Headlight Assembly: Disassembly

WARNING: This page is about a different car, the 2006 Lexus IS 350 and 2006 Lexus IS 250. However, it is still accessible from the selected car via links, so may be relevant.

REMOVE NO. 1 HEADLIGHT BULB (for Halogen Headlight)
1. Remove the headlight socket cover as shown in the illustration.
2. Remove the headlight gasket.
  
  Fig 1: Identifying Headlight Socket Cover
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  
  NOTE: After the headlight gasket is removed, be sure to replace it with a new one. Failure to do this may cause water ingress.
3. Disconnect the connector.
4. Remove the No. 1 headlight bulb as shown in the illustration.
Fig 2: Identifying No. 1 Headlight Bulb
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVE DISCHARGE HEADLIGHT BULB (for Discharge Headlight)
1. Remove the headlight socket cover as shown in the illustration.
2. Remove the headlight gasket.
  
  Fig 3: Identifying Headlight Socket Cover
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  
  NOTE: After the headlight gasket is removed, be sure to replace it with a new one. Failure to do this may cause water ingress.
3. Separate the light control ECU socket as shown in the illustration.
  
  Fig 4: Identifying Light Control ECU Socket
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
4. Release the set spring and remove the discharge headlight bulb as shown in the illustration.
Fig 5: Identifying Discharge Headlight Bulb
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVE NO. 2 HEADLIGHT BULB
1. Remove the headlight socket cover as shown in the illustration.
2. Remove the headlight gasket.
  
  Fig 6: Identifying Headlight Socket Cover
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
  
  NOTE: After the headlight gasket is removed, be sure to replace it with a new one. Failure to do this may cause water ingress.
3. Disconnect the connector.
4. Remove the No. 2 headlight bulb as shown in the illustration.
  
  Fig 7: Identifying No. 2 Headlight Bulb
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVE PARKING LIGHT BULB
1. Turn the parking light bulb and the parking light socket in the direction indicated by the arrow and remove them as a unit.
2. Remove the parking light bulb from the parking light socket.
REMOVE PARKING LIGHT SOCKET
1. Disconnect the connector and remove the parking light socket.
Fig 8: Removing Parking Light Bulb From Parking Light Socket
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVE FRONT TURN SIGNAL LIGHT BULB
1. Turn the front turn signal light bulb and the front turn signal lights socket in the direction indicated by the arrow and remove them as a unit.
  
  Fig 9: Identifying Front Turn Signal Light Bulb
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Turn the 2 front turn signal light bulbs and the 2 front turn signal light sockets in the direction indicated by the arrow and remove them as a unit.
3. Remove the 2 front turn signal light bulbs from the 2 front turn signal light sockets.
Fig 10: Turning Front Turn Signal Light Bulbs And Front Turn Signal Light Sockets
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVE HEADLIGHT WIRE HARNESS
1. Disconnect the connector and remove the headlight wire harness.
Fig 11: Identifying Headlight Wire Harness Connector
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVE FRONT BUMPER SIDE SUPPORT
1. Remove the 3 screws and front bumper side support.
Fig 12: Identifying Screws And Front Bumper Side Support
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVE HEADLIGHT LEVELING MOTOR (for Discharge Headlight)
1. Align the notches of the headlight leveling motor and the housing, and pull out the headlight leveling motor slightly.
  
  Fig 13: Pulling Out Headlight Leveling Motor
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Lower the tip of the headlight leveling motor to disengage it from the reflector and remove the headlight leveling motor.
REMOVE HEADLIGHT LEVELING MOTOR BASE PACKING
1. Remove the headlight leveling motor base packing.
  
  Fig 14: Identifying Headlight Leveling Motor Base Packing
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
NOTE: After the headlight leveling motor base packing is removed, be sure to replace it with a new one. Failure to do this may cause water ingress.
REMOVE HEADLIGHT SWIVEL MOTOR (for Discharge Headlight)
1. Remove the screw and headlight protector.
  
  Fig 15: Identifying Screw And Headlight Protector
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
2. Remove the 4 screws.
  
  Fig 16: Identifying Screws
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
3. Install a drill bit into a drill.
4. Wrap the drill bit of the drill with tape.
  HINT:
  
  Tape is used to prevent drilling too deeply into the headlight unit.
5. Press the drill lightly against the point shown by the arrow and drill into the headlight unit.
6. Using a file, enlarge the hole in the headlight using the groove as a guideline.
  
  Fig 17: Pressing Drill Against P And Drill Into Headlight Unit
  Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
7. Remove the 3 screws.
8. Disconnect the connector and remove the washer and headlight swivel motor.
Fig 18: Identifying Screws
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
REMOVE LIGHT CONTROL ECU SUB-ASSEMBLY (for Discharge Headlight)
1. Disconnect the connector and remove the light control ECU sub-assembly.
NOTE: The light control ECU sub-assembly cannot be removed unless the headlight swivel motor is removed.
REMOVE HEADLIGHT GASKET
1. Remove the headlight gasket.
NOTE: After the headlight gasket is removed, be sure to replace it with a new one. Failure to do this may cause water ingress.

Fig 19: Identifying Light Control ECU Sub-Assembly
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.