HEADLIGHT ASSEMBLY(for ALPHARD) 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.

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

    2. B006LSCC01
      B006N8A Tightening Direction

      While holding the headlight unit assembly LH with one hand so that it does not fall over, tighten the horizontal and vertical aiming screw 5 rotations until the headlight unit assembly LH is connected.

    3. A01UD1P

      Attach the pivot collar.

    4. B006LSCC01
      B006N8A Tightening in this Direction

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

    5. Connect the 2 connectors.

    6. Attach the claw to install the headlight unit bezel.

  2. INSTALL 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. Install the cornering light unit assembly LH with the 3 screws.

    2. Install the cornering light unit bezel with the 2 screws.

  3. INSTALL 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. B006OZQC01
      B006Q1Z Place Hands Here

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

    2. Install the circuit sub-assembly with the 2 screws.

    3. Connect the connector.

    4. Install the clearance light LED unit assembly LH with the 4 screws.

    5. Connect the 2 connectors.

  4. INSTALL HEADLIGHT LENS GASKET


    1. B006MWMC01
      B006PCE 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. B006NHR

      Using scissors, cut the headlight lens gasket 23 cm (9.0551 in.) from the end at 90°.

    4. B006MANC01
      B006REU Starting Point
      B006N8A Counterclockwise

      Starting at the center headlight lens LH screw installation point, set the headlight lens gasket into the straight groove counterclockwise until it meets the corner groove.

      Note

      Lightly set the gasket in place without pulling.

    5. Using 2 screwdrivers with their tips wrapped with peeling paper, push the headlight lens gasket into the bottom of the groove.

    6. B006LJHC01
      B006LKF Corner Groove
      B006REL Headlight Lens Gasket
      B006PCE 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.

    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 the corner groove and 4) push into bottom of groove.

    8. B006QHDC01
      *a 20 mm (0.7874 in.)
      B006LKF 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.

  5. INSTALL HEADLIGHT LENS ASSEMBLY LH

    Note


    • Perform work using rubber gloves.

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

    • If dirty, lightly wipe with a soft cloth.


    1. Clean the headlight lens gasket contact surface.

    2. Set the headlight lens assembly LH in place.

      Note

      B006NIQC01
      B006N7C Headlight Lens Gasket
      B006NAX Headlight Body
      B006PCE Headlight Lens Assembly LH

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

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

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

      Tech Tips

      Attach the claw at the base point first.

      B006OM7C01
      *a Base Point - -

    5. Install the 7 screws.

    6. Check the condition of the headlight lens gasket.

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

  6. INSTALL HEADLIGHT GASKET

    Click here

  7. INSTALL HEADLIGHT LIGHT CONTROL ECU SUB-ASSEMBLY LH


    1. Connect the 2 connectors.

    2. Install the headlight light control ECU sub-assembly LH with the 3 screws.

  8. INSTALL CLEARANCE LIGHT LED UNIT LH (w/o Cornering Light)

    Note

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


    1. Connect the connector.

    2. B006PB0C01
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark
      B006N8A Clockwise

      Align the matchmark of the clearance light LED unit LH to the unlock position mark, and then rotate the clearance light LED unit LH clockwise until the lock position mark to install the clearance light LED unit LH.

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

  9. INSTALL FRONT TURN SIGNAL LIGHT BULB


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

    2. B006RE8C01
      *a Matchmark
      *b Unlock Position Mark
      *c Lock Position Mark
      B006N8A Clockwise

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

  10. INSTALL HEADLIGHT PROTECTOR LH


    1. B006KL3C01
      B006PCE Area to Clean

      Clean the application area of the headlight protector LH shown in the illustration.

      Note

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

    2. A01UFHA

      Remove approximately 3 cm of the peeling paper from a new headlight protector LH.

    3. Align the angle of the headlight protector LH with the application start position, and then set only the part with peeling paper removed into place.

      Tech Tips

      The application start position is not level.

    4. 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.

      B006OZAC01
      *a Application Start Position *b Align angle with application start position, and then set into place
      *c The application start position is not level. - -
      B006N8A Press Here - -
    5. B006OL7C01
      *a Align angle of end of headlight protector LH with application end position, and then set into place
      *b The application end position is not level.

      While removing the peeling tape, align the angle of the end of the headlight protector LH with the application end position, and then set it into place.

      Tech Tips

      The application end position is not level.

    6. B006LD0C01
      *a Application Start Position
      *b Application end position.
      B006N8A Press Here

      Press along the entire headlight protector LH with your finger to secure it, moving from the application end position to the application start position.

      Note

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