HEADLIGHT ASSEMBLY(for ALPHARD) DISASSEMBLY

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are installed, removed or replaced during the headlight light control ECU sub-assembly LH removal/installation are shown below.

Necessary procedure after parts removed/installed/replaced
Replacement Part or Procedure Necessary Procedures Effects/Inoperative Functions when not Performed Link
Headlight light control ECU sub-assembly LH

  • Vehicle information registration for the headlight light control ECU sub-assembly LH

  • Initialization of the headlight light control ECU sub-assembly LH

 Automatic headlight beam level control system

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Note

Even if the headlight light control ECU sub-assembly RH is replaced with a new one, vehicle information registration and initialization are not necessary.

PROCEDURE


  1. PRECAUTION

    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.

  2. REMOVE HEADLIGHT PROTECTOR LH


    1. A01UCM3

      Remove the headlight protector LH.

      Note

      The headlight protector LH must not be reused.

  3. REMOVE FRONT TURN SIGNAL LIGHT BULB


    1. B006PG4C01
      *a Matchmark
      *b Unlock Position Mark
      B006N8A Counterclockwise

      Turn the bulb socket counterclockwise until the matchmark is aligned with the unlock position mark to disconnect the bulb socket.

    2. B006RHRC01
      B006N8A Remove in this Direction

      Remove the front turn signal light bulb from the bulb socket.

  4. REMOVE CLEARANCE LIGHT LED UNIT LH (w/o Cornering Light)


    1. A01UD2X

      Using a T20H "TORX" driver, remove the "TORX" screw.

    2. B006ONDC01
      *a Matchmark
      *b Unlock Position Mark
      B006N8A Counterclockwise

      Turn the clearance light LED unit LH counterclockwise until the matchmark is aligned with the unlock position mark to remove the clearance light LED unit LH.

    3. A01UFBV

      Disconnect the connector.

      Note

      Do not touch the LED and printed wire board with bare hands.

  5. REMOVE HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY LH


    1. A01UEQ8

      Remove the 3 screws and headlight light control ECU sub-assembly LH.

    2. A01UF37

      Disconnect the 2 connectors.

  6. REMOVE HEADLIGHT GASKET

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  7. REMOVE HEADLIGHT LENS ASSEMBLY LH


    1. A01UCL2

      Remove the 7 screws.

    2. Detach the claw.

      Tech Tips

      It is not necessary to detach the claw at the base point as the claw is detached in a later step.

      B006OM7C01
      *a Base Point - -
    3. A01UF9O

      Using a dryer, heat the backside of the headlight assembly LH.

      Note

      If the headlight assembly LH is heated unevenly, it will deform or melt.

    4. With the headlight lens assembly LH slightly lifted, cut the headlight lens gasket with scissors and disconnect the headlight lens assembly LH.

      Tech Tips


      • If the headlight lens assembly LH cannot be removed even after heating, using a screwdriver, lift the headlight light lens assembly LH.

      • Tape the screwdriver tip before use.

    5. Detach the claw at the base point to remove the headlight lens assembly LH.

      Note


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

      • If dirty, lightly wipe with a soft cloth.

  8. REMOVE HEADLIGHT LENS GASKET


    1. Remove the headlight lens gasket from the headlight lens assembly LH and headlight body.

  9. REMOVE CLEARANCE LIGHT LED UNIT ASSEMBLY LH (w/ Conering Light)

    Note


    • Perform work using rubber gloves.

    • Do not touch the clearance light LED unit assembly LH and circuit sub-assembly with bare hands.

    • If dirty, lightly wipe with a soft cloth.


    1. A01UCG1

      Disconnect the 2 connectors.

    2. Remove the 4 screws and clearance light LED unit assembly LH.

    3. B006OZQC01
      B006Q1Z Place Hands Here

      Disconnect the connector.

    4. Remove the 2 screws.

    5. Place your hand at the location shown in the illustration, and remove the circuit sub-assembly.

  10. REMOVE CORNERING LIGHT UNIT ASSEMBLY LH (w/ Conering Light)

    Note


    • Perform work using rubber gloves.

    • Do not touch the cornering light unit assembly LH and cornering light unit bezel 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.


    1. A01UDR7

      Remove the 2 screws and cornering light unit bezel.

    2. A01UCCR

      Remove the 3 screws and cornering light unit assembly LH.

  11. REMOVE HEADLIGHT UNIT ASSEMBLY LH

    Note


    • Perform work using rubber gloves.

    • Do not touch the headlight unit assembly LH and headlight unit bezel 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.


    1. A01UFIG

      Detach the claw and remove the headlight unit bezel.

    2. A01UEZS

      Disconnect the 2 connectors.

    3. B006PFSC01
      *a Protrusion Amount Measurement Area

      Using a vernier caliper, measure and record the protrusion amount of the horizontal and vertical aiming screw.

    4. B006QQJC01
      B006N8A Loosening in this Direction

      Loosen the horizontal and vertical aiming screw 5 rotations.

    5. A01UFEZ

      Detach the claw and disconnect the headlight unit assembly LH from the pivot collar.

    6. B006QQJC01
      B006N8A Loosening in this Direction

      While holding the headlight unit assembly LH with one hand so that it does not fall over, loosen the horizontal and vertical aiming screw until the headlight unit assembly LH is disconnected.

    7. B006KLGC01
      B006PCE Protective Tape

      Using a clip remover, remove the pivot collar and attach the claw to install it to the headlight unit assembly LH.

      Tech Tips

      Tape the clip remover tip before use.