HEADLIGHT ASSEMBLY(for 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.

  • 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.

  2. INSTALL HEADLIGHT LEVELING MOTOR LH


    1. B001GEQ

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

      Tech Tips

      For the headlight assembly RH, turn the headlight leveling motor RH counterclockwise to install it.

    2. Connect the connector.

  3. INSTALL HEADLIGHT UNIT ASSEMBLY 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 assembly 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.

    • If there are fingerprints on the inner surface of the lens, lightly wiped with a soft cloth.

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

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

    1. Set the both rail, beam axis horizontal and vertical adjustment aiming screws for the headlight unit assembly LH.

      Tech Tips

      Align and set them according to the white and black arrows shown in the illustration.

      B001GUF
    2. B001FXY

      While holding the headlight unit assembly LH with one hand so that it does not fall over, tighten the vertical aiming screw and horizontal aiming screw 20 rotations.

    3. Push the headlight unit assembly LH to connect the headlight leveling motor LH.

      B001FIX
    4. B001FXY

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

    5. B001G9A

      Connect the connector.

  4. INSTALL HEADLIGHT LENS GASKET

    Note


    • The headlight lens gasket must not be reused.

    • 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.

    • If there are fingerprints on the inner surface of the lens, lightly wiped with a soft cloth.

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


    1. B001DB2C01
      B001CE2 Area to Clean

      Clean the headlight lens gasket installation groove.

    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. B001HPC

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

    4. B001HRPC01
      B001E1P Starting Point

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

      Tech Tips

      Lightly set the gasket in place without pulling.

    5. B001HHBC01
      B001DEF Corner Groove
      B001IGJ Headlight Lens Gasket
      B001CE2 Peeling Paper

      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.

      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. B001GK1C01
      *a 20 mm (0.79 in.)
      B001DEF 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 (0.79 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 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.

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

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

    1. B001G1CC01
      B001CE2 Area to Clean

      Clean the headlight lens gasket contact surface.

    2. Set the headlight lens LH in place.

      Note

      B001IFMC01
      B001FGK Headlight Lens Gasket
      B001IGR Head Light Housing
      B001CE2 Headlight Lens LH

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

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

    4. Attach the base point claw.

      Tech Tips

      Install the headlight lens LH from the installation starting point shown in the illustration.

      B001E5WC01
      *a Base Point Claw - -
      B001DEF Installation Starting Point - -

    5. Attach the remaining claw to install the headlight lens LH.

      B001H0O
    6. B001G2E

      Connect the connector.

    7. B001COLC01
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark

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

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

    9. Install the 7 screws.

      B001H8IC01
      *a "TORX" Screw - -

    10. Check the condition of the headlight lens gasket.

      OK
      Gasket contacts headlight lens LH and does not protrude out.

  6. INSTALL HEADLIGHT BRACKET LH


    1. Attach the claw to install the headlight bracket LH.

    2. Install the 7 screws.

  7. INSTALL HEADLIGHT SEAL


    1. B001G3IC01
      B001CE2 Area to Clean

      Clean the application area as shown in the illustration.

      Note

      Remove any remaining double-sided tape, and then clean and degrease the area.

    2. Remove approximately 30 mm (1.18 in.) of the peeling tape from a new headlight seal.

    3. B001GD8C01
      *a Alignment Line

      Align the headlight seal with the alignment line and set it.

    4. B001FV4C01
      B001IGJ Peeling Tape

      While peeling the peeling tape, align the headlight seal to the curve and set it.

    5. B001IC1

      Press the set portion of the part with your finger to secure it.

      Note

      Do not slide your finger horizontally, as doing so may stretch the part unnecessarily.

  8. INSTALL FRONT BUMPER BAR REINFORCEMENT LH


    1. Install the front bumper bar reinforcement LH with the 2 screws.

  9. INSTALL HEADLIGHT GASKET

    Click here

  10. INSTALL NO. 1 HEADLIGHT ECU SUB-ASSEMBLY LH

    Click here

  11. INSTALL FRONT TURN SIGNAL LIGHT BULB


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

    2. B001H3NC01
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark

      Align the matchmark of the bulb socket with the unlock position mark, and then rotate the bulb socket clockwise until the lock position mark to connect the bulb socket.