Toyota Prius: Headlight Assembly

• Precaution
• Removal
• Disassembly
• Inspection
• Adjustment
• Reassembly
• Installation

Precaution

PRECAUTION

NOTICE:

When disassembling the headlight assembly, use static electricity countermeasures SST (desktop anti-static mat set) and observe all precautions to prevent damage to the system by electrostatic discharge (ESD).

STATIC ELECTRICITY COUNTERMEASURES SST

SST: Desktop anti-static mat set (09890-47010)

PRECAUTIONS DURING REPLACEMENT

(a) Precautions during procedures:

(1) Before performing any procedures, touch an unpainted metal part or ground bolt of the Toyota Prius vehicle to eliminate any static electricity.

(2) To prevent damage to electrical equipment, disconnect the battery power supply before installing and removing electrical equipment.

(3) Never touch the electronic parts of a printed wire board or the pins of an integrated circuit.

(4) When performing procedures, do not allow clothing to come near or contact parts.

(b) Wear SST (wristband) firmly on your wrist.

SST:

09891-04020

(c) Connect SST (No. 2 grounding wire) and SST (anti-static mat) to an appropriate grounding point in the workspace and on the work table.

SST:

09891-04040

09891-04010

HINT:

When working inside the Toyota Prius vehicle:

Connect SST (No. 2 grounding wire) to an unpainted metal part or a ground bolt, etc.

(d) Connect SST (No. 1 grounding wire), SST (wristband) and SST (anti-static mat).

SST:

09891-04030

(e) Always place the headlight assembly and its components on SST (anti-static mat).

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during headlight assembly removal/installation are shown below.

Necessary Procedures After Parts Removed/Installed/Replaced

Replaced Part or Performed Procedure	Necessary Procedures	Effect/Inoperative Function When Necessary Procedures are not Performed	Link
*1: Even when not replacing the part, it is necessary to perform the specified necessary procedures after installation.
Front bumper assembly*1	Front television camera view adjustment	Panoramic View Monitor System
		Advanced Park
Replacement or removal and installation of 2 or more parts: Front television camera assembly, Radiator grille or Front bumper assembly Rear television camera assembly Side television camera assembly LH, Parking assist light LH or Outer rear view mirror assembly LH Side television camera assembly RH, Parking assist light RH or Outer rear view mirror assembly RH	Television camera view adjustment	Panoramic View Monitor System

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (REMOVAL)

Procedure		Part Name Code
1	FRONT BUMPER ASSEMBLY	-	-	-	-
2	FRONT SIDE RADAR SENSOR	882B1		-	-
3	HEADLIGHT ASSEMBLY	-		-	-

*A

w/ Front Side Radar

-

-

PROCEDURE

1. REMOVE FRONT BUMPER ASSEMBLY

Click here

2. REMOVE FRONT SIDE RADAR SENSOR (w/ Front Side Radar)

Click here

3. REMOVE HEADLIGHT ASSEMBLY

*a	Bolt	*b	Screw
	Protective Tape		Disengage in this Direction

(1) Apply protective tape around the headlight assembly as shown in the illustration.

(2) Remove the bolt and 3 screws.

(3) Disengage the 3 guides as shown in the illustration.

(4) Disconnect the 2 connectors and disengage the 2 clamps to remove the headlight assembly.

Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (DISASSEMBLY)

Procedure		Part Name Code
1	HEADLIGHT FRONT TURN SIGNAL LED	8113A	-	-	-
2	HEADLIGHT BRACKET	53246B	-	-	-
3	FRONT SIDE RADAR SENSOR BRACKET	88215C	-	-	-

*A	w/ Front Turn Signal LED Socket	*B	w/ Front Side Radar
*1	HEADLIGHT UNIT SUB-ASSEMBLY	-	-

Procedure		Part Name Code
4	HEADLIGHT LENS	81186		-	-
5	HEADLIGHT LENS GASKET	81132B		-	-
6	INNER LENS ASSEMBLY	-	-	-	-
7	REFLECTOR	-	-	-	-
8	INNER ASSEMBLY	-		-	-
9	HEADLIGHT UNIT	81175		-	-
10	HEADLIGHT LEVELING MOTOR	85691	-	-	-
11	LIGHT CONTROL LED ECU	85967D	-	-	-

