HEADLIGHT ASSEMBLY(for Single Beam 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 LH


    1. Install the headlight leveling motor LH with the 2 screws.

    2. Connect the connector and attach the wire harness clamp.

  2. 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.

    • 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. B002KFF

      Set the both rail, beam axis vertical and 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.

    2. B002IMK

      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 10 rotations.

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

      B002J9D
    4. B002IMK

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

    5. Connect the connector.

  3. 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. B002JAFC01
      B002JLO 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 piecesof peeling paper in place with tape.

      Tech Tips

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

    3. B002H8L

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

    4. B002JIDC01
      B002JNS 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. B002K0NC01
      B002I10 Corner Groove
      B002H91 Headlight Lens Gasket
      B002JLO 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. B002J6TC01
      *a 20 mm (0.79 in.)
      B002I10 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.

  4. INSTALL HEADLIGHT LENS LH

    Note


    • Perform work using clean rubber gloves.

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

    • If dirty, lightly wipe with a soft cloth.


    1. B002JXKC01
      B002JLO Area to Clean

      Clean the headlight lens gasket contact surface.

    2. Attach the base point claw to set the headlight lens LH.

      Tech Tips

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

      B002J5EC01
      *a Base Point Claw - -
    3. B002HTEC01
      B002H91 Headlight Lens Gasket
      B002J82 Headlight Housing
      B002JLO Headlight Lens LH

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

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

      B002I0M

    5. Install the 3 screws.

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

      B002IBLC01
      *A Headlight Assembly LH Surface *B Headlight assembly LH Back Side
      *a "TORX" Screw - -

    7. Check the condition of the headlight lens gasket.

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

  5. INSTALL HEADLIGHT GASKET

    Click here

  6. INSTALL HEADLIGHT ECU SUB-ASSEMBLY LH

    Click here