Headlight Assembly Installation

Connect each connector.

Engage the clamp.

Install the headlight assembly with the bolt and 2 screws.

Torque:

3.6 N*m{37 kgf*cm, 32 in.*lbf}

w/ Headlight Cleaner System:

1. Connect the headlight cleaner washer hose.
   

Connect each connector.

w/ TOYOTA Parking Assist-sensor System:

1. Connect the No. 1 ultrasonic sensor connector and engage the clamp.
   

Engage the 2 claws.

HINT:

Use the same procedure for the RH side and LH side.

Install the front bumper assembly with the 8 screws, 2 clips, 2 radiator grille protectors and bolt.

Install the pin hold clip.

NOTICE:

Insert the pin hold clip with the slot aligned vertically. Do not rotate the clip after inserting it. After installation, confirm that the slot is vertical.

HINT:

Use the same procedure for the RH side and LH side.

Remove the applied protective tape on the front bumper assembly.

Install the cool air intake duct seal with the 7 clips.

Prepare the vehicle:

1. Ensure there is no damage or deformation to the body around the headlights.
   
2. Fill the fuel tank.
   
3. Make sure that the oil is filled to the specified level.
   
4. Make sure that the coolant is filled to the specified level.
   
5. Inflate the tires to the appropriate pressure.
   
6. Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions.
   
7. Sit a person of average weight (75 kg, 165 lb) in the driver's seat.
   


8. Vehicles with manual headlight beam level control system should be adjusted to "0".
   

Prepare the vehicle:

1. Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot.
   
2. Place the vehicle at a 90° angle to the wall.
   
3. Create a 25 m (82 ft.) distance between the vehicle (headlight bulb center) and the wall.
   
4. Make sure that the vehicle is on a level surface.
   
5. Position the front wheels straight ahead.
   
6. Bounce the vehicle up and down to settle the suspension.
   

   NOTICE:

   A distance of 25 m (82 ft.) between the vehicle (headlight bulb center) 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.)

Prepare a piece of thick white paper (approximately 2 m (6.6 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen.

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

Set the screen as shown in the illustration.

HINT:

1. Stand the screen perpendicular to the ground.
   
2. Align the V line on the screen with the center of the vehicle.
   

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

HINT:

1. The base lines differ for "low beam inspection" and "high beam inspection".
   
2. Mark the headlight bulb center marks on the screen. If the center mark cannot be observed on the headlight, use the center of the headlight bulb or the manufacturer's name marked on the headlight as the center mark.
   

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 headlight bulb center marks of the low beam headlights.
   

2. V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights):
   Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low beam headlight bulbs).
   

Cover the headlight or disconnect the connector of the headlight/headlight ECU on the opposite side to prevent light from the headlight that is not being inspected from affecting the headlight aiming inspection.

CAUTION:

Do not disconnect the HID high voltage connector for the bulb when performing this 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 or disconnect the connector.

Start the engine.

Turn on the headlights and check if the cutoff line for each low beam matches the preferred cutoff line in the illustration.

HINT:

1. Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.
   
2. If the alignment distance is 25 m (82 ft.):
   The low beam cutoff line should be within 48 mm (1.89 in.) and 698 mm (27.4 in.) below the H line as well as 248 mm (9.79 in.) left or right of the V LH or V RH line.
   
3. If the alignment distance is 3 m (9.84 ft.):
   The low beam cutoff line should be within 6 mm (0.227 in.) and 83 mm (3.29 in.) below the H line as well as 29 mm (1.17 in.) left or right of the V LH or V RH line.
   
4. If the alignment distance is 25 m (82 ft.):
   The horizontal line of the preferred low beam cutoff line is 249 mm (9.79 in.) below the H line and point A of the preferred low beam cutoff line is on the V LH or V RH line.
   
5. If the alignment distance is 3 m (9.84 ft.):
   The horizontal line of the preferred low beam cutoff line is 30 mm (1.18 in.) below the H line and point A of the preferred low beam cutoff line is on the V LH or V RH line.
   

Turn on the high beams and check if the center of intensity for each high beam matches the preferred center of the intensity in the illustration.

HINT:

1. Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.
   
