    1. B001ZXB

      Insert and turn the No. 2 headlight bulb clockwise until the bulb stops to install it.

      Note

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

    2. Connect the connector.

  12. INSTALL HEADLIGHT SOCKET COVER


    1. B001XG7E01
      Text in Illustration
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark

      Align the matchmark of the headlight socket cover with the unlock position mark, and then rotate the headlight socket cover clockwise until the lock position mark to install the headlight socket cover.