Toyota RAV4 manuals

Toyota RAV4 Service Manual: Headlight assembly

Toyota RAV4 Service Manual / Lighting / Headlight assembly

Components

Toyota RAV4. Headlight assembly


Toyota RAV4. Headlight assembly


Removal

Hint:

  1. Disconnect cable from negative battery terminal

  2. Remove front fender liner lh (see page et-4)

  3. Remove front fender liner rh (see page et-4)

  4. Remove radiator support opening cover (see page et-4)

  5. Remove front bumper cover (see page et-5)

  6. Remove front bumper reinforcement subassembly upper

  1. Disconnect the 2 horn connectors.
  2. Remove the 2 bolts and reinforcement.
  1. Remove headlight assembly

Toyota RAV4. Remove headlight assembly


  1. Remove the 3 screws and bolt.
  2. Disconnect the connectors and remove the headlight.

Disassembly

Hint:

  1. Remove no. 1 Headlight bulb

Toyota RAV4. Remove no. 1 Headlight bulb


  1. Turn the bulb in the direction indicated by the arrow and pull to remove it.
  1. Remove no. 2 Headlight bulb

Toyota RAV4. Remove no. 2 Headlight bulb


  1. Turn the bulb in the direction indicated by the arrow and pull to remove it.
  1. Remove clearance light bulb

Toyota RAV4. Remove clearance light bulb


  1. Turn the bulb in the direction indicated by the arrow and pull to remove it.
  1. Remove front turn signal light bulb

Toyota RAV4. Remove front turn signal light bulb


  1. Turn the bulb/socket unit in the direction indicated by the arrow and pull to remove it.
  2. Remove the bulb from the socket.

Adjustment

  1. Vehicle preparation for headlight aim adjustment

  1. Prepare the vehicle:
  1. Preparation for headlight aiming (using a screen)

  1. Prepare the vehicle according to the following conditions:

Hint:

A distance of 10 m (32.8 Ft.) Between the vehicle and the wall is necessary for proper aim adjustment.

If unavailable, secure a distance of exactly 3 m (9.8 Ft.). In the illustrations below, view the part of the illustration applicable to the distance from the vehicle to the wall

Notice:

Be careful not to damage the suspension.

  1. Prepare a piece of thick white paper that is approximately 2 m (6.6 Ft.) (Height) x 4 m (13.1 Ft.) (Width) to use as a screen.
  2. Draw a vertical line down the center of the screen (v line).
  3. Set the screen as shown in the illustration.

Hint:

Toyota RAV4. Preparation for headlight aiming (using a screen)


Toyota RAV4. Preparation for headlight aiming (using a screen)


  1. Draw base lines (h line and v lh, v rh lines) on the screen as shown in the illustration.

Hint:

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 lo beam headlights.

V lh line, v rh line (center mark position of lh and rh headlights): draw 2 vertical lines so that they intersect the h line at each center mark.

  1. Inspect headlight aiming

  1. Choose a headlight to inspect first. Cover or disconnect the connector of the other headlight to prevent light from that headlight from affecting the headlight aiming inspection.

Hint:

When checking the aim of the hi beam bulb, cover the lo beam bulb or disconnect the connector.

Notice:

Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, and may easily melt or be damaged due to heat.

  1. Start the engine.

Notice:

Engine speed must be 1,500 rpm or more.

  1. Turn on the headlights and make sure that the cutoff line is within the specified area shown in the illustration.

Toyota RAV4. Inspect headlight aiming


  1. Adjust headlight aiming

Toyota RAV4. Adjust headlight aiming


  1. Adjust the vertical headlight aim into the specified range by turning aiming screw a with a screwdriver.

Hint:

Notice:

If the screw is tightened too much, loosen it and then retighten it so that the final turn of the screw is in the clockwise direction.

  1. Adjust the horizontal headlight aim into the specified range by turning aiming screw b with a screwdriver.

Hint:

Perform lo beam aim adjustment.

Notice:

If the screw is tightened too much, loosen it and then retighten it so that the final turn of the screw is in the clockwise direction.

Reassembly

Hint:

  1. Install front turn signal light bulb

Toyota RAV4. Install front turn signal light bulb


  1. Install the bulb to the socket.
  2. Insert the bulb/socket unit into the headlight.
  3. Turn the bulb/socket unit in the direction indicated by the arrow to install it.
  1. Install clearance light bulb

Toyota RAV4. Install clearance light bulb


  1. Insert the bulb into the headlight.
  2. Turn the bulb in the direction indicated by the arrow to install it.
  1. Install no. 2 Headlight bulb

Toyota RAV4. Install no. 2 Headlight bulb


  1. Insert the bulb into the headlight.
  2. Turn the bulb in the direction indicated by the arrow to install it.
  1. Install no. 1 Headlight bulb

Toyota RAV4. Install no. 1 Headlight bulb


  1. Insert the bulb into the headlight.
  2. Turn the bulb in the direction indicated by the arrow to install it.

Installation

Hint:

  1. Install headlight assembly lh

Toyota RAV4. Install headlight assembly lh


  1. Connect the connectors with the headlight.
  2. Install the 3 screws and bolt
  1. Install front bumper reinforcement subassembly upper

  1. Install the reinforcement with the 2 bolts.
  2. Connect the 2 horns connectors.
  1. Install front bumper cover (see page et-11)

  2. Install radiator support opening cover (see page et-12)

  3. Install front fender liner rh (see page et- 10)

  4. Install front fender liner lh (see page et- 12)

  5. Connect cable to negative battery terminal

  6. Adjust headlight aiming

  1. Adjust the headlight aiming (see page li-94 ).
Taillight relay circuit
Description When the light control switch, located on the headlight dimmer switch, is turned to the tail position, the taillight relay (marking: t-lp) turns on to illuminate the front side marker ...

Fog light assembly
Components Removal Hint: Use the same procedures for the rh and lh sides. The procedures listed below are for the lh side. Disconnect cable from negative battery terminal Caution: ...

Other materials:

Battery temperature sensor circuit
Description The battery temperature sensor installed on the battery current sensor detects battery temperature. A thermistor is integrated into the battery temperature sensor, and the resistance in the battery temperature sensor changes according to the battery temperature. The r ...

General maintenance (2005/11-2006/01)
Inspect steering linkage and gear housing Check the steering wheel free play. Check the steering linkage for looseness or damage. Check that the tie rod ends do not have excessive play Check that the dust seals and boots are not damaged. Check that the boot clamps are not ...

Assist map number un-writing
Description The power steering ecu outputs this dtc when it determines that the assist map is not written in the ecu. Hint: The assist map data is written in the power steering ecu to control assisting power. The assist map has 3 types. Select an assist map according to the vehicle ...

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