*1	HEADLIGHT LEVELING MOTOR WITH BRACKET	*2	HEADLIGHT LEVELING MOTOR BRACKET
●	Non-reusable part	-	-

PROCEDURE

1. REMOVE HEADLIGHT FRONT TURN SIGNAL LED (w/ Front Turn Signal LED Socket)

2. REMOVE HEADLIGHT BRACKET

3. REMOVE FRONT SIDE RADAR SENSOR BRACKET (w/ Front Side Radar)

4. REMOVE HEADLIGHT LENS

NOTICE: Make sure to wear clean rubber gloves when performing this procedure. Do not allow dirt or foreign matter to get on the headlight lens. 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 any fingerprints or foreign matter on the back of the headlight lens, wipe them off 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

*a

"TORX" screw

*b

Screw

(1) Remove the 6 screws.

(2) Using a T20H "TORX" driver, remove the "TORX" screw.

*a

Separation Starting Point

-

-

(1) Disengage the 8 claws.

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

NOTICE:

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

	Headlight Lens		Separation Starting Point
	Headlight Lens Gasket		Headlight Housing

(1) Insert a finger between the headlight lens and headlight housing and lift up the headlight lens.

(2) Using a screwdriver with its tip wrapped with protective tape, pull out the headlight lens gasket through the opening.

NOTICE:

Do not damage the groove in the headlight housing or the headlight lens.

	Separation Starting Point		Headlight Lens Gasket
	Pull out in this Direction		Remove in this Direction

(1) Pull out the headlight lens gasket as shown in the illustration to remove the headlight lens.

(2) Remove the headlight lens from the headlight housing from the separation starting point toward the outside of the Toyota Prius vehicle as shown in the illustration.

5. REMOVE HEADLIGHT LENS GASKET

NOTICE: The headlight lens gasket must not be reused. Make sure to wear clean rubber gloves when performing this procedure. 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 any fingerprints or foreign matter on the headlight unit or other components, wipe them off with a soft cloth. Do not use solvent to clean components. Only clean them with a dry cloth.

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

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

6. REMOVE INNER LENS ASSEMBLY

7. REMOVE REFLECTOR

8. REMOVE INNER ASSEMBLY

Place Hand Here

Remove in this Direction

(1) Remove the 5 screws.

(2) Disengage the clip to remove the inner assembly as shown in the illustration.

9. REMOVE HEADLIGHT UNIT

NOTICE: Make sure to wear clean rubber gloves when performing this procedure. Do not allow dirt or foreign matter to get on the headlight unit or other components. Prevention of static electricity is required during this procedure. Use static electricity countermeasures SST (desktop anti-static mat set) and observe all precautions to prevent damage to the system by electrostatic discharge (ESD). Do not touch the headlight unit 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 any fingerprints or foreign matter on the headlight unit or other components, wipe them off 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) Using a vernier caliper, record the dimensions of a and b shown in the illustration.

Turn in this Direction

Remove in this Direction

(1) Disconnect the connector.

(2) Disengage the 2 claws.

(3) While holding the headlight unit assembly by hand, turn the aiming screws as shown in the illustration until the aiming screws are separated from the headlight unit.

(4) Remove the pivot collar as shown in the illustration.

10. REMOVE HEADLIGHT LEVELING MOTOR

*a	Connector	*b	Screw
	Remove in this Direction	-	-

11. REMOVE LIGHT CONTROL LED ECU

Inspection

INSPECTION

PROCEDURE

1. INSPECT HEADLIGHT HOUSING LH (w/ Front Turn Signal LED Socket)

(a) Measure the resistance according to the value(s) in the table below.

*1	Headlight Housing LH (Headlight Cord)	-	-
*a	Component without harness connected (to No. 1 Headlight Clearance LED LH)	*b	Component without harness connected (to Wire Harness)
*c	Component without harness connected (to Headlight Leveling Motor LH)	*d	Component without harness connected (to Headlight Unit LH)
*e	Component without harness connected (to Light Control ECU)	*f	Component without harness connected (to Headlight Turn Signal LED Unit)

(1) Inspect the clearance light/daytime running light circuit.

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
A-1 - F-5	Always	Below 1 Ω	Ω
A-2 - E-6	Always	Below 1 Ω	Ω
E-7 - F-1	Always	Below 1 Ω	Ω
E-12 - F-8	Always	Below 1 Ω	Ω
E-13 - F-9	Always	Below 1 Ω	Ω
E-14 - F-2	Always	Below 1 Ω	Ω
E-17 - F-4	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

(2) Inspect the Lo/Hi beam circuit.

