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 DISASSEMBLY )
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 the illustration and sand smooth with sandpaper.
      NOTE: After cutting off the part, place the headlight protector retainer UPR LH against the bosses and gradually file away until installation is possible.
      Fig 1: Identifying Cutting Area

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

   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 the illustration 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 Cutting Area

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

   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 ADJUSTMENT )
10. PREPARE FOR HEADLIGHT AIMING (for Using a Tester)  (See ADJUSTMENT )
11. PREPARE FOR HEADLIGHT AIMING (for Using a Screen)  (See ADJUSTMENT )
12. INSPECT HEADLIGHT AIMING  (See ADJUSTMENT )
13. ADJUST HEADLIGHT AIMING  (See ADJUSTMENT )
14. PREPARE VEHICLE FOR FOG LIGHT AIMING ADJUSTMENT  (See ADJUSTMENT )
15. PREPARE FOR FOG LIGHT AIMING  (See ADJUSTMENT )
16. INSPECT FOG LIGHT AIMING  (See ADJUSTMENT )
17. ADJUST FOG LIGHT AIMING  (See ADJUSTMENT )