HEADLIGHT ASSEMBLY > REPAIR

for Preparation Click here


HINT:
  1. Use the same procedure for both the RH and LH sides.
  2. The procedure described below is for the LH side.
  3. If only the installation area of the headlight is damaged, the repairs described below can be performed inexpensively by using brackets for the repair. This may only be done if the other areas of the headlight are not damaged.



1. REMOVE FRONT BUMPER COVER
(Click here)


2. REMOVE HEADLIGHT ASSEMBLY LH


B214164

  1. Remove the 2 bolts and screw.

  1. Disconnect the connectors and then remove the headlight.



3. INSTALL HEADLIGHT PROTECTOR UPPER RETAINER

HINT:
  1. If only the installation area of the headlight is damaged, use a bracket for a low-cost repair.
  2. Ensure that other areas of the headlight are not damaged.



    B215517

  1. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.

    HINT:
    After cutting off the shaded portion, place the headlight protector upper retainer against the bosses and gradually file away the shaded portion until installation is possible.



    B215518

  1. Install the headlight protector upper retainer with the 2 screws.



4. INSTALL HEADLIGHT PROTECTOR LOWER RETAINER

HINT:
  1. If only the installation area of the headlight is damaged, use a bracket for a low-cost repair.
  2. Ensure that other areas of the headlight are not damaged.



    B215519

  1. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.

    HINT:
    After cutting off the shaded portion, place the headlight protector against the bosses and gradually file away the shaded portion until installation is possible.



    B215520

  1. Install the headlight protector lower retainer with the 2 screws.



5. INSTALL HEADLIGHT NO. 2 PROTECTOR LOWER RETAINER

HINT:
  1. If only the installation area of the headlight is damaged, use a bracket for a low-cost repair.
  2. Ensure that other areas of the headlight are not damaged.



    B219570

  1. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.

    HINT:
    After cutting off the shaded portion, place the headlight protector against the bosses and gradually file away the shaded portion until installation is possible.



    B219571

  1. Install the headlight No. 2 protector lower retainer with the 2 screws.



6. INSTALL HEADLIGHT ASSEMBLY LH


B214164

  1. Connect the connectors.

  1. Install the headlight with the 2 bolts and screw.



7. INSTALL FRONT BUMPER COVER
(Click here)


8. PREPARE VEHICLE FOR HEADLIGHT AIMING ADJUSTMENT

  1. Prepare the vehicle:

    1. Ensure that there is no damage or deformation of the body around the headlights.
    2. Fill the fuel tank.
    3. Fill the oil to the specified level.
    4. Fill the coolant to the specified level.
    5. Inflate the tires to the appropriate pressure.
    6. Place the tools and jack in their original positions.
    7. Unload the trunk.
    8. Sit a person of average weight (75 kg, 165 lb) in the driver seat.



9. PREPARE FOR HEADLIGHT AIMING (for Using a Screen)


B216592E02

  1. Prepare the vehicle in accordance with the following conditions:

    1. Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot.
    2. Place the vehicle at a 90° angle to the wall.
    3. Keep a 25 m (82 ft) distance between the center of the headlight bulb and the wall.
    4. Place the vehicle on a level surface.
    5. Bounce the vehicle up and down to settle the suspension.

      HINT:
      A distance of 25 m (82 ft) between the vehicle (the center of the headlight bulb) and the wall is necessary for proper aim adjustment. If unable to secure a distance of 25 m (82 ft), set a distance of exactly 3 m (9.84 ft) to check and adjust the headlight aim. Since the target zone changes depending on the distance, follow the instructions shown in the illustration.

  1. Prepare a piece of thick white paper (approximately 2 m (6.6 ft) high x 4 m (13.1 ft) wide) to use as a screen.

  1. Draw a vertical line down the center of the screen (V line).



  1. Set the screen, as shown in the illustration.


    B216331E02

    HINT:
    1. Stand the screen perpendicular to the ground.
    2. Align the V line on the screen with the center of the vehicle.



    I033423E02

  1. Draw base lines (H line, V LH and V RH lines) on the screen, as shown in the illustration.

    HINT:
    1. The base lines differ for "low-beam inspection" and "high-beam inspection".
    2. Mark the headlight bulb center marks on the screen. If the center mark cannot be observed on the headlight, use the center of the headlight bulb.


    1. H Line (Headlight height):
      Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the headlight bulb center marks of the low-beam headlights.

    2. V LH Line and V RH Line (Center mark positions of left-hand (LH) and right-hand (RH) headlights):
      Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low-beam headlight bulbs).



10. INSPECT HEADLIGHT AIMING

  1. Cover the headlight on the opposite side or disconnect its connector, to prevent light from the headlight not being inspected from affecting the headlight aiming inspection.

    NOTICE:
    Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, and may easily melt or be damaged due to heat.

  1. Start the engine.

    HINT:
    Engine speed must be 1500 rpm or more.

  1. w/ Headlight leveling:
    Set the headlight leveling switch to 0 (zero).



  1. Turn on the headlight and make sure that the cutoff line falls within the specified area, as shown in the illustration.


    E141774E11

    HINT:
    1. Alignment distance is 25 m (82 ft):
      The cutoff line is 48 mm (1.88 in.) to 698 mm (27.48 in.) below the H line with low-beam (ECE Regulation No. 48).
    2. Alignment distance is 3 m (9.84 ft):
      The cutoff line is 6 mm (0.23 in.) to 84 mm (3.3 in.) below the H line with low-beam (ECE Regulation No. 48).
    3. Alignment distance is 25 m (82 ft):
      The cutoff line is 249 mm (9.8 in.) below the H line with low-beam.
    4. Alignment distance is 3 m (9.84 ft):
      The cutoff line is 30 mm (1.18 in.) below the H line with low-beam.
    5. Since the low-beam light and the high-beam light are a unit, if the aiming on one is correct, the other should also be correct. However, check both beams just to make sure.



11. ADJUST HEADLIGHT AIMING


B215502E01

  1. Adjust the aiming vertically:
    Adjust the headlight aim to within the specified range by turning aiming screw A with a screwdriver.

    HINT:
    The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.

  1. Perform low-beam aim adjustment.

    HINT:
    The headlight aim moves down when the aiming screw is turned clockwise, and moves up when the aiming screw is turned counterclockwise.

  1. Adjust the aim horizontally:
    Adjust the headlight aim to within the specified range by turning aiming screw B with a screwdriver.

    HINT:
    The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.