Lighting (Ext). Headlight Assembly (For Halogen Headlight And Led Headlight) Disassembly

Vehicle Exterior. Land Cruiser. Urj200, 202 Grj200 Vdj200

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

REMOVE HEADLIGHT SOCKET COVER
REMOVE NO. 2 HEADLIGHT BULB
REMOVE FRONT TURN SIGNAL LIGHT BULB
REMOVE FRONT TURN SIGNAL LIGHT SOCKET
REMOVE HEADLIGHT BRACKET LH (for Outside)
REMOVE HEADLIGHT BRACKET LH (for Inside)
REMOVE FRONT BUMPER BAR REINFORCEMENT LH
REMOVE HEADLIGHT LENS LH
REMOVE HEADLIGHT LENS GASKET
REMOVE HEADLIGHT UNIT LH
REMOVE HEADLIGHT LEVELING MOTOR LH
REMOVE HEADLIGHT LEVELING MOTOR BASE PACKING

Headlight Assembly (For Halogen Headlight And Led Headlight) -- Disassembly

NOTICE:

Handle components indoors as much as possible to prevent foreign matter from entering and adhering to headlight assembly components.
Do not reuse parts which have reduced fastening ability due to thread damage.
Do not touch the inner surface of the lens and metallic surfaces as much as possible, or they may become dirty.
Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wiped with a soft cloth.
When installing components, make sure that the wire harness is not pinched or pulled.
Do not use solvent to clean components. Only clean them with a dry cloth.

HINT:

Use the same procedure for the RH and LH sides.
The procedure listed below is for the LH side.

1. REMOVE HEADLIGHT SOCKET COVER

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

Turn the headlight socket cover counterclockwise until the matchmark is aligned with the unlock position mark to remove the headlight socket cover.
Text in Illustration
*a
Matchmark
*b
Unlock Position Mark

Text in Illustration
*a	Matchmark
*b	Unlock Position Mark

2. REMOVE NO. 2 HEADLIGHT BULB

Disconnect the connector.

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

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

3. REMOVE FRONT TURN SIGNAL LIGHT BULB

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

Text in Illustration
*a	Matchmark
*b	Unlock Position Mark

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

4. REMOVE FRONT TURN SIGNAL LIGHT SOCKET

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

5. REMOVE HEADLIGHT BRACKET LH (for Outside)

Remove the 3 screws and headlight bracket LH.

6. REMOVE HEADLIGHT BRACKET LH (for Inside)

Remove the 3 screws and headlight bracket LH.

7. REMOVE FRONT BUMPER BAR REINFORCEMENT LH

Remove the 2 screws.

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

8. REMOVE HEADLIGHT LENS LH

NOTICE:

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

Remove the 2 screws and inner bracket.

Remove the 2 screws and outer bracket.

Turn the locking cap counterclockwise until the matchmark is aligned with the unlock position mark to remove the locking cap.
Text in Illustration
*a
Matchmark
*b
Unlock Position Mark

Text in Illustration
*a	Matchmark
*b	Unlock Position Mark

Disconnect the connector.

Remove the 7 screws.

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

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

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.
  
  Text in Illustration
  *A
  Headlight Assembly LH Surface
  *B
  Headlight Assembly LH Backside
  *a
  Separation Starting Point
  -
  -
  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.
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.
  
  Text in Illustration
  *a
  Claw A
  *b
  Claw B
  *c
  Claw C
  *d
  Claw D

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

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

9. REMOVE HEADLIGHT LENS GASKET

NOTICE:

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

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.

10. REMOVE HEADLIGHT UNIT LH

NOTICE:

Perform work using clean rubber gloves.
Do not touch the headlight unit LH with bare hands.
Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wiped with a soft cloth.

Using a vernier caliper, measure and record the protrusion amount of the horizontal and vertical aiming screw.

Text in Illustration
*a
Protrusion Amount Measurement Area
-
-

Text in Illustration
*a	Protrusion Amount Measurement Area	-	-

Disconnect the connector.

Using a screwdriver, detach the 6 claws and remove the headlight unit LH.

Text in Illustration

Protective Tape
-
-

Text in Illustration
	Protective Tape	-	-

Remove the leveling motor joint.
HINT:
Install the removed leveling motor joint to the headlight unit LH.

Turn the aiming screw joint counterclockwise and remove it.
HINT:
1. Use the same procedure to remove the aiming screw joint on the other side.
2. Install the removed aiming screw joint to the headlight unit LH.

11. REMOVE HEADLIGHT LEVELING MOTOR LH

Disconnect the connector.

Turn the headlight leveling motor LH counter clockwise and remove it.

12. REMOVE HEADLIGHT LEVELING MOTOR BASE PACKING

Remove the headlight leveling motor base packing from the headlight leveling motor LH.
NOTICE:
The packing must not be reused.