HEADLIGHT ASSEMBLY(for VELLFIRE) 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 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 ECU sub-assembly LH

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

  • Initialization of the headlight ECU sub-assembly LH

 Automatic headlight beam level control system

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Note

Even if the headlight 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 COVER LH


    1. B006ONSC01
      B006PCE Protective Tape
      B006Q1Z Place Hands Here

      Apply protective tape around the headlight cover LH.

    2. Place your hands at the location indicated shown in the illustration, detach the claw.

    3. B006RAYC01
      B006Q1Z Place Hands Here

      Place your hands in the open gap, detach the remaining claw, and then remove the headlight cover LH.

  3. REMOVE HEADLIGHT PROTECTOR LH


    1. B006R5C

      Remove the headlight protector LH.

      Note

      The headlight protector LH must not be reused.

  4. REMOVE HEADLIGHT ECU SUB-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).

    • If the headlight ECU sub-assembly LH has been dropped, replace it with a new one.

    • If the headlight ECU sub-assembly LH has been removed, replace the headlight gasket with a new one.

    • Perform work using clean rubber gloves.

    • Do not touch the headlight ECU sub-assembly LH connector with bare hands.

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

    1. B006LLY

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

    2. B006PHQ

      Disconnect the connector.

      Note

      Do not drop the connector in the headlight assembly LH.

  5. REMOVE HEADLIGHT GASKET

    Click here

  6. REMOVE HEADLIGHT LENS 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 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.

    • 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. B006LIOC01
      B006N8A Counterclockwise

      Turn the connector cap counterclockwise until it stops and then remove the connector cap.

    2. B006QEW

      Disconnect the connector.

    3. B006QZI

      Remove the 9 screws.

    4. Remove the headlight lens LH:

      Tech Tips

      Remove the headlight lens LH from the headlight housing from the separation starting point toward the outside of the vehicle as shown in the illustration.

      B006LV5C01
      *a Separation Starting Point - -
      B006N8A Remove in this Direction - -

      1. 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.

        B006PWXC01
        *a Base Point Claw - -
      2. B006N2R

        Using a dryer, warm the headlight lens gasket from the backside of the headlight assembly LH at the separation starting point of the headlight lens LH and headlight housing.

        Note

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

      3. Insert a finger between the headlight lens LH and headlight housing and lift up the headlight lens LH.

        Tech Tips


        • With all of the claws detached, lift up the headlight lens LH.

        • When the headlight lens LH is lifted up, the claws may re-attach.

      4. Using a screwdriver, pull out the headlight lens gasket through the opening.

        Note

        Do not damage the groove in the headlight housing or the surface of the headlight lens LH gasket.

        Tech Tips

        Tape the screwdriver tip before use.

        B006NSZC01
        B006N7C Headlight Lens Gasket B006REL Headlight Lens LH
        B006NAX Headlight Housing B006PCE Protective Tape
      5. B006L2FC01
        B006N8A Pull Out

        While lifting up the headlight lens LH, pull out the headlight lens gasket until it reaches the base point claw.

        Tech Tips


        • When the headlight lens LH is lifted up, the claws may re-attach.

        • Before lifting up the headlight lens LH, check that the surrounding claws are not re-attached.

        • If the headlight lens gasket is disconnected while being pulled out, lift up the headlight lens and pull the headlight lens gasket again.

      6. Detach the base point claw to remove the headlight lens LH.

        Note

        Take care of the base point claw connections on the headlight lens LH (black areas in illustration) as they break easily.

        B006LVPC01
        B006REU Easily damaged area - -

  7. REMOVE 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 wipe with a soft cloth.

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


    1. Remove the remaining headlight lens gasket from the headlight lens and headlight housing.

      B006PG5C01
      *A Headlight Housing Side *B Headlight Lens Side
      B006PCE Headlight Lens Gasket - -

  8. REMOVE 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 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.

    • If there are fingerprints on the inner surface of the lens, lightly wipe with a soft cloth.

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

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

    1. B006R2I

      Disconnect the connector and detach the wire harness clamp.

    2. Remove the 5 screws and headlight clearance LED unit LH.

  9. REMOVE HEADLIGHT LED 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 LED 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 wipe with a soft cloth.

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

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

    1. B006MM2

      Disconnect the 2 connectors.

    2. B006Q6OC01
      B006N8A Counterclockwise

      Loosen the aiming screws for beam axis vertical and horizontal adjustments counterclockwise by 10 turns.

    3. B006MCX

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

    4. B006Q6OC01
      B006N8A Counterclockwise

      Hold the headlight LED unit assembly LH with one hand to prevent it from tipping over and loosen the aiming screws for beam axis vertical and horizontal adjustments counterclockwise until the headlight LED unit assembly LH is disconnected.

      Tech Tips

      Count and record the number of turns of the aiming screw before the headlight unit LH is disconnected.

    5. B006LAEC01
      B006PCE Protective Tape

      Using a clip remover, remove the pivot collar

      Tech Tips

      Tape the clip remover tip before use.

    6. Install the removed pivot collar to the headlight LED unit assembly LH.