Headlamp: Service and Repair

LH Headlamp Assy:

LH HEADLAMP ASSEMBLY

OVERHAUL

HINT:
- Use the same procedures for the RH side and LH side.
- The procedures listed for the LH side.
- Installation is in the reverse order of removal.

1. REMOVE RADIATOR GRILLE
2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
4. REMOVE FRONT BUMPER COVER

5. REMOVE LH HEADLAMP ASSEMBLY




a. Remove the 2 screws.




b. Pull out the LH headlamp assembly forward, then release the pin and the headlamp bracket.
c. Disconnect the connectors, and remove the LH head lamp assembly.




6. REMOVE HEADLAMP, NO.1 BULB
a. Remove the headlamp, No.1 bulb as shown in the illustration.




7. REMOVE HEADLAMP, NO.2 BULB
a. Remove the headlamp, No.2 bulb as shown in the illustration.




8. REMOVE CLEARANCE LAMP BULB
a. Remove the clearance lamp bulb and the socket as shown in the illustration.
b. Remove the clearance lamp bulb from the socket as shown in the illustration.

9. REMOVE CLEARANCE LAMP SOCKET & WIRE
10. REMOVE HEADLAMP UNIT LH
11. INSTALL HEADLAMP PROTECTOR RETAINER UPPER LH

HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair.




a. Cut off the part shaded in the illustration and sand smooth with sandpaper.

NOTE: After cutting off the part, place the headlamp protector retainer upper LH against the bosses and gradually file away until installation is possible.




b. Install the headlamp protector retainer upper LH with the 2 screws.

12. INSTALL HEADLAMP PROTECTOR RETAINER LWR LH

HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair.




a. Cut off the part shaded in the illustration and sand smooth with sandpaper.

NOTE: After cutting off the part, place the headlamp protector retainer LWR LH against the bosses and gradually file away until installation is possible.




b. Install the headlamp protector retainer LWR LH with the 2 screws.

13. INSTALL HEADLAMP BRACKET LWR LH

HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair.




a. Cut off the part shaded in the illustration and sand smooth with sandpaper.

NOTE: After cutting off the part, place the headlamp bracket LWR LH against the bosses and gradually file away until installation is possible.




b. Install the headlamp bracket LWR LH with the screw.

14. VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT
15. PREPARATION FOR HEADLAMP AIMING (Using a screen)
16. HEADLAMP AIMING INSPECTION
17. HEADLAMP AIMING ADJUSTMENT