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
D-1 - E-16	Always	Below 1 Ω	Ω
D-2 - E-10	Always	Below 1 Ω	Ω
D-3 - E-15	Always	Below 1 Ω	Ω
D-4 - E-4	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

(3) Inspect the headlight leveling motor circuit.

Standard Resistance:

Click Location & Routing(A38) Click Connector(A38)

Tester Connection	Condition	Specified Condition	Result
A38-2 (B) - C-3	Always	Below 1 Ω	Ω
A38-3 (LHM ) - C-2	Always	Below 1 Ω	Ω
A38-4 (LH T) - C-1	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

(4) Inspect the light control ECU power source circuit.

Standard Resistance:

Click Location & Routing(A38) Click Connector(A38)

Tester Connection	Condition	Specified Condition	Result
A38-2 (B) - E-8	Always	Below 1 Ω	Ω
A38-5 (AT1) - E-19	Always	Below 1 Ω	Ω
A38-6 (LO) - E-11	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

2. INSPECT HEADLIGHT HOUSING LH (w/o Front Turn Signal LED Socket)

(a) Measure the resistance according to the value(s) in the table below.

*1	Headlight Housing LH (Headlight Cord)	-	-
*a	Component without harness connected (to No. 1 Headlight Clearance LED LH)	*b	Component without harness connected (to Wire Harness)
*c	Component without harness connected (to Headlight Turn Signal LED Unit)	*d	Component without harness connected (to No. 2 Headlight Clearance LED LH)
*e	Component without harness connected (to Headlight Leveling Motor LH)	*f	Component without harness connected (to Headlight Unit LH)
*g	Component without harness connected (to Light Control ECU)	*h	Component without harness connected (to No. 3 Headlight Clearance LED LH)

(1) Inspect the clearance light/daytime running light circuit.

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
A-1 - H-7	Always	Below 1 Ω	Ω
A-2 - G-6	Always	Below 1 Ω	Ω
D-1 - G-20	Always	Below 1 Ω	Ω
D-2 - G-3	Always	Below 1 Ω	Ω
G-7 - H-10	Always	Below 1 Ω	Ω
G-12 - H-1	Always	Below 1 Ω	Ω
G-13 - H-2	Always	Below 1 Ω	Ω
G-14 - H-11	Always	Below 1 Ω	Ω
G-17 - H-8	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

(2) Inspect the turn signal light circuit.

Standard Resistance:

Click Location & Routing(A38) Click Connector(A38)

Tester Connection	Condition	Specified Condition	Result
A38-1 (E) - C-2	Always	Below 1 Ω	Ω
A38-2 (B) - C-3	Always	Below 1 Ω	Ω
C-4 - H-5	Always	Below 1 Ω	Ω
C-5 - H-3	Always	Below 1 Ω	Ω
C-6 - H-4	Always	Below 1 Ω	Ω
C-8 - H-6	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

(3) Inspect the Lo/Hi beam circuit.

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
F-1 - G-16	Always	Below 1 Ω	Ω
F-2 - G-10	Always	Below 1 Ω	Ω
F-3 - G-15	Always	Below 1 Ω	Ω
F-4 - G-4	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

(4) Inspect the headlight leveling motor circuit.

Standard Resistance:

Click Location & Routing(A38) Click Connector(A38)

Tester Connection	Condition	Specified Condition	Result
A38-2 (B) - E-3	Always	Below 1 Ω	Ω
A38-3 (LHM ) - E-2	Always	Below 1 Ω	Ω
A38-4 (LH T) - E-1	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

(5) Inspect the light control ECU power source circuit.

Standard Resistance:

Click Location & Routing(A38) Click Connector(A38)

Tester Connection	Condition	Specified Condition	Result
A38-2 (B) - G-8	Always	Below 1 Ω	Ω
A38-5 (AT1) - G-19	Always	Below 1 Ω	Ω
A38-6 (LO) - G-11	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing LH (headlight cord).

3. INSPECT HEADLIGHT HOUSING RH (w/ Front Turn Signal LED Socket)

(a) Measure the resistance according to the value(s) in the table below.

*1	Headlight Housing RH (Headlight Cord)	-	-
*a	Component without harness connected (to No. 1 Headlight Clearance LED RH)	*b	Component without harness connected (to Wire Harness)
*c	Component without harness connected (to Headlight Leveling Motor RH)	*d	Component without harness connected (to Headlight Unit RH)
*e	Component without harness connected (to Light Control ECU)	*f	Component without harness connected (to Headlight Turn Signal LED Unit)

(1) Inspect the clearance light/daytime running light circuit.

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
A-1 - F-5	Always	Below 1 Ω	Ω
A-2 - E-6	Always	Below 1 Ω	Ω
E-7 - F-1	Always	Below 1 Ω	Ω
E-12 - F-8	Always	Below 1 Ω	Ω
E-13 - F-9	Always	Below 1 Ω	Ω
E-14 - F-2	Always	Below 1 Ω	Ω
E-17 - F-4	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

(2) Inspect the Lo/Hi beam circuit.

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
D-1 - E-16	Always	Below 1 Ω	Ω
D-2 - E-10	Always	Below 1 Ω	Ω
D-3 - E-15	Always	Below 1 Ω	Ω
D-4 - E-4	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

(3) Inspect the headlight leveling motor circuit.

Standard Resistance:

Click Location & Routing(A36) Click Connector(A36)

Tester Connection	Condition	Specified Condition	Result
A36-2 (B) - C-3	Always	Below 1 Ω	Ω
A36-3 (RHM ) - C-2	Always	Below 1 Ω	Ω
A36-4 (RH T) - C-1	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

(4) Inspect the light control ECU power source circuit.

Standard Resistance:

Click Location & Routing(A36) Click Connector(A36)

Tester Connection	Condition	Specified Condition	Result
A36-2 (B) - E-8	Always	Below 1 Ω	Ω
A36-5 (AS1) - E-19	Always	Below 1 Ω	Ω
A36-6 (LO) - E-11	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

4. INSPECT HEADLIGHT HOUSING RH (w/o Front Turn Signal LED Socket)

(a) Measure the resistance according to the value(s) in the table below.

*1	Headlight Housing RH (Headlight Cord)	-	-
*a	Component without harness connected (to No. 1 Headlight Clearance LED RH)	*b	Component without harness connected (to Wire Harness)
*c	Component without harness connected (to Headlight Turn Signal LED Unit)	*d	Component without harness connected (to No. 2 Headlight Clearance LED RH)
*e	Component without harness connected (to Headlight Leveling Motor RH)	*f	Component without harness connected (to Headlight Unit RH)
*g	Component without harness connected (to Light Control ECU)	*h	Component without harness connected (to No. 3 Headlight Clearance LED RH)

(1) Inspect the clearance light/daytime running light circuit.

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
A-1 - H-4	Always	Below 1 Ω	Ω
A-2 - G-6	Always	Below 1 Ω	Ω
D-1 - G-20	Always	Below 1 Ω	Ω
D-2 - G-3	Always	Below 1 Ω	Ω
G-7 - H-1	Always	Below 1 Ω	Ω
G-12 - H-10	Always	Below 1 Ω	Ω
G-13 - H-11	Always	Below 1 Ω	Ω
G-14 - H-2	Always	Below 1 Ω	Ω
G-17 - H-5	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

(2) Inspect the turn signal light circuit.

Standard Resistance:

Click Location & Routing(A36) Click Connector(A36)

Tester Connection	Condition	Specified Condition	Result
A36-1 (E) - C-2	Always	Below 1 Ω	Ω
A36-2 (B) - C-3	Always	Below 1 Ω	Ω
C-4 - H-6	Always	Below 1 Ω	Ω
C-5 - H-8	Always	Below 1 Ω	Ω
C-6 - H-9	Always	Below 1 Ω	Ω
C-8 - H-7	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

(3) Inspect the Lo/Hi beam circuit.

Standard Resistance:

Tester Connection	Condition	Specified Condition	Result
F-1 - G-16	Always	Below 1 Ω	Ω
F-2 - G-10	Always	Below 1 Ω	Ω
F-3 - G-15	Always	Below 1 Ω	Ω
F-4 - G-4	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

(4) Inspect the headlight leveling motor circuit.

Standard Resistance:

Click Location & Routing(A36) Click Connector(A36)

Tester Connection	Condition	Specified Condition	Result
A36-2 (B) - E-3	Always	Below 1 Ω	Ω
A36-3 (RHM ) - E-2	Always	Below 1 Ω	Ω
A36-4 (RH T) - E-1	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

(5) Inspect the light control ECU power source circuit.

Standard Resistance:

Click Location & Routing(A36) Click Connector(A36)

Tester Connection	Condition	Specified Condition	Result
A36-2 (B) - G-8	Always	Below 1 Ω	Ω
A36-5 (AS1) - G-19	Always	Below 1 Ω	Ω
A36-6 (LO) - G-11	Always	Below 1 Ω	Ω

If the result is not as specified, replace the headlight housing RH (headlight cord).

Adjustment

ADJUSTMENT

CAUTION / NOTICE / HINT

PROCEDURE

1. PREPARE VEHICLE FOR HEADLIGHT AIM ADJUSTMENT

(a) Prepare the Toyota Prius vehicle:

2. PREPARE FOR HEADLIGHT AIMING (Using a headlight aim test machine)

(a) Adjust the headlight aim in accordance with the headlight aim test machine instructions.

3. PREPARE FOR HEADLIGHT AIMING (Using a screen)

(a) Prepare the Toyota Prius vehicle:

*a	Center Mark

NOTICE:

A distance of 7.62 m (25 ft.) between the Toyota Prius vehicle (center marks of the headlights) and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of headlight aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

(b) Prepare a piece of thick white paper (approximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen.

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

(d) Set the screen as shown in the illustration.

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

*a	Center Mark

*a	V LH Line
*b	V Line
*c	V RH Line
*d	H Line
*e	Ground

(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 center marks of the headlights.

(2) V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights):

Draw 2 vertical lines so that they intersect the H line at each center mark (aligned with the center marks of the headlights).

4. INSPECT HEADLIGHT AIMING

(a) Cover the headlight on the opposite side to prevent light from the headlight that is 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, which may melt or be damaged due to excessive heat.

HINT:

When checking the aim of the high beam, cover the low beam.

(b) Start the engine.

(c) Turn on the headlights and check the aiming of each beam.

5. ADJUST HEADLIGHT AIMING

(a) Adjust the aim vertically:

(1) Adjust the aim of each headlight to the specified range by turning each aiming screw with a screwdriver.

*a

Aiming Screw

-

-

NOTICE:

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.

Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (REASSEMBLY)

Procedure		Part Name Code
1	LIGHT CONTROL LED ECU	85967D	-	-	-
2	HEADLIGHT LEVELING MOTOR	85691	-	-	-
3	HEADLIGHT UNIT	81171A		-	-
4	INNER LENS ASSEMBLY	-	-	-	-
5	REFLECTOR	-	-	-	-
6	INNER LENS ASSEMBLY	-	-	-	-
7	HEADLIGHT LENS GASKET	81132B		-	-
8	HEADLIGHT LENS	81186		-	-

*1	HEADLIGHT LEVELING MOTOR WITH BRACKET	*2	HEADLIGHT LEVELING MOTOR BRACKET
●	Non-reusable part	-	-

Procedure		Part Name Code
9	FRONT SIDE RADAR SENSOR BRACKET	88215C	-	-	-
10	HEADLIGHT BRACKET	53246B	-	-	-
11	HEADLIGHT FRONT TURN SIGNAL LED	8113A	-	-	-

*A	w/ Front Turn Signal LED Socket	*B	w/ Front Side Radar
*1	HEADLIGHT UNIT SUB-ASSEMBLY	-	-

PROCEDURE

1. INSTALL LIGHT CONTROL LED ECU

2. INSTALL HEADLIGHT LEVELING MOTOR

3. INSTALL HEADLIGHT UNIT

NOTICE: Make sure to wear clean rubber gloves when performing this procedure. Do not allow dirt or foreign matter to get on the headlight unit or other components. Prevention of static electricity is required during this procedure. Use static electricity countermeasures SST (desktop anti-static mat set) and observe all precautions to prevent damage to the system by electrostatic discharge (ESD). Do not touch the headlight unit 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 any fingerprints or foreign matter on the headlight unit or other components, wipe them off 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

	Adjustment Aiming Screws		Adjustment Aiming Rail
	Install in this Direction		Turn in this Direction

(1) Install the pivot collar as shown in the illustration.

(2) Temporarily install the headlight unit assembly to the 2 adjustment aiming rails and 2 adjustment aiming screws as shown in the illustration.

(3) Hold the headlight unit assembly LH with one hand to prevent it from tipping over, alternately tighten the 2 adjustment aiming screws in the direction indicated by the arrow shown in the illustration, and align the dimensions with the recorded values at removal.

(1) Engage the 2 claws to connect the pivot collar.

(2) Connect the connector to install the headlight unit.

4. INSTALL INNER ASSEMBLY

5. INSTALL REFLECTOR

6. INSTALL INNER LENS ASSEMBLY

7. INSTALL HEADLIGHT LENS GASKET

NOTICE: The headlight lens gasket must not be reused. Make sure to wear clean rubber gloves when performing this procedure. 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 any fingerprints or foreign matter on the headlight unit or other components, wipe them off with a soft cloth. Do not use solvent to clean components. Only clean them with a dry cloth.

*a	Release Paper	*b	Tape
*c	90°	-	-
	Cleaning Area	-	-

(1) Clean the installation groove of the headlight lens.

(2) Partially remove the release paper from a new headlight lens gasket, and cut off a piece of it.

(3) 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.

(4) Using scissors, cut the end of the headlight lens gasket at a 90° angle.

Starting Position

-

-

(1) Starting from the position shown in the illustration and moving clockwise, temporarily install the headlight lens gasket as shown in the illustration.

NOTICE:

Gently install the headlight lens gasket without pulling it.

	Straight Groove		Press in this Direction
	Release Paper	-	-

(1) Repeat the following until the headlight lens gasket reaches the starting position.

1. Using 2 screwdrivers with their tips wrapped with release paper, completely press the headlight lens gasket into the straight groove to install it.

2. Temporarily install the headlight lens gasket to the straight groove.

3. Temporarily install it to the corner groove.

4. Completely press it into the groove.

Corner Groove

-

-

(1) Using scissors, cut the headlight lens gasket at a 45° angle at the starting position so that the headlight lens gasket overlaps itself 10 mm (0.394 in.) or more.

Standard Dimension:

Area	Dimension	-	-
A	10 mm (0.394 in.) or more	-	-

(2) Check the installation condition of the headlight lens gasket.

8. INSTALL HEADLIGHT LENS

NOTICE: Make sure to wear clean rubber gloves when performing this procedure. Do not allow dirt or foreign matter to get on the headlight lens. 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 any fingerprints or foreign matter on the back of the headlight lens, wipe them off with a soft cloth. Do not use solvent to clean components. Only clean them with a dry cloth.

	Cleaning Area		Headlight Lens Gasket
	Headlight Lens		Headlight Housing

(1) Clean the sealing surface of the headlight lens.

(2) Temporarily install the headlight lens to the headlight housing.

*a

"TORX" Screw

*b

Screw

(1) Engage the 8 claws in the order shown in the illustration to install the headlight lens.

NOTICE:

Make sure all of the claws are engaged.

(2) Install the 6 screws.

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

(4) Check the installation condition of the headlight lens gasket.

NOTICE:

Make sure the headlight lens gasket is not protruding and completely contacts the headlight lens.

9. INSTALL FRONT SIDE RADAR SENSOR BRACKET (w/ Front Side Radar)

10. INSTALL HEADLIGHT BRACKET

11. INSTALL HEADLIGHT FRONT TURN SIGNAL LED (w/ Front Turn Signal LED Socket)

Installation

INSTALLATION

CAUTION / NOTICE / HINT

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

Procedure		Part Name Code
1	HEADLIGHT ASSEMBLY	-	-	-	-
2	FRONT SIDE RADAR SENSOR	882B1		-	-
3	FRONT BUMPER ASSEMBLY	-	-	-	-
4	ADJUST HEADLIGHT AIMING	-	-	-

*A	w/ Front Side Radar	-	-
	N*m (kgf*cm, ft.*lbf): Specified torque	-	-

PROCEDURE

1. INSTALL HEADLIGHT ASSEMBLY

Torque:

Bolt :

7.0 N·m {71 kgf·cm, 62 in·lbf}

2. INSTALL FRONT SIDE RADAR SENSOR (w/ Front Side Radar)

Click here

3. INSTALL FRONT BUMPER ASSEMBLY

Click here

4. ADJUST HEADLIGHT AIMING

Click here