Tài liệu hướng dẫn sửa chữa Hệ thống chiếu sáng trên xe 28 2005 2006 toyota hilux factory service manual lighting system he thong chieu sang. Cung cấp các thông tin cần thiết cho Kỹ thuật viện tiến hành chẩn đoán, sửa chữa nhanh chóng, chính xác
LI–18 LIGHTING – FOG LIGHT ASSEMBLY INSTALLATION INSTALL FOG LIGHT ASSEMBLY (a) Install the fog light bulb into the light socket (b) To install the fog light bulb socket and bulb, turn them in the direction indicated by the arrow in the illustration E076084E01 (c) Engage the claws and install the fog light assembly LH (d) Connect the connector E076082E01 LI CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) VEHICLE PREPARATION FOR FOG LIGHT AIM ADJUSTMENT (See page LI-14) PREPARATION FOR FOG LIGHT AIMING (See page LI-14) FOG LIGHT AIMING INSPECTION (See page LI-16) FOG LIGHT AIMING ADJUSTMENT (See page LI-17) LI–20 LIGHTING – REAR COMBINATION LIGHT ASSEMBLY INSTALLATION INSTALL REAR COMBINATION LIGHT ASSEMBLY (a) Install the light bulbs into the light sockets (b) To install the light bulb sockets and bulbs, turn them in the direction indicated by the arrow in the illustration (c) Install the wire harness clamp E076086E01 (d) Connect the connector, then install the tail light (rear combination light) assembly LH with the bolts Torque: 5.4 N*m (55 kgf*cm, 48 in.*lbf) E076052E01 LI CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) LIGHTING – LICENSE PLATE LIGHT ASSEMBLY LI–23 INSTALLATION REMOVE LICENSE PLATE LIGHT ASSEMBLY (a) Install the license plate light bulb into the light socket (b) To install the license plate light bulb socket and bulb, turn them in the direction indicated by the arrow in the illustration E076087E01 (c) Install the license plate light assembly with the screw CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) E076068E01 LI LIGHTING – HIGH MOUNTED STOP LIGHT ASSEMBLY LI–25 INSTALLATION INSTALL CENTER STOP LIGHT ASSEMBLY (a) Install the center stop light bulbs into the light sockets (b) To install the center stop light sockets and bulbs, turn them in the direction indicated by the arrow in the illustration (c) Install the wire harness clamp E076089E01 (d) Connect the connector E076055E01 (e) Install the center stop light assembly with the screws CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) E076054E01 LI LI–30 LIGHTING – HEADLIGHT DIMMER SWITCH INSPECTION Connector Front side: E8 E076075E01 INSPECT HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Check the resistance of the light control switch (1) Measure the resistance using an ohmmeter, and check the results in accordance with the value(s) in the table below Standard Tester Connection Condition Specified Condition - OFF 10 kΩ or higher 12-18 TAIL Below 1Ω 12-18-20 HEAD Below 1Ω If the result is not as specified, replace the headlight dimmer switch assembly (b) Check the resistance of the headlight dimmer switch (1) Measure the resistance using an ohmmeter, and check the results in accordance with the value(s) in the table below Standard Tester Connection Condition Specified Condition 11-12-17 FLASH Below 1Ω 12-16 LOW BEAM Below 1Ω 11-12 HI BEAM Below 1Ω If the result is not as specified, replace the headlight dimmer switch assembly (c) Check the resistance of the turn signal switch (1) Measure the resistance using an ohmmeter, and check the results in accordance with the value(s) in the table below Standard Tester Connection Condition Specified Condition 12-13 Right turn Below 1Ω - Neutral 10 kΩ or higher 12-15 Left turn Below 1Ω If the result is not as specified, replace the headlight dimmer switch assembly INSTALLATION LI