2. If the alignment distance is 25 m (82 ft.):
   The high beam center of intensity should be within 174 mm (6.87 in.) above and 248 mm (9.79 in.) below the H line as well as 248 mm (9.79 in.) left or right of the V LH or V RH line.
   
3. If the alignment distance is 3 m (9.84 ft.):
   The high beam center of intensity should be within 20 mm (0.824 in.) above and 29 mm (1.17 in.) below the H line as well as 29 mm (1.17 in.) left or right of the V LH or V RH line.
   
4. If the alignment distance is 25 m (82 ft.):
   The preferred high beam center of intensity is 87 mm (3.44 in.) below the H line and is on the V LH or V RH line.
   
5. If the alignment distance is 3 m (9.84 ft.):
   The preferred high beam center of intensity is 10 mm (0.412 in.) below the H line and is on the V LH or V RH line.
   

Remove any covers necessary to access the headlight adjusters.

Adjust the aim vertically:

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.

HINT:

1. Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.
   
2. If it is not possible to correctly adjust headlight aim, check bulb, headlight unit and headlight unit reflector installation.
   
3. The headlight aim moves down when turning the aiming screw clockwise, and moves up when turning the aiming screw counterclockwise.
   
4. Confirm the direction of rotation of the aiming screw by observing it while it is being adjusted. Due to the position of the screwdriver, the direction of rotation of the adjusting screw can be different than the direction of rotation of the screwdriver being used to adjust it.
   

Adjust the aim horizontally:

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.

HINT:

1. Since the low beam light and the high beam light are a unit, if the aim on the low beam is correct, the high beam should also be correct. However, check both beams just to make sure.
   
2. If it is not possible to correctly adjust headlight aim, check bulb, headlight unit and headlight unit reflector installation.
   
3. Confirm the direction of rotation of the aiming screw by observing it while it is being adjusted. Due to the position of the screwdriver, the direction of rotation of the adjusting screw can be different than the direction of rotation of the screwdriver being used to adjust it.
   

Install any covers that were removed to access the headlight adjusters.

Prepare the vehicle:

1. Ensure there is no damage or deformation to the body around the fog lights.
   
2. Fill the fuel tank.
   
3. Make sure that the oil is filled to the specified level.
   
4. Make sure that the engine coolant is filled to the specified level.
   
5. Inflate the tires to the appropriate pressure.
   
6. Unload the trunk and vehicle, ensuring that the spare tire, tools, and jack are in their original positions.
   
7. Sit a person of average weight (75 kg, 165 lb) in the driver's seat.
   
8. Vehicles with height adjustable suspension should set the vehicle height to the lowest setting prior to adjusting the fog light aim.
   

Prepare the vehicle:

1. Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the fog lights can be observed and above which it cannot.
   
2. Place the vehicle at a 90° angle to the wall.
   
3. Create a 25 m (82 ft) distance between the vehicle (fog light bulb center) and the wall.
   
4. Make sure that the vehicle is on a level surface.
   
5. Bounce the vehicle up and down to settle the suspension.
   

   NOTICE:

   A distance of 25 m (82 ft) between the vehicle (fog light bulb center) 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 fog light aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

Prepare a piece of thick white paper (approximately 2 m (6.6 ft) (height) x 4 m (13.1 ft) (width)) to use as a screen.

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

Set the screen as shown in the illustration.

HINT:

1. Stand the screen perpendicular to the ground.
   
2. Align the V line on the screen with the center of the vehicle.
   

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

HINT:

Mark the fog light bulb center marks on the screen. If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark.

1. H Line (Fog light 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 fog light bulb center marks of the low-beam fog lights.
   

2. V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) fog lights):
   Draw two vertical lines so that they intersect the H line at each center mark.
   

Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light that is not being inspected from affecting the fog light aiming inspection.

NOTICE:

Do not keep the fog light covered for more than 3 minutes. The fog light lens is made of synthetic resin, which may melt or be damaged due to excessive heat.

Start the engine.

Turn on the fog light and check if the cut off line falls within the specified area in the following illustration.

Adjust the aim vertically:
Adjust the aim of each fog light to the specified range by turning each aiming screw with a screwdriver.

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.

HINT:

If it is not possible to correctly adjust fog light aim, check bulb, fog light unit, and fog light unit reflector installation.