Section 515 (Headlamps): Overhaul

HINT:

• Use the same procedures for the RH side and LJ side.
• The procedures listed below are for the LH side.
• Reassembly is in the reverse order of overhaul.

1. REMOVE ENGINE UNDER COVER NO.1 (SEE  ON-VEHICLE INSPECTION  ) 
2. REMOVE FRONT FENDER LINER LH (SEE  ON-VEHICLE INSPECTION  ) 
3. REMOVE FRONT FENDER LINER RH (SEE  ON-VEHICLE INSPECTION  ) 
4. REMOVE FRONT BUMPER COVER (SEE  ON-VEHICLE INSPECTION  ) 
5. REMOVE LH HEADLAMP ASSY 
   1. Remove the 3 screws.
   2. Pull out the LH headlamp assy forward.
   3. Disconnect the connectors and remove the LH headlamp assy.
      Fig 1: Removing Headlamp Assembly (LH)

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE DISCHARGE HEADLAMP BULB 
   1. Turn the headlamp socket cover as shown in the illustration.
      Fig 2: Identifying Headlamp Socket Cover Turning Direction

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Remove the discharge headlamp bulb socket as shown in the illustration.
      Fig 3: Removing Discharge Headlamp Bulb Socket

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   3. Release the lock of the set spring and remove the discharge headlamp bulb.
      Fig 4: Removing Discharge Headlamp Bulb

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. REMOVE HEADLAMP, NO.2 BULB 
   1. Remove the headlamp, No. 2 bulb as shown in the illustration.
      Fig 5: Removing Headlamp No. 2 Bulb

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
8. REMOVE FRONT TURN SIGNAL LAMP BULB 
   1. Remove the front turn signal lamp bulb and the front turn signal lamp socket as shown in the illustration.
   2. Remove the front turn signal lamp bulb from the front turn signal lamp socket.
      Fig 6: Removing Front Turn Signal Lamp Bulb

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. REMOVE FRONT SIDE MAKER LAMP BULB 
   1. Remove the front side make lamp bulb and front side maker lamp socket as shown in the illustration.
   2. Remove the front side maker lamp bulb from the front side make lamp socket.
      Fig 7: Removing Front Side Maker Lamp Bulb

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
10. REMOVE CLEARANCE LAMP BULB 
    1. Remove the clearance lamp bulb and the clearance lamp bulb socket as shown in the illustration.
    2. Remove the clearance lamp bulb from the clearance lamp bulb socket.
       Fig 8: Removing Clearance Lamp Bulb

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
11. REMOVE HEADLAMP COVER NO. 1 
    1. Remove the 2 screws and the headlamp cover No. 1.
       Fig 9: Removing Headlamp Cover No. 1

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Release the claw fitting, disconnect the connector from the light control ECU and remove the headlamp cover No. 1.
    3. Remove the headlamp gasket from the headlamp cover No. 1.
       Fig 10: Disconnecting Connector From Light Control ECU

       Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
12. INSTALL FRONT BUMPER COVER (SEE  ON-VEHICLE INSPECTION  ) 
13. INSTALL FRONT FENDER LINER LH (SEE  ON-VEHICLE INSPECTION  ) 
14. INSTALL FRONT FENDER LINER RH (SEE  ON-VEHICLE INSPECTION  ) 
15. INSTALL ENGINE UNDER COVER NO.1 (SEE  ON-VEHICLE INSPECTION  ) 
16. HEADLIGHT AIM ONLY (SEE  ADJUSTMENT  ) 
17. ADJUST FOG LIGHT AIM (SEE  ADJUSTMENT  )