HEADLIGHT ASSEMBLY REASSEMBLY

CAUTION / NOTICE / HINT

Tech Tips


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

  • The following procedure is for the LH side.

PROCEDURE


  1. INSTALL HEADLIGHT HOUSING


    1. B004PJJ

      Engage the 5 clamps to install the headlight cord.

  2. INSTALL HEADLIGHT LEVELING MOTOR


    1. B004R0L

      Install the headlight leveling motor with the 2 screws.

    2. Connect the connector.

  3. INSTALL HEADLIGHT UNIT

    Note


    • Make sure to wear clean rubber gloves when performing this procedure.

    • Do not allow dirt or foreign matter to get on the headlight unit or other components.

    • If there are any fingerprints or foreign matter on the headlight unit or other components, wipe them off with a soft cloth.


    1. B004OL4

      Engage the pivot collar to temporarily install the headlight unit.

    2. B004Q78C01
      B004PI4 Turn in this Direction

      While holding the headlight unit by hand, turn the aiming screws as shown in the illustration to install the headlight unit.

      Tech Tips

      Turn the aiming screw the same number of times as it was turned during removal.

    3. B004OYV

      Connect the connector.

    4. B004QUY

      Install the reflector with the 2 screws.

  4. INSTALL HEADLIGHT LENS GASKET


    1. Completely remove the old headlight lens gasket.

    2. B004OK8C01
      B004PFI Cleaning Area

      Clean the installation groove of the headlight lens.

    3. B004Q1UC09
      *a Release Paper
      *b Tape
      *c 45°

      Partially remove the release paper from a new headlight lens gasket, and cut off a piece of it.

    4. Fold the release paper over the tip of a screwdriver and secure it in place with tape as indicated by the arrows, in the order shown in the illustration.

    5. Using scissors, cut the end of the headlight lens gasket at a 45° angle.

    6. B004OXBC01
      B004PYE Starting Position

      Starting from the position shown in the illustration and moving counterclockwise, temporarily install the headlight lens gasket as shown in the illustration.

      Note

      Gently install the headlight lens gasket without pulling it.

    7. B004QUQC01
      B004PRK Corner Groove

      Set the headlight lens gasket into the corner groove.

      Note


      • Gently install the headlight lens gasket without pulling it.

      • If the headlight lens gasket is pulled while it is installed, it will not be installed properly in the corner groove.

    8. B004PMUC01
      B004PI4 Press in this Direction
      B004PFI Release Paper

      Using 2 screwdrivers with their tips wrapped with release paper, completely press the headlight lens gasket into the groove to install it.

      Note


      • Gently install the headlight lens gasket without pulling it.

      • If the headlight lens gasket is pulled while it is installed, it will not be installed properly in the corner groove.

    9. B004PCKC01
      A 10 mm (0.394 in.) or more
      B004PRK Corner Groove

      Repeat the following until the headlight lens gasket reaches the starting position: Temporarily install the headlight lens gasket to the straight groove and completely press it into the groove, and then temporarily install it to the corner groove and completely press it into the groove.

    10. After installing the headlight lens gasket completely, check that the ends overlap for 10 mm (0.394 in.) or more.

    11. Check the installation condition of the headlight lens gasket.

      Note


      • Make sure the headlight lens gasket is not protruding and is installed properly.

      • Make sure there is no gap between the ends of the headlight lens gasket.

      • Make sure to thoroughly check the corners as the headlight lens gasket is likely to be improperly installed in the corners.

  5. INSTALL HEADLIGHT LENS

    Note


    • Make sure to wear clean rubber gloves when performing this procedure.

    • Do not allow dirt or foreign matter to get on the headlight lens.

    • If there are any fingerprints or foreign matter on the back of the headlight lens, wipe them off with a soft cloth.


    1. Clean the sealing surface of the headlight lens.

    2. B004PIG

      Connect the connector.

    3. B004OKY

      Engage the 8 claws to install the headlight lens to the housing.

      Note

      Make sure all of the claws are engaged.

    4. B004PS7C01
      *a Screw
      *b "TORX" screws

      Install the 6 screws.

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

    6. Check the installation condition of the headlight lens gasket.

      Note

      Make sure the headlight lens gasket is not protruding and completely contacts the headlight lens.

  6. INSTALL FRONT TURN SIGNAL LIGHT SOCKET

  7. INSTALL FRONT TURN SIGNAL LIGHT BULB


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

    2. B004QE9C01
      B004PI4 Install in this Direction

      Turn the front turn signal light socket with the front turn signal light bulb as shown in the illustration to install them as a unit.

  8. INSTALL NO. 1 HEADLIGHT COVER


    1. B004OGCC01
      B004PI4 Install in this Direction

      Turn the No. 1 headlight cover as shown in the illustration to install it.

  9. INSTALL HEADLIGHT GASKET

    Click here

  10. INSTALL NO. 1 HEADLIGHT ECU SUB-ASSEMBLY

    Click here