HEADLIGHT ASSEMBLY(for Single Beam Headlight) REASSEMBLY

PROCEDURE


  1. INSTALL HEADLIGHT UNIT

    Note


    • Be sure to wear clean rubber gloves.

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

    • If there are fingerprints on the headlight unit assembly, wipe them off with a soft cloth.


    1. A01O9OP

      Engage the 2 claws to install the pivot collar to the bracket.

    2. A01OAOS

      Engage the clamp to temporarily install the bracket.

    3. A01OCKT

      While holding the bracket by hand, turn the horizontal aiming screw as shown in the illustration to install it.

      Tech Tips

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

    4. A01ODK5

      Install the projector unit assembly with the 3 screws.

    5. Engage the 2 clamps.

    6. Connect the connector.

    7. A01OCQZ

      Engage the 2 guides.

    8. Install the cover with the 3 screws.

    9. A01OAQQ

      Install the reflector with the 3 screws.

  2. INSTALL LIGHT CONTROL ECU


    1. A01OAOC

      Install the 2 light control ECUs with the 4 screws.

    2. A01OBET

      Connect the 2 connectors.

  3. INSTALL HEADLIGHT LENS GASKET


    1. Completely remove the old headlight lens gasket.

    2. A01OBG7C01
      B008GB8 Cleaning Area

      Clean the installation groove of the headlight lens.

    3. A01OBI8C09
      *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. A01OBMPC01
      B004FOV 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. A01ODF9C01
      B008GAS 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. A01OA93C01
      B008GAS Press
      B008GB8 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. A01OD53C01
      A 10 mm (0.394 in.) or more
      B008GAS 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.

  4. INSTALL HEADLIGHT LENS

    Note


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

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


    1. Clean the sealing surface of the headlight lens.

    2. A01OBSW

      Engage the 6 claws to install the headlight lens to the housing.

      Note

      Make sure all of the claws are engaged.

    3. A01O9XUC01
      *a Screw
      *b "TORX" Screw

      Install the 4 screws.

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

    5. 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.

  5. INSTALL HEADLIGHT LEVELING MOTOR BASE PACKING


    1. Install a new headlight leveling motor base packing.

  6. INSTALL HEADLIGHT LEVELING MOTOR


    1. A01OBGYC01
      *a Aiming Screw

      Insert the headlight leveling motor in the direction indicated by the arrow (1) shown in the illustration.

    2. Turn the aiming screw of the headlight leveling motor in the direction indicated by the arrow (2) shown in the illustration to engage the shaft.

      Tech Tips

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

    3. A01OD04C01
      *a Aiming Screw

      Turn the headlight leveling motor in the direction indicated by the arrow (3) shown in the illustration and engage the pin to install the headlight leveling motor to the headlight assembly.

      Tech Tips

      When installing the headlight leveling motor of the headlight assembly RH, turn the headlight leveling motor in the opposite direction of the arrow (3) shown in the illustration.

    4. Turn the aiming screw of the headlight leveling motor in the direction indicated by the arrow (4) shown in the illustration.

      Tech Tips

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

  7. INSTALL HEADLIGHT CORD


    1. A01OAUA

      Engage each clamp to install the headlight cord.

    2. Connect the connector.

  8. INSTALL FRONT TURN SIGNAL LIGHT BULB


    1. A01ODJX

      Install the front turn signal light bulb to the headlight cord.

    2. A01ODAQ

      Turn the headlight cord with the front turn signal light bulb as shown in the illustration to connect them as a unit.