Headlight Assembly (For Halogen Headlight) Disassembly

Vehicle Exterior. Land Cruiser. Urj200, 202 Grj200 Vdj200
Lighting (Ext). Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. REMOVE FRONT TURN SIGNAL LIGHT BULB

  2. REMOVE FRONT TURN SIGNAL LIGHT SOCKET

  3. REMOVE CLEARANCE LIGHT BULB

  4. REMOVE NO. 1 HEADLIGHT BULB

  5. REMOVE NO. 2 HEADLIGHT BULB

  6. REMOVE HEADLIGHT CORD

  7. REMOVE FRONT BUMPER BAR REINFORCEMENT LH

  8. REMOVE HEADLIGHT LENS LH

  9. REMOVE HEADLIGHT LENS GASKET

Headlight Assembly (For Halogen Headlight) -- Disassembly


NOTICE:
  1. Handle components indoors as much as possible to prevent foreign matter from entering and adhering to headlight assembly components.
  2. Do not reuse parts which have reduced fastening ability due to thread damage.
  3. Do not touch the inner surface of the lens and metallic surfaces as much as possible, or they may become dirty.
  4. Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wiped with a soft cloth.
  5. When installing components, make sure that the wire harness is not pinched or pulled.
  6. Do not use solvent to clean components. Only clean them with a dry cloth.
HINT:
  1. Use the same procedure for the RH and LH sides.
  2. The procedure listed below is for the LH side.


1. REMOVE FRONT TURN SIGNAL LIGHT BULB


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Lighting (Ext).Lighting System.Headlight Assembly (For Halogen Headlight) Disassembly

  1. Turn the front turn signal light socket counterclockwise until the matchmark is aligned with the unlock position mark to disconnect the front turn signal light socket.

    Text in Illustration
    *a
    		Matchmark
    *b
    		Unlock Position Mark


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the front turn signal light bulb from the front turn signal light socket.



2. REMOVE FRONT TURN SIGNAL LIGHT SOCKET


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the connector and remove the front turn signal light socket.



3. REMOVE CLEARANCE LIGHT BULB


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Lighting (Ext).Lighting System.Headlight Assembly (For Halogen Headlight) Disassembly

  1. Turn the bulb socket counterclockwise until the matchmark is aligned with the unlock position mark to disconnect the bulb socket.

    Text in Illustration
    *a
    		Matchmark
    *b
    		Unlock Position Mark


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the clearance light bulb from the bulb socket.



4. REMOVE NO. 1 HEADLIGHT BULB


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the connector.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Turn the No. 1 headlight bulb counterclockwise until the bulb stops.

  1. Pull out the No. 1 headlight bulb and remove it.

    NOTICE:
    Do not touch the glass part of the No. 1 headlight bulb.


5. REMOVE NO. 2 HEADLIGHT BULB


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Disconnect the connector.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Turn the No. 2 headlight bulb counterclockwise until the bulb stops.

  1. Pull out the No. 2 headlight bulb and remove it.

    NOTICE:
    Do not touch the glass part of the No. 2 headlight bulb.


6. REMOVE HEADLIGHT CORD


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the 2 claws and disconnect the 2 connectors.

  1. Detach the wire harness clamp and remove the headlight cord.



7. REMOVE FRONT BUMPER BAR REINFORCEMENT LH


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 screws.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Detach the 2 guides and remove the front bumper reinforcement LH.



8. REMOVE HEADLIGHT LENS LH
NOTICE:
  1. Perform work using clean rubber gloves.
  2. Do not touch the inner surface of the lens and metallic surfaces as much as possible, or they may become dirty.
  3. Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wiped with a soft cloth.


    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 screws and inner bracket.



    Land Cruiser. Urj200, 202 Grj200 Vdj200

  1. Remove the 2 screws and outer bracket.



  1. Remove the 7 screws.


    Land Cruiser. Urj200, 202 Grj200 Vdj200.Lighting (Ext).Lighting System.Headlight Assembly (For Halogen Headlight) Disassembly


    Text in Illustration
    *A
    		Headlight Assembly LH Backside
    		*B
    		Headlight Assembly LH Surface


  1. Remove the headlight lens LH:

    NOTICE:
    1. Perform work using clean rubber gloves.
    2. Do not touch the inner surface of the lens and metallic surfaces as much as possible, or they may become dirty.
    3. Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wiped with a soft cloth.
    HINT:
    1. The connection between the headlight lens LH and headlight housing is extremely tight. Therefore, make sure to use the following method of using a dryer to warm and soften the headlight lens gasket to separate the headlight lens LH and headlight housing.
    2. With the headlight lens LH slightly lifted, cut the headlight lens gasket and separate the headlight lens LH.



    1. Using a dryer, warm the headlight lens gasket from the backside of the headlight assembly LH at the separation starting point of the headlight lens LH and headlight housing.

      NOTICE:
      If the headlight assembly LH is heated unevenly, it will deform or melt.
      HINT:
      1. If the headlight lens LH cannot be lifted, even after heating, using a screwdriver, lift the headlight lens LH.
      2. Tape the screwdriver tip before use.


      Land Cruiser. Urj200, 202 Grj200 Vdj200.Lighting (Ext).Lighting System.Headlight Assembly (For Halogen Headlight) Disassembly


      Text in Illustration
      *A
      		Headlight Assembly LH Surface
      		*B
      		Headlight Assembly LH Backside
      *a
      		Separation Starting Point
      		-
      		-

    2. Detach the 2 claws A and slightly lift the headlight lens LH.

    3. Heat the headlight lens gasket starting from the backside of the headlight assembly LH and finishing at the area around claw B.

    4. Detach the claw B and slightly lift the headlight lens LH.

    5. Heat the headlight lens gasket starting from the backside of the headlight assembly LH and finishing at the area around claw C.

    6. Detach the 2 claws C and slightly lift the headlight lens LH.

    7. Heat the headlight lens gasket starting from the backside of the headlight assembly LH and finishing at the area around claw D.



    8. Detach the 2 claws D and remove the headlight lens LH.


      Land Cruiser. Urj200, 202 Grj200 Vdj200.Lighting (Ext).Lighting System.Headlight Assembly (For Halogen Headlight) Disassembly


      Text in Illustration
      *a
      		Claw A
      		*b
      		Claw B
      *c
      		Claw C
      		*d
      		Claw D


9. REMOVE HEADLIGHT LENS GASKET
NOTICE:
  1. Perform work using clean rubber gloves.
  2. Do not touch the inner surface of the lens and metallic surfaces as much as possible, or they may become dirty.
  3. Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wiped with a soft cloth.
  4. The gasket must not be reused.

  1. Remove the headlight lens gasket from the headlight lens and headlight housing.

    HINT:
    Using a dryer, heat the headlight lens gasket. While softening the headlight lens gasket, remove it from the headlight lens LH and headlight housing.