Toyota Highlander manuals

Toyota Highlander Service Manual: Overhaul

HINT:

1. REMOVE RADIATOR GRILLE (SEE PAGE 76-2 )

2. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY LH (SEE PAGE 76-2 )

3. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSY RH (SEE PAGE 76-2 )

4. REMOVE FRONT BUMPER COVER (SEE PAGE 76-2 )

5. REMOVE LH HEADLAMP ASSY

REMOVE LH HEADLAMP ASSY


(a) Remove the 2 screws.

REMOVE LH HEADLAMP ASSY


(b) Pull out the LH headlamp assy forward, then release the pin and the headlamp bracket.

(c) Disconnect the connectors, and remove the LH head lamp assy.

6. REMOVE HEADLAMP, NO.1 BULB

REMOVE HEADLAMP, NO.1 BULB


(a) Remove the headlamp, No.1 bulb as shown in the illustration.

7. REMOVE HEADLAMP, NO.2 BULB

 REMOVE HEADLAMP, NO.2 BULB


(a) Remove the headlamp, No.2 bulb as shown in the illustration.

8. REMOVE CLEARANCE LAMP BULB

REMOVE CLEARANCE LAMP BULB


(a) Remove the clearance lamp bulb and the socket as shown in the illustration.

(b) Remove the clearance lamp bulb from the socket as shown in the illustration.

9. REMOVE CLEARANCE LAMP SOCKET & WIRE

10. REMOVE HEADLAMP UNIT LH

11. INSTALL HEADLAMP PROTECTOR RETAINER UPPER LH

HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair.

 INSTALL HEADLAMP PROTECTOR RETAINER UPPER LH


(a) Cut off the part shaded in the illustration and sand smooth with sandpaper.

NOTICE: After cutting off the part, place the headlamp protector retainer upper LH against the bosses and gradually file away until installation is possible.

 INSTALL HEADLAMP PROTECTOR RETAINER UPPER LH


(b) Install the headlamp protector retainer upper LH with the 2 screws.

12. INSTALL HEADLAMP PROTECTOR RETAINER LWR LH

HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair.

INSTALL HEADLAMP PROTECTOR RETAINER LWR LH


(a) Cut off the part shaded in the illustration and sand smooth with sandpaper.

NOTICE: After cutting off the part, place the headlamp protector retainer LWR LH against the bosses and gradually file away until installation is possible.

INSTALL HEADLAMP PROTECTOR RETAINER LWR LH


(b) Install the headlamp protector retainer LWR LH with the 2 screws.

13. INSTALL HEADLAMP BRACKET LWR LH

HINT: To minimize damage to the headlamp unit in case of a collision, the stays for the headlamp unit have been constructed to break off. The stays are available as supply parts for low-cost repair.

INSTALL HEADLAMP BRACKET LWR LH


(a) Cut off the part shaded in the illustration and sand smooth with sandpaper.

NOTICE: After cutting off the part, place the headlamp bracket LWR LH against the bosses and gradually file away until installation is possible.

INSTALL HEADLAMP BRACKET LWR LH


(b) Install the headlamp bracket LWR LH with the screw.

14. VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT (SEE PAGE 65-14 )

15. PREPARATION FOR HEADLAMP AIMING (Using a screen) (SEE PAGE 65-14 )

16. HEADLAMP AIMING INSPECTION (SEE PAGE 65-14 )

17. HEADLAMP AIMING ADJUSTMENT (SEE PAGE 65-14 )

LH headlamp ASSY
COMPONENTS ...

Adjustment
1. VEHICLE PREPARATION FOR HEADLAMP AIM ADJUSTMENT (a) Prepare the vehicle: Ensure there is no damage or deformation to the body around the headlamps. Fill the fuel tank. Make sure that th ...

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