Headlight Assembly: Repair

HINT:

• Use the same procedures for the RH side and LH side.
• The procedures listed below are for the LH side.
• If the area where the headlight unit LH is installed is broken, 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. REMOVE RADIATOR GRILLE SUB-ASSEMBLY (See  REMOVAL  ) 
2. REMOVE FRONT BUMPER ASSEMBLY (See  REMOVAL  ) 
3. REMOVE HEADLIGHT ASSEMBLY (See  REMOVAL  ) 
4. REMOVE HEADLIGHT BRACKET (See  REMOVAL  ) 
5. REMOVE HEADLIGHT PROTECTOR RETAINER UPPER 

   HINT:

   • If the installation area of the headlight assembly LH is damaged, use the supply bracket for low-cost repair.
   • Ensure that the headlight assembly LH is not damaged.
   1. Cut off part shaded in Fig 1 and sand smooth with sandpaper.
      Fig 1: Identifying Cut Off Part

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: After cutting off the part, place the headlight protector retainer UPR LH against the bosses and gradually file away until installation is possible.
   2. Install the headlight protector retainer UPR LH with the 2 screws.
   Fig 2: Installing Headlight Protector Retainer UPR LH
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
6. REMOVE HEADLIGHT PROTECTOR RETAINER LOWER 

   HINT:

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

      Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
   2. Install the headlight protector retainer LWR LH with the 2 screws.
   Fig 4: Installing Headlight Protector Retainer LWR LH
   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
7. INSTALL FRONT BUMPER ASSEMBLY (See  INSTALLATION  ) 
8. INSTALL RADIATOR GRILLE SUB-ASSEMBLY (See  INSTALLATION  ) 
9. PREPARE VEHICLE FOR HEADLIGHT AIMING ADJUSTMENT (See  HEADLIGHT BEAM LEVEL WARNING CIRCUIT  ) 
10. PREPARE FOR HEADLIGHT AIMING (for Using a Tester) (See  HEADLIGHT BEAM LEVEL WARNING CIRCUIT  ) 
11. PREPARE FOR HEADLIGHT AIMING (for Using a Screen) (See  HEADLIGHT BEAM LEVEL WARNING CIRCUIT  ) 
12. INSPECT HEADLIGHT AIMING (See  INSPECTION PROCEDURE  ) 
13. ADJUST HEADLIGHT AIMING (See  ADJUSTMENT  ) 
14. PREPARE VEHICLE FOR FOG LIGHT AIMING ADJUSTMENT (See  REPAIR  ) 
15. PREPARE FOR FOG LIGHT AIMING (See  FOG LIGHT ASSEMBLY  ) 
16. INSPECT FOG LIGHT AIMING (See  ADJUSTMENT  ) 
17. ADJUST FOG LIGHT AIMING (See  ADJUSTMENT  )