E068372E06 INSTALL HEADLIGHT DIMMER SWITCH ASSEMBLY (a) Engage the claws and install the headlight dimmer switch assembly as shown in the illustration LIGHTING – HEADLIGHT DIMMER SWITCH LI–31 (b) Install the headlight dimmer switch assembly with the clamp (c) Connect the connector INSTALL WINDSHIELD WIPER SWITCH ASSEMBLY (See page WW-19) INSTALL SPIRAL CABLE SUB-ASSEMBLY (See page RS-567) INSTALL STEERING COLUMN UPPER COVER (See page SR-18) INSTALL STEERING COLUMN LOWER COVER (See page SR-18) CENTER SPIRAL CABLE (See page RS-567) INSTALL STEERING WHEEL ASSEMBLY (See page SR-18) INSPECT STEERING WHEEL CENTER POINT INSPECT HORN BUTTON ASSEMBLY I037768E05 10 INSTALL HORN BUTTON ASSEMBLY 11 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 12 INSPECT SRS WARNING LIGHT 13 INSTALL NO STEERING WHEEL LOWER COVER (See page RS-559) 14 INSTALL NO STEERING WHEEL LOWER COVER (See page RS-559) LI LIGHTING – LIGHTING SYSTEM LI–1 LIGHTING SYSTEM PRECAUTION PRECAUTION OF HEADLIGHT BULB REPLACEMENT (a) If even a thin film of oil is left on the surface of the halogen light, its service life will be shortened because the light will burn at a higher temperature (b) Handle any halogen light with great care Dropping, hitting or damaging the bulb in any way may result in exploding and shattering it because the internal pressure is high (c) Always prepare a new bulb for immediate replacement While replacing the bulb, the lens may attract dust and moisture if removed from the vehicle for too long (d) Always use a bulb of the same wattage for replacement (e) Firmly reinstall the socket after bulb replacement The lens may become cloudy or the light cavity may fill with water through the gaps around the socket LI LI–2 LIGHTING – HEADLIGHT ASSEMBLY HEADLIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS CLIP FRONT FENDER LINER RH CLIP CLIP FRONT BUMPER FILLER CLIP FRONT FENDER LINER LH CLIP RADIATOR GRILLE CLIP CLIP FRONT BUMPER COVER LI CLIP CLIP E076117E01 LI–3 LIGHTING – HEADLIGHT ASSEMBLY FRONT TURN SIGNAL LIGHT BULB SOCKET FRONT TURN SIGNAL LIGHT BULB NO HEADLIGHT, BULB SOCKET COVER CLEARANCE LIGHT BULB SOCKET HEADLIGHT ASSEMBLY CLEARANCE LIGHT BULB 2.0 (20, 17 in.*lbf) Bracket for Repair: x2 x2 x2 HEADLIGHT PROTECTOR LOWER RETAINER HEADLIGHT PROTECTOR UPPER RETAINER HEADLIGHT LOWER BRACKET LI N*m (kgf*cm, ft*lbf) : Specified torque E076118E01 LIGHTING – FOG LIGHT ASSEMBLY LI–13 FOG LIGHT ASSEMBLY BODY ELECTRICAL LIGHTING COMPONENTS FOG LIGHT BULB FOG LIGHT ASSEMBLY LI E076093E01 LI–54 LIGHTING – TOWING CONVERTER RELAY 30 REMOVE FRONT CONSOLE BOX (for Automatic Transmission on Separate Seat Type) (See page IP10) 31 REMOVE FRONT CONSOLE BOX (for Manual Transmission on Separate Seat Type) (See page IP11) 32 REMOVE FRONT CONSOLE BOX (for Automatic Transmission on Bench Seat Type) (See page IP-11) 33 REMOVE FRONT CONSOLE BOX (for Manual Transmission on Bench Seat Type) (See page IP-11) 34 REMOVE AIR CONDITIONING CONTROL ASSEMBLY (See page IP-12) 35 REMOVE RADIO RECEIVER ASSEMBLY (See page AV-69) 36 SEPARATE HOOD LOCK CONTROL LEVER SUBASSEMBLY (See page ED-3) 37 REMOVE LOWER NO INSTRUMENT PANEL FINFISH PANEL (See page IP-12) 38 REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See page IP-12) 39 REMOVE COMBINATION METER ASSEMBLY (See page IP-13) 40 REMOVE INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY (See page IP-13) 41 REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-13) 42 REMOVE INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY RH (See page IP-14) 43 REMOVE LOWER INSTRUMENT PANEL LH (See page IP-14) 44 REMOVE LOWER INSTRUMENT COVER SUBASSEMBLY (See page