HEADLIGHT ASSEMBLY(for Single Beam Headlight) REASSEMBLY

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. INSTALL HEADLIGHT LEVELING MOTOR (w/o AFS)


    1. B002BHK

      Set the headlight leveling motor to the bracket and turn the headlight leveling motor counterclockwise and install the headlight leveling motor.

    2. Install the headlight leveling motor LH together with the bracket with the 2 screws.

    3. Connect the connector.

  2. INSTALL HEADLIGHT SWIVEL MOTOR LH (w/ AFS)

    Note


    • Prevention of static electricity is required during this procedure.

    • Use static electricity countermeasures SST (desktop antistatic 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.

    • 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 headlight swivel motor LH onto the headlight unit LH, and then slide the headlight swivel motor LH back to install it.

      B002BZ7

      Note

      Before installing the screw, make sure that there is no gap between the headlight swivel motor LH and headlight unit LH.

      B002BKQE01
      Text in Illustration
      *a Correct *b Incorrect

    2. Install the screw.

  3. INSTALL HEADLIGHT UNIT ASSEMBLY LH

    Note


    • Prevention of static electricity is required during this procedure.

    • Use static electricity countermeasures SST (desktop antistatic 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.

    • 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 headlight unit assembly LH to the vertical and horizontal aiming screw and vertical aiming screw.

      B002BSWE01
      Text in Illustration
      *A w/o AFS *B w/ AFS
    2. B002C1V

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

    3. Lightly push the pivot joint to attach it.

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

      B002BM3E02
      Text in Illustration
      *A w/o AFS *B w/ AFS
      *a Protrusion Amount Measurement Area - -

    5. Connect each connector.

      B002B7XE01
      Text in Illustration
      *A w/o AFS *B w/ AFS
    6. B002BHA

      Hold the shaded areas shown in the illustration and set the turn signal reflector into place.

      Text in Illustration
      B002BQR Hold Here

    7. Install the 2 screws.

  4. INSTALL NO. 1 HEADLIGHT CLEARANCE LED UNIT LH

    Note


    • Prevention of static electricity is required during this procedure.

    • Use static electricity countermeasures SST (desktop antistatic 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 inner bezel and No. 1 headlight clearance LED 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.

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

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

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

    1. Install the lower side of the No. 1 headlight clearance LED unit LH with the 2 screws.

    2. Install the headlight inner bezel with the 5 screws.

    3. Connect the connector.

  5. INSTALL HEADLIGHT LENS GASKET

    Note


    • Perform work using clean rubber gloves.

    • 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.


    1. B002BAR

      Clean the headlight lens gasket installation groove.

      Text in Illustration
      B002BQR 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. B002C3O

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

    4. B002C02

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

      Note

      Lightly set the gasket in place without pulling.

      Text in Illustration
      B002B9H Starting Point

    5. Fold the peeling paper over the tip of a screwdriver and fix it in place with tape.

      Note

      Use the peeling paper that is supplied with the seal.

    6. B002BR8

      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.

      Text in Illustration
      B002BBR Corner Groove
      B002BPS Headlight Lens Gasket
      B002BQR Peeling Paper

    7. 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.

    8. B002BN9E02
      Text in Illustration
      *a 20 mm (0.7874 in.)
      B002BBR 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.

    9. 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.

  6. INSTALL HEADLIGHT LENS LH

    Note


    • 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.


    1. Clean the headlight lens gasket contact surface.

    2. B002B8V

      Set the headlight lens LH in place.

      Text in Illustration
      B002BZV Headlight Lens Gasket
      B002BOO Headlight Housing
      B002BQR 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 claw D, 2 claws C, 2 claws B, and then claw A.

      B002BFNE02
      Text in Illustration
      *a Claw A *b Claw B
      *c Claw C *d Claw D

    5. Using a T20H "TORX" driver, install the 3 "TORX" screws.

    6. Install the 5 screws.

      B002BYQE03
      Text in Illustration
      *A Headlight Assembly LH Backside *B Headlight Assembly LH Surface
      *a "TORX" Screw - -

    7. Check the condition of the headlight lens gasket.

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

    8. Connect the connector.

    9. B002BEVE02
      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.

  7. INSTALL HEADLIGHT GASKET

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  8. INSTALL HEADLIGHT ECU SUB-ASSEMBLY LH

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  9. INSTALL HEADLIGHT BRACKET LH (for Inside)


    1. Attach the 2 guides to set the headlight bracket LH.

    2. Install the 2 screws.

  10. INSTALL HEADLIGHT BRACKET LH (for Outside)


    1. Attach the 2 guides to set the headlight bracket LH.

    2. Install the 3 screws.

  11. INSTALL HEADLIGHT COVER LH


    1. Attach the 5 claws to install the headlight cover LH.

  12. INSTALL HEADLIGHT CORD


    1. Connect the connector.

    2. Attach the 2 wire harness clamps to install the headlight cord.

  13. INSTALL FRONT TURN SIGNAL LIGHT BULB


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

    2. B002BJGE01
      Text in Illustration
      *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.