Headlamp Repair Procedures

Removal

Headlamps become very hot during use; do not touch them or any attached equipment immediately after switching them off.

Do not remove the headlamp bulb from the headlamp assembly until a new bulb is ready to be installed. Leaving the bulb removed for an extended period may affect headlamp performance. Contaminants may enter the lamp housing and settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp assembly.

1. 1
   Disconnect the negative (-) battery terminal.
2. 2
   Remove the front bumper. (Refer to Body - "Front Bumper")
3. 3
   Disconnect the headlamp connector (A).

   

   Be careful not to damage the locking clip (A).

4. 4
   Remove the headlamp (A) after loosening the bolts.

   

   

Installation

1. 1
   Install the headlamp bulbs.
2. 2
   Install the headlamp bulb covers.
3. 3
   Assemble the headlamp assembly after connecting the bulb connector.

Replacement

Turn off the headlamp switch to avoid high voltage. Be careful not to damage the bulb, and use only genuine bulbs. Do not apply excessive force, and install it correctly. Check that the bulb is locked.

Bulb (high/low)

1. 1
   Turn off the headlamp switch.
2. 2
   Disconnect the power connector from the bulb.
3. 3
   Remove the bulb assembly.
4. 4
   Remove the dust cover.
5. 5
   Disconnect the connector (A) from the bulb.

   

6. 6
   Remove the bulb clip (B) and the bulb from the lamp assembly.
7. 7
   Installation is the reverse of removal.
8. 8
   Turn off the headlamp switch.
9. 9
   Remove the bulb assembly.
10. 10
    Turn the bulb socket (A) counterclockwise to remove the turn signal bulb (B).

    

Turn signal lamp and side marker lamp

Adjustment

Headlamp Aiming Instructions Headlamps must be aimed using correct beam setting equipment and in accordance with the equipment manufacturer's instructions.

If there are any regulations regarding headlamp aiming in the area where the vehicle will be used, adjust the aim to meet those requirements.

Alternately turn the adjusting mechanism to adjust the headlamp aim. If beam setting equipment is not available, proceed as follows:

1. 1
   Inflate the tires to the specified pressure and remove all loads from the vehicle except the driver, spare tire, and tools.
2. 2
   The vehicle must be on a level floor.
3. 3
   Draw vertical lines (vertical lines passing through the respective centers of the headlamps) and a horizontal line (horizontal line passing through the center of the headlamps) on the screen.
4. 4
   With the headlamp and battery in normal condition, aim the headlamps so that the brightest part is on the vertical lines. Adjust the vertical (A) low beam using the adjusting wheel.

   

   

   

   

5. 5
   General type

   A.	Turn on the low beam without the driver.

   B.	The cutoff line must project within the allowable range (shaded area) shown in the illustration.

   C.	If a headlamp leveling device is installed, set the headlamp leveling switch to position 0.

   

6. 6
   Turn on the front fog lamps with the driver seated in the vehicle. The cutoff line must project within the allowable range shown in the illustration.

   

Front Fog Lamp Aiming Front fog lamps must be aimed in the same way as the headlamps. With the front fog lamps and battery in normal condition, aim the front fog lamps by turning the adjusting mechanism (A). Aiming point of headlamps and fog lamps