Headlight Assembly: Repair

WARNING: This page is about a different car, the 2008 Scion xB. However, it is still accessible from the selected car via links, so may be relevant.

HINT:

Use the same procedure for both the RH and LH sides.
The procedure described below is for the LH side.
If only the installation area of the headlight is damaged, the repairs described below can be performed inexpensively by using brackets for the repair. This may only be done if the other areas of the headlight are not damaged.

REMOVE NO. 1 RADIATOR GRILLE GARNISH (See REMOVAL )
REMOVE RADIATOR GRILLE (See REMOVAL )
REMOVE FRONT BUMPER COVER (See REMOVAL )
REMOVE HEADLIGHT UNIT (See REMOVAL )
INSTALL HEADLIGHT PROTECTOR