RM35X0E _59 Vehicle Exterior _079256 LIGHTING (EXT) _0396098 HEADLIGHT ASSEMBLY(for LED Headlight) A

LIGHTING (EXT)  HEADLIGHT ASSEMBLY(for LED Headlight)  REASSEMBLY  


CAUTION / NOTICE / HINT

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.



PROCEDURE

Hide 85662 1.INSTALL HEADLIGHT LEVELING MOTOR LH

a.
B541950

Install the headlight leveling motor LH with the 2 screws.


b.
B541949

Connect the connector.


Hide 81160 2.INSTALL HEADLIGHT SUB-ASSEMBLY LH

NOTICE:
·

Prevention of static electricity is required during this procedure.

·

Use static electricity countermeasures SST (desktop antistatic mat set) and observe all precautions to prevent damage to the system by electrostatic discharge (ESD).

·

Perform work using clean rubber gloves.

·

Do not touch the headlight sub-assembly LH with bare hands.

·

Do not allow metallic surfaces to become dirty, as such surfaces become damaged even if they are only lightly wipe with a soft cloth.

·

If there are fingerprints on the inner surface of the lens, lightly wiped with a soft cloth.

·

Do not use solvent to clean components. Only clean them with a dry cloth.



SST
09890-47010  (09891-04020, 09891-04010, 09891-04030, 09891-04040)

a.
B541951

Set the headlight sub-assembly LH onto the left and right rails and aiming screws for beam axis vertical and horizontal adjustments.

HINT:

Set it into place by aligning the arrows shown in the illustration: black with black, and white with white.



b.
B541947C01
0,0 0,0 false
V113147

Tighten in this Direction


Hold the headlight sub-assembly LH with one hand to prevent it from tipping over and make the aiming screws for beam axis vertical and horizontal adjustments flush with the aiming screw holder by tightening it clockwise.

NOTICE:

Do not touch the metallic surface to the headlight sub-assembly LH.



c.
B541952

Connect the pivot.


d.
B541947C02
0,0 0,0 false
V113147

Tighten in this Direction


Tighten the aiming screws for beam axis vertical and horizontal adjustments until the protrusion amount is the same as that recorded.


e.
B541953

Install the 3 screws and install the headlight unit bezel.


f.
B541942

Connect the connector.


g.

Attach the clamp.


h.
B541940

Install the turn signal reflector with the 2 screws.


Hide 81132B 3.INSTALL HEADLIGHT LENS GASKET

NOTICE:
·

The headlight lens gasket must not be reused.

·

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.

·

If there are fingerprints on the inner surface of the lens, lightly wipe with a soft cloth.

·

Do not use solvent to clean components. Only clean them with a dry cloth.



a.
B541954C01
0,0 0,0 false
V100155

Area to Clean


Clean the headlight lens gasket installation groove.


b.

Prepare 2 screwdrivers, fold a piece of peeling paper over the tip of each screwdriver and fix the pieces of peeling paper in place with tape.

HINT:

Use the peeling paper that is supplied with the headlight lens gasket.



c.
E237693C17
1.323,1.281 1.365,1.042 false 0.625,1.125 0.667,0.896 false 1.229,1.292 1.531,1.542 0.302,0.25 10 *1 0.531,1.146 0.865,1.396 0.333,0.25 10 *2 1.458,0.469 1.698,0.635 0.24,0.167 10 (1) 0.177,0.604 0.417,0.771 0.24,0.167 10 (2) 1.479,1.875 2.01,2.177 0.531,0.302 10 *a
*1 Release Paper
*2 Tape
*a 45°


Partially remove the release paper from a new headlight lens gasket, and cut off a piece of it.


d.

Fold the release paper over the tip of a screwdriver and secure it in place with tape as indicated by the arrows, in the order shown in the illustration.


e.

Using scissors, cut the end of the headlight lens gasket at a 45° angle.


f.
B541955C02
0,0 0,0 false
V100144

Starting Position


Starting from the position shown in the illustration and moving clockwise, temporarily install the headlight lens gasket as shown in the illustration.

NOTICE:

Lightly set the gasket in place without pulling.



g.
B553433C01
0,0 0,0 false
V100135

Corner Groove


Set the headlight lens gasket into the corner groove.

NOTICE:
·

Lightly set the gasket in place without pulling.

·

If the headlight lens gasket is pulled while it is installed, it will not be installed properly in the corner groove.




h.
B541956C01
0,0 0,0 false
V113147

Press in this Direction
V100155

Release Paper


Using 2 screwdrivers with their tips wrapped with release paper, completely press the headlight lens gasket into the groove to install it.

NOTICE:
·

Lightly set the gasket in place without pulling.

·

If the headlight lens gasket is pulled while it is installed, it will not be installed properly in the corner groove.




i.
B541957C01
1.865,2.958 2.177,3.115 0.313,0.156 10 false *a
*a 5 to 15 mm (0.197 to 0.591 in.)
V100135

Corner Groove


Repeat the following until the headlight lens gasket reaches the starting position:

i.

Temporarily install the headlight lens gasket to the straight groove and completely press it into the groove, and then temporarily install it to the corner groove and completely press it into the groove.



j.

After installing the headlight lens gasket completely, check that the ends overlap for 5 to 15 mm (0.197 to 0.591 in.).


k.

Check the installation condition of the headlight lens gasket.

NOTICE:
·

Make sure the headlight lens gasket is not protruding and is installed properly.

·

Make sure there is no gap between the ends of the headlight lens gasket.

·

Make sure to thoroughly check the corners as the headlight lens gasket is likely to be improperly installed in the corners.




Hide 8110B 4.INSTALL HEADLIGHT LENS SUB-ASSEMBLY 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.

·

Do not use solvent to clean components. Only clean them with a dry cloth.



a.
B541958

Clean the headlight lens gasket contact surface.


b.

Set the headlight lens LH sub-assembly LH straight down in place.

NOTICE:
E317610C01
0,0 0,0 false
V100144

Headlight Lens Gasket
V100146

Headlight Housing
V100155

Headlight Lens Sub-assembly LH


Set the headlight lens LH sub-assembly LH in the middle of the headlight lens gasket as shown in the illustration.


B541938C01
0,0 0,0 false
V113147

Set in this Direction - -



c.

Check that the entire circumference of the headlight lens sub-assembly LH is positioned above the middle of the headlight lens gasket.


d.

Attach the claw and install the headlight lens sub-assembly LH.

B541933

HINT:

Install the headlight lens sub-assembly LH to the headlight housing from the starting point of installation toward the inside of the vehicle as shown in the illustration.

B541959C01
5.156,0.281 5.323,0.469 0.167,0.188 10 true *a
*a Installation Starting Point - -
V100135

Install in this order - -




e.
B541931C02
3.24,1.667 3.167,1.281 true 3.052,1.042 3.271,1.26 0.219,0.219 10 true *a
*a "TORX" Screw


Install the 7 screws.


f.

Using a T20H "TORX" driver, install the "TORX" screw.


g.

Check the condition of the headlight lens gasket.

OK:

Gasket contacts headlight lens sub-assembly LH and does not protrude out.



h.
B541930

Connect the connector.


i.
B541929C01
2.26,0.781 2.677,0.781 true 2.135,0.875 2.135,0.375 true 2.365,3.573 2.802,3.573 true 2.031,0.156 2.229,0.354 0.198,0.198 10 true *a 2.708,0.698 2.885,0.875 0.177,0.177 10 true *b 2.844,3.469 3.052,3.646 0.208,0.177 10 true *c
*a Matchmark
*b Unlock Position Mark
*c Lock Position Mark
V113147

Turn in this Direction


Align the matchmark of the headlight back cover with the unlock position mark, and then turn the headlight back cover clockwise until the lock position mark to install the headlight back cover.


Hide 81158 5.INSTALL HEADLIGHT BRACKET LH

a.
B541932

Attach the guide.


b.

Install the headlight bracket LH with the 2 screws.


Hide 81194A 8.INSTALL HEADLIGHT PROTECTOR LH

a.
B541919C01
0,0 0,0 false
V100155

Area to Clean


Clean the application area of the headlight protector LH shown in the illustration.

NOTICE:

Remove any remaining double-sided tape, and then clean and degrease the area.



b.
B541920

Remove approximately 3.0 cm (1.18 in.) of the peeling paper from a new headlight protector LH.


c.
B541921C01
0.51,2.271 0.729,2.479 0.219,0.208 10 true *a
*a Application Start Position
V113147

Set in this Direction


Align the angle of the headlight protector LH with the application start position, and then set only the part with peeling paper removed into place.


d.

Press the set portion of the part with your finger to secure it.

NOTICE:

Do not slide your finger horizontally, as doing so may stretch the part unnecessarily.



e.
B541922C01
0,0 0,0 false
V113147

Remove in this Direction


Align with the curve and set only the part where the peeling type tape was removed from into place.


f.
B541923C01
0,0 0,0 false
V100155

Press Area


Press the entire length of the headlight seal and install it.

NOTICE:

When pressing, do not slide your finger, as doing so may stretch the part.



Hide 81510C 9.INSTALL FRONT TURN SIGNAL LIGHT BULB

a.
E413162C02
0,0 0,0 false
V113147

Install in this Direction


Install the front turn signal light bulb to the bulb socket.


b.
B541917C01
2.073,0.875 2.01,0.427 true 2.208,0.771 2.448,0.771 true 2.323,3.604 2.49,3.448 true 1.927,0.229 2.115,0.406 0.188,0.177 10 true *a 2.479,0.688 2.677,0.875 0.198,0.188 10 true *b 2.49,3.292 2.688,3.49 0.198,0.198 10 true *c
*a Matchmark
*b Unlock Position Mark
*c Lock Position Mark
V113147

Turn in this Direction


Align the matchmark of the bulb socket with the unlock position mark, and then turn the bulb socket clockwise until the lock position mark to connect the bulb socket.


c.
B541915

Connect the connector.