IP-14) 45 REMOVE INSTRUMENT SIDE PANEL RH (See page IP-14) 46 DISCONNECT PASSENGER AIRBAG CONNECTOR (See page RS-576) 47 REMOVE INSTRUMENT PANEL SUB-ASSEMBLY W/ PASSENGER AIRBAG ASSEMBLY (See page IP-14) LI LIGHTING – TOWING CONVERTER RELAY LI–55 48 REMOVE TOWING CONVERTER RELAY (a) Disconnect the connector (b) Remove the bolt and towing converter relay E076057E01 INSTALLATION E076057E01 INSTALL TOWING CONVERTER RELAY (a) Install the towing converter relay with the bolt Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf) (b) Connect the connector INSTALL INSTRUMENT PANEL SUB-ASSEMBLY W/ PASSENGER AIRBAG ASSEMBLY (See page IP-18) CONNECT PASSENGER AIRBAG CONNECTOR INSTALL INSTRUMENT SIDE PANEL RH (See page IP-20) INSTALL INSTRUMENT LOWER COVER SUBASSEMBLY (See page IP-20) INSTALL LOWER INSTRUMENT PANEL LH (See page IP-20) INSTALL INSTRUMENT PANEL LOWER FINISH PANEL SUB-ASSEMBLY RH (See page IP-20) INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY (See page IP-20) INSTALL INSTRUMENT CLUSTER CENTER FINISH PANEL SUB-ASSEMBLY (See page IP-21) 10 INSTALL COMBINATION METER ASSEMBLY (See page IP-21) 11 INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSEMBLY (See page IP-21) 12 INSTALL LOWER NO.1 INSTRUMENT PANEL FINISH PANEL (See page IP-22) 13 CONNECT HOOD LOCK CONTROL LEVER SUBASSEMBLY (See page ED-8) 14 INSTALL RADIO RECEIVER ASSEMBLY (See page AV-70) 15 INSTALL AIR CONDITIONING CONTROL ASSEMBLY (See page IP-22) 16 INSTALL FRONT CONSOLE BOX (for Manual Transmission on Bench Seat Type) (See page IP-22) 17 INSTALL FRONT CONSOLE BOX (for Automatic Transmission on Bench Seat Type) (See page IP-23) LI LI–56 LIGHTING – TOWING CONVERTER RELAY 18 INSTALL FRONT CONSOLE BOX (for Manual Transmission on Separate Seat Type) (See page IP23) 19 INSTALL FRONT CONSOLE BOX (for Automatic Transmission on Separate Seat Type) (See page IP24) 20 INSTALL INSTRUMENT PANEL CUP HOLDER TRAY (for Automatic Transmission on Separate Seat Type) (See page IP-24) 21 INSTALL REAR CONSOLE BOX ASSEMBLY (for Separate Seat Type) (See page IP-24) 22 INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY (for Manual Transmission on Separate Seat Type) (See page IP-25) 23 INSTALL CONSOLE UPPER REAR PANEL SUBASSEMBLY (for Automatic Transmission on Separate Seat Type) (See page IP-25) 24 INSTALL INSTRUMENT PANEL HOLE COVER (for Lever Type Parking Brake) (See page IP-25) 25 INSTALL INSTRUMENT PANEL UNDER TRAY (for Pedal Type Parking Brake) (See page IP-25) 26 INSTALL FRONT PILLAR GARNISH LH (for Regular Cab) (See page IR-51) 27 INSTALL FRONT PILLAR GARNISH LH (for Access Cab) (See page IR-74) 28 INSTALL FRONT PILLAR GARNISH LH (for Double Cab) (See page IR-28) 29 INSTALL FRONT PILLAR GARNISH RH (for Regular Cab) (See page IR-52) 30 INSTALL FRONT PILLAR GARNISH RH (for Access Cab) (See page IR-74) 31 INSTALL FRONT PILLAR GARNISH RH (for Double Cab) (See page IR-28) 32 INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP LH 33 INSTALL FRONT DOOR OPENING TRIM WEATHERSTRIP RH LI 34 INSTALL COWL SIDE TRIM BOARD LH (for Regular Cab) (See page IR-52) 35 INSTALL COWL SIDE TRIM BOARD LH (for Access Cab) (See page IR-75) 36 INSTALL COWL SIDE TRIM BOARD LH (for Double Cab) (See page IR-29) 37 INSTALL COWL SIDE TRIM BOARD RH (for Regular Cab) (See page IR-52) LIGHTING – TOWING CONVERTER RELAY LI–57 38 INSTALL COWL SIDE TRIM BOARD RH (for Access Cab) (See page IR-75) 39 INSTALL COWL SIDE TRIM BOARD RH (for Double Cab) (See page IR-29) 40 INSTALL FRONT DOOR SCUFF PLATE LH (for Regular Cab) (See page IR-52) 41 INSTALL FRONT DOOR SCUFF PLATE LH (for Access Cab) (See page IR-75) 42 INSTALL FRONT DOOR SCUFF PLATE LH (for Double Cab) (See page IR-29) 43 INSTALL FRONT DOOR SCUFF PLATE RH (for Regular Cab) (See page IR-52) 44 INSTALL FRONT DOOR SCUFF PLATE RH (for Access Cab) (See page IR-75) 45 INSTALL FRONT DOOR SCUFF PLATE RH (for Double Cab) (See page IR-29) 46 INSTALL FRONT FLOOR FOOTREST (See page IR-1) 47 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 48 INSPECT SRS WARNING LIGHT (See page RS-28) LI LI–6 LIGHTING – HEADLIGHT ASSEMBLY ADJUSTMENT LI VEHICLE PREPARATION FOR HEADLIGHT AIM ADJUSTMENT (a) Prepare the vehicle: • Ensure that there is no damage or deformation to the body around the headlights • Fill the fuel tank • Make sure that the oil is filled to the specified level • Make sure that the coolant is filled to the specified level • Inflate the tires to the appropriate pressure • Place the spare tire, tools, and jack in their original positions • Unload the trunk • Sit a person of average weight (68 kg, 150 lb) in the driver side seat PREPARATION FOR HEADLIGHT AIMING (for Using a Tester) (a) Prepare the vehicle for headlight aim check (b) Perform adjustment in accordance with the headlight tester instructions PREPARATION FOR HEADLIGHT AIMING (for Using a Screen) (a) Prepare the vehicle according to the following conditions: • Place the vehicle in a location that is dark enough to clearly observe the cutoff line The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot • Place the vehicle at a 90° angle to the wall • Keep a 7.62 m (25 ft) distance between the center of the headlight bulb and the wall • Place the vehicle on a level surface • Bounce the vehicle up and down to settle the suspension NOTICE: A distance of 7.62 m (25 ft) between the vehicle (center of the headlight bulb) and the wall is necessary for proper aim adjustment If unavailable to secure a distance of 7.62 m (25 ft), secure a distance of exactly m (9.84 ft) to check and adjust the headlight aim (Since the target zone will change with the distance, follow the instructions shown in the illustration.) (b) Prepare a piece of thick white paper (approximately m (6.6 ft) (height) x m (13.1 ft) (width)) to use as a screen (c) Draw a vertical line down the center of screen (V line) LI–7 LIGHTING – HEADLIGHT ASSEMBLY (d) Set the screen as shown in the illustration Aligning distance 7.62 m (25 ft) Aligning distance m (9.84 ft) V RH Line V RH Line 90q 90q V Line 7.62 m (25 ft) m (9.84 ft) V LH Line V Line V LH Line H Line H Line 90q 90q 7.62 m (25 ft) m (9.84 ft) E076099E01 HINT: • Stand the screen perpendicular to the ground • Align the V line on the screen with the center of the vehicle V LH Line V Line V RH Line H Line Ground I033423E08 (e) Draw base lines (H line, V LH, V RH lines) on the screen as shown in the illustration HINT: • The base lines differ for "low-beam inspection" and "high-beam inspection" • Follow the same procedures as for "high-beam inspection" • Mark the headlight bulb center marks on the screen If the center mark cannot be observed on the headlight, use the center of the headlight bulb or the manufacturer name marked on the headlight as the center mark (1) H Line (Headlight height): Draw a horizontal line across the screen so that it passes through the center marks The H line should be at the same height as the headlight bulb center marks of the low-beam headlights (2) V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights): Draw two vertical lines so that they intersect the H line at each center mark (aligned with the center of the low-beam headlight bulbs) LI LI–8 LIGHTING – HEADLIGHT ASSEMBLY HEADLIGHT AIMING INSPECTION (a) Cover the headlight or disconnect the connector