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

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


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 81510C 1.REMOVE FRONT TURN SIGNAL LIGHT BULB

a.
B541915

Disconnect the connector.


b.
B541916C01
2.302,1.5 2.146,1.125 true 2.604,3.25 2.208,3.25 true 2.292,1.542 2.5,1.74 0.208,0.198 10 true *a 2.646,3.167 2.854,3.344 0.208,0.177 10 true *b
*a Matchmark
*b Unlock Position Mark
V113147

Turn in this Direction


Turn the bulb socket counterclockwise until the matchmark is aligned with the unlock position mark and remove it.


c.
E413161C02
0,0 0,0 false
V113147

Remove in this Direction


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


Hide 81194A 2.REMOVE HEADLIGHT PROTECTOR LH

a.
B541918

Remove the headlight protector LH.

NOTICE:

The headlight protector LH must not be reused.



Hide 81158 5.REMOVE HEADLIGHT BRACKET LH

a.
B541932

Remove the 2 screws.


b.

Detach the guide and remove the headlight bracket LH.


Hide 8110B 6.REMOVE 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.
B541928C01
2.188,1.104 2.833,1.563 true 2.948,3.563 2.26,3.26 true 2.885,1.542 3.115,1.729 0.229,0.188 10 true *a 2.99,3.531 3.198,3.719 0.208,0.188 10 true *b
*a Matchmark
*b Unlock Position Mark
V113147

Turn in this Direction


Turn the headlight back cover counterclockwise until the matchmark is aligned with the unlock position mark and remove it.


b.
B541930

Disconnect the connector.


c.
B541931C01
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


Remove the 8 screws.


d.

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


e.

Detach the claw.

B541933


f.
B524515C01
1.906,1.104 2.219,1.26 0.313,0.156 10 false *a
*a 7.6 mm (0.299 in.)


Prepare a cable tie with a width of 7.6 mm (0.299 in.).

HINT:

Cable ties with a narrow width (2.5 mm (0.0984 in.) etc.) are difficult to pull out through the headlight lens gasket.



g.
B541934

Using a dryer, warm the area around the cable tie insertion area on the headlight lens gasket at the rear of the headlight housing.

NOTICE:

If the headlight is heated unevenly, it will deform or melt.


HINT:

The headlight lens gasket becomes soft and easy to pull through when warmed.



h.
B541935C01
0,0 0,0 false
V100143

Cable Tie
V100144

Headlight Lens Gasket
V100145

Headlight Lens Sub-assembly LH
V100146

Headlight Housing


Insert a cable tie between the headlight lens sub-assembly LH and headlight housing and pull out the headlight lens gasket as shown in the illustration.

NOTICE:

Do not damage the groove in the headlight housing or the surface of the headlight lens sub-assembly LH.



i.
B541936C01
0,0 0,0 false
V113147

Remove in this Direction


Pull out the headlight lens gasket in the direction indicated by the arrow until the headlight lens sub-assembly LH and headlight housing adhesion is gone.

HINT:

If the headlight lens gasket is disconnected while being pulled out, insert a cable tie between the headlight lens sub-assembly LH and headlight housing and pull out the headlight lens gasket again.



j.

Lift up the headlight lens sub-assembly LH directly upwards and remove it.

B541937C01
0,0 0,0 false
V113147

Remove in this Direction - -



Hide 81132B 7.REMOVE 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.

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

B541939C01
0.167,0.188 0.583,0.521 0.417,0.333 12 false *A 3.458,0.177 3.875,0.51 0.417,0.333 12 false *B
*A Headlight Lens Side *B Headlight Housing Side
V100144

Headlight Lens Gasket - -



Hide 81160 8.REMOVE 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 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.



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

a.
B541940

Remove the 2 screws and turn signal reflector.


b.
B541941

Disconnect the connector.


c.
B541943

Remove the 3 screws.


d.
B541944

Detach the clamp and remove the headlight unit bezel.


e.
B541945C01
0.552,3.094 0.729,3.281 0.177,0.188 10 true *a 2.719,3.146 2.896,3.333 0.177,0.188 10 true *a
*a Protrusion Amount Measurement Area


Using a vernier caliper, measure and record the dimensions of the protrusion of the aiming screws for beam axis vertical and horizontal adjustments.


f.
B541946C01
0,0 0,0 false
V113147

Loosen in this Direction


Hold the headlight sub-assembly LH with one hand to prevent it from tipping over and loosen the aiming screws for beam axis vertical and horizontal adjustments counterclockwise by 10 turns.


g.
B541968

Detach the claw and disconnect the headlight sub-assembly LH from the pivot collar.


h.
B541946C01
0,0 0,0 false
V113147

Loosen in this Direction


Hold the headlight sub-assembly LH with one hand to prevent it from tipping over and loosen the aiming screws for beam axis vertical and horizontal adjustments counterclockwise until the headlight sub-assembly LH is disconnected.


i.
B541948C01
0,0 0,0 false
V113147

Remove in this Direction.


Detach the guide and remove the pivot collar as shown in the illustration.


j.

Install the removed pivot collar to the headlight sub-assembly LH.


Hide 85662 9.REMOVE HEADLIGHT LEVELING MOTOR LH

a.
B541949

Disconnect the connector.


b.
B541950

Remove the 2 screws and headlight leveling motor LH.