Headlight Assembly: Repair

HINT:

• Use the same procedures for the RH and LH.
• The procedures listed below are for the LH side.
• If the area where the headlight unit LH is installed is damaged, the repairs listed below can be performed inexpensively through the use of a repair use bracket. This may only be done if the headlight assembly LH itself is not damaged.

1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL 
2. REMOVE RADIATOR GRILLE (See  REMOVAL  ) 
3. REMOVE FRONT BUMPER COVER (See  REMOVAL  ) 
4. REMOVE FRONT BUMPER FILLER (See  REMOVAL  ) 
5. REMOVE HEADLIGHT ASSEMBLY (See  REMOVAL   ) 
6. INSTALL HEADLIGHT PROTECTOR UPPER RETAINER 

   HINT:

   • If the installation area of the LH headlight assembly is damaged, use the supply bracket for low-cost repair.
   • Ensure that the LH headlight assembly is not damaged.
   1. Cut off the portion indicated by the shaded portion in Fig 1 and smooth the surface with sandpaper.
      NOTE: After cutting off the shaded portion, place the LH headlight protector upper retainer LH against the bosses and gradually file away the shaded portion until installation is possible.
      Fig 1: Identifying Cutting Area

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the headlight protector upper retainer LH with the 2 screws.
      Fig 2: Installing Headlight Protector Upper Retainer LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL HEADLIGHT PROTECTOR LOWER RETAINER 

   HINT:

   • If the installation area of the LH headlight assembly is damaged, use the supply bracket for low-cost repair.
   • Ensure that the LH headlight assembly is not damaged.
   1. Cut off the portion indicated by the shaded portion in Fig 3 and smooth the surface with sandpaper.
      NOTE: After cutting off the shaded portion, place the headlight protector lower retainer LH against the bosses and gradually file away the shaded portion until installation is possible.
      Fig 3: Identifying Cutting Area

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the headlight protector lower retainer LH with the 2 screws.
   Fig 4: Installing Headlight Protector Lower Retainer LH

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. INSTALL HEADLIGHT LOWER BRACKET 

   HINT:

   • If the installation area of the LH headlight assembly is damaged, use the supply bracket for low-cost repair.
   • Make sure that the LH headlight assembly is not damaged.
   1. Cut off the portion indicated by the shaded portion in Fig 5 and smooth the surface with sandpaper.
      NOTE: After cutting off the shaded portion, place the headlight lower bracket LH against the bosses and gradually file away the shaded portion until installation is possible.
      Fig 5: Identifying Cutting Area

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the headlight lower bracket LH with the 2 screws.
      Fig 6: Installing Headlight Lower Bracket LH

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. INSTALL HEADLIGHT ASSEMBLY 
10. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 

    Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 

11. INSTALL FRONT BUMPER FILLER (See  INSTALLATION  ) 
12. INSTALL FRONT BUMPER COVER (See  INSTALLATION  ) 
13. INSTALL RADIATOR GRILLE (See  INSTALLATION  ) 
14. VEHICLE PREPARATION FOR HEADLIGHT AIM ADJUSTMENT (See  ADJUSTMENT   ) 
15. PREPARE FOR HEADLIGHT AIMING (for Using a Tester) (See  ADJUSTMENT   ) 
16. PREPARE FOR HEADLIGHT AIMING (for Using a Screen) (See  ADJUSTMENT   ) 
17. HEADLIGHT AIMING INSPECTION (See  ADJUSTMENT   ) 
18. HEADLIGHT AIMING ADJUSTMENT (See  ADJUSTMENT   )