of the headlight on the opposite side to prevent light from the headlight not being inspected from affecting headlight aiming inspection NOTICE: Do not keep the headlight covered for more than minutes The headlight lens is made of synthetic resin, and may easily melt or be damaged due to heat (b) Start the engine NOTICE: Engine rpm must be 1,500 or more (c) Turn on the headlight and make sure that the cutoff line falls within the specified area, as shown in the illustration Aligning distance 7.62 m (25 ft): Aligning distance m (9.84 ft): Low Beam: Low Beam: V LH Line V RH Line 101 mm (3.97 in.) mm (0 in.) 40 mm (1.57 in.) H Line H Line 101 mm (3.97 in.) 40 mm (1.57 in.) Cutoff Line High Beam: 101 mm (3.97 in.) 101 mm (3.97 in.) V LH Line V RH Line Cutoff Line High Beam: 101 mm (3.97 in.) 40 mm (1.57 in.) H Line H Line 101 mm (3.97 in.) 40 mm (1.57 in.) 101 mm (3.97 in.) 101 mm (3.97 in.) V LH Line V RH Line mm (0 in.) 40 mm (1.57 in.) 40 mm (1.57 in.) V LH Line V RH Line 40 mm (1.57 in.) 40 mm (1.57 in.) LI E113067E01 HINT: • Alignment distance is 7.62 m (25 ft): The cutoff line is 101 mm (3.97 in.) above and below the H line as well as to the left and right of the V line with low-beam (SAEJ599) LIGHTING – HEADLIGHT ASSEMBLY LI–9 • Alignment distance is m (9.84 ft): The cutoff line is 40 mm (1.57 in.) above and below the H line as well as to the left and right of the V line with low-beam (SAEJ599) • Alignment distance is 7.62 m (25 ft): The cutoff line is 101 mm (3.97 in.) above and below the H line as well as to the left and right of the V line with high-beam (SAEJ599) • Alignment distance is m (9.84 ft): The cutoff line is 40 mm (1.57 in.) above and below the H line as well as to the left and right of the V line with high-beam (SAEJ599) • Alignment distance is 7.62 m (25 ft): The cutoff line is mm (0 in.) below the H line with low-beam • Alignment distance is m (9.84 ft): The cutoff line is mm (0 in.) below the H line with low-beam A E076100E01 HEADLIGHT AIMING ADJUSTMENT (a) Adjust the aim vertically: Adjust the headlight aim into the specified range by turning aiming screw A with a screwdriver NOTICE: The final turn of the aiming screw should be made in the clockwise direction If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction (b) Perform low-beam aim adjustment HINT: The headlight aim moves up when turning the aiming screw clockwise, and moves down when turning the aiming screw counterclockwise (c) Adjust the aim horizontally: Adjust the headlight aim into the specified range by turning aiming screw B with a screwdriver NOTICE: The final turn of the aiming screw should be made in the clockwise direction If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction B E076101E01 INSTALLATION E076051E01 INSTALL NO HEADLIGHT, BULB (a) Install the No headlight bulb LI LI–10 LIGHTING – HEADLIGHT ASSEMBLY (b) Lock the set spring by moving it in the direction indicated by the arrow in the illustration E076079E01 (c) Install the socket cover INSTALL CLEARANCE LIGHT BULB (a) Install the clearance light bulb into the light socket E076049E01 (b) To install the clearance light bulb socket and bulb, turn them in the direction indicated by the arrow in the illustration INSTALL FRONT TURN SIGNAL LIGHT BULB (a) Install the front turn signal light bulb into the light socket E076080E01 (b) To install the front turn signal light bulb socket and bulb, turn them in the direction indicated by the arrow in the illustration INSTALL HEADLIGHT ASSEMBLY (a) Connect the connectors E076081E01 (b) Install the LH headlight assembly with the bolt and screws Torque: 2.0 N*m (20 kgf*cm, 17 in.*lbf) LI Bolt E076046E02 INSTALL FRONT BUMPER FILLER (See page ET-9) INSTALL FRONT BUMPER COVER (See page ET-11) INSTALL RADIATOR GRILLE (See page ET-11) CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) LIGHTING – HEADLIGHT ASSEMBLY LI–11 VEHICLE PREPARATION FOR HEADLIGHT AIM ADJUSTMENT (See page LI-5) 10 PREPARATION FOR HEADLIGHT AIMING (for Using a Tester) (See page LI-5) 11 PREPARATION FOR HEADLIGHT AIMING (for Using a Screen) (See page LI-5) 12 HEADLIGHT AIMING INSPECTION (See page LI-7) 13 HEADLIGHT AIMING ADJUSTMENT (See page LI-9) LI LI–12 LIGHTING – HEADLIGHT ASSEMBLY REPAIR HINT: • Use the same procedures for the RH and LH • The procedures listed below are for the LH side • If the area where the headlight unit LH is installed is damaged, the repairs listed below can be performed inexpensively through the use of a repair use bracket This may only be done if the headlight assembly LH itself is not damaged DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL REMOVE RADIATOR GRILLE (See page ET-4) REMOVE FRONT BUMPER COVER (See page ET-4) REMOVE FRONT BUMPER FILLER (See page ET-6) REMOVE HEADLIGHT ASSEMBLY (See page LI-4) INSTALL HEADLIGHT PROTECTOR UPPER RETAINER HINT: • If the installation area of the LH headlight assembly is damaged, use the supply bracket for low-cost repair • Ensure that the LH headlight assembly is not damaged (a) Cut off the portion indicated by the shaded portion in the illustration and smooth the surface with sandpaper NOTICE: After cutting off the shaded portion, place the LH headlight protector upper retainer LH against the bosses and gradually file away the shaded portion until installation is possible E076109E01 (b) Install the headlight protector upper retainer LH with the screws LI E076112E01 INSTALL HEADLIGHT PROTECTOR LOWER RETAINER HINT: • If the installation area of the LH headlight assembly is damaged, use the supply bracket for low-cost repair • Ensure that the LH headlight assembly is not damaged LIGHTING – HEADLIGHT ASSEMBLY LI–13 (a) Cut off the portion indicated by the shaded portion in the illustration and smooth the surface with sandpaper NOTICE: After cutting off the shaded portion, place the headlight protector lower retainer LH against the bosses and gradually file away the shaded portion until installation is possible E076108E01 (b) Install the headlight protector lower retainer LH with the screws INSTALL HEADLIGHT LOWER BRACKET HINT: • If the installation area of the LH headlight assembly is damaged, use the supply bracket for low-cost repair • Make sure that the LH headlight assembly is not damaged E076111E01 (a) Cut off the portion indicated by the shaded portion in the illustration and smooth the surface with sandpaper NOTICE: After cutting off the shaded portion, place the headlight lower bracket LH against the bosses and gradually file away the shaded portion until installation is possible E076107E01 (b) Install the headlight lower bracket LH with the screws INSTALL HEADLIGHT ASSEMBLY 10 CONNECT CABLE TO NEGATIVE BATTERY TERMINAL Torque: 3.9 N*m (40 kgf*cm, 35 in.*lbf) 11 INSTALL FRONT BUMPER FILLER (See page ET-9) E076110E01 12 INSTALL FRONT BUMPER COVER (See page ET-11) 13 INSTALL RADIATOR GRILLE (See page ET-11) 14 VEHICLE PREPARATION FOR HEADLIGHT AIM ADJUSTMENT (See page LI-5) 15 PREPARE FOR HEADLIGHT AIMING (for Using a Tester) (See page LI-5) 16 PREPARE FOR HEADLIGHT AIMING (for Using a Screen) (See page LI-5) 17 HEADLIGHT AIMING INSPECTION (See page LI-7) 18 HEADLIGHT AIMING ADJUSTMENT (See page LI-9) LI LIGHTING – FOG LIGHT ASSEMBLY LI–15 ADJUSTMENT 90° 7.62 m (25 ft) m (9.84 ft) E076102E01 VEHICLE PREPARATION FOR FOG LIGHT AIM ADJUSTMENT (a) Prepare the vehicle: HINT: • Ensure that there is no damage or deformation to the body around the fog lights • Fill the fuel tank • Make sure that the oil is filled to the specified level • Make sure that the coolant is filled to the specified level • Inflate the tires to the appropriate pressure • Place the spare tire, tools, and jack in their original positions • Unload the trunk • Sit a person of average weight (68 kg, 150 lb) in the driver side seat PREPARATION FOR FOG LIGHT AIMING (a) Prepare the vehicle according to the following conditions: HINT: • Place the vehicle in a location that is dark enough to clearly observe the cutoff line The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot • Place the vehicle at a 90° angle to the wall • Keep a 7.62 m (25 ft) distance between the center of the fog light bulb and the wall • Place the vehicle on a level surface • Bounce the vehicle up and down to settle the suspension NOTICE: A distance of 7.62 m (25 ft) between the vehicle (center of the fog light bulb) and the wall is necessary for proper aim adjustment If unavailable to secure a distance of 7.62 m (25 ft), secure a distance of exactly m (9.84 ft) to check and adjust the fog light aim (Since the target zone will change with the distance, follow the instructions shown in the illustration.) (b) Prepare a piece of thick white paper (approximately m (6.6 ft) (height) x m (13.1 ft) (width)) to use as a screen (c) Draw a vertical line down the center of screen (V line) LI LI–16 LIGHTING – FOG LIGHT ASSEMBLY (d) Set the screen as shown in the illustration Aligning distance 7.62 m (25 ft): Aligning distance m (9.84 ft): V RH Line V RH Line 90q 90q V Line 7.62 m (25 ft) m (9.84 ft) V Line V LH Line V LH Line H Line H Line 90q 7.62 m (25 ft) 90q m (9.84 ft) E076103E01 HINT: • Stand the screen perpendicular to the ground • Align the V line on the screen with the center of the vehicle V LH Line V Line V RH Line H Line Ground I033423E08 LI (e) Draw base lines (H line, V LH, V RH lines) on the screen as shown in the illustration HINT: Mark the fog light bulb center marks on the screen If the center mark cannot be observed on the fog light, use the center of the fog light bulb or the manufacturer's name marked on the fog light as the center mark (1) H Line (Fog light height): Draw a horizontal line across the screen so that it passes through the center marks The H line should be at the same height as the fog light bulb center marks of the low-beam fog lights (2) V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) fog lights): Draw two vertical lines so that they intersect the H line at each center mark LI–17 LIGHTING – FOG LIGHT ASSEMBLY FOG LIGHT AIMING INSPECTION (a) Cover the fog light or disconnect the connector of the fog light on the opposite side to prevent light from the fog light not being inspected from affecting fog light aiming inspection (b) Start the engine NOTICE: Engine rpm must be 1,500 or more (c) Turn on the fog light and make sure that the cutoff line falls within the specified area, as shown in the illustration Aligning distance 7.62 m (25 ft): V LH Line Aligning distance m (9.84 ft): 133 mm (5.23 in.) V LH Line 52 mm (2.04 in.) V RH Line V RH Line H Line H Line I041221E03 FOG LIGHT AIMING ADJUSTMENT (a) Adjust the fog light aim into the specified range by turning the aiming screw with a screwdriver NOTICE: The final turn of the aiming screw should be made in the clockwise direction If the screw is tightened excessively, Loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction E076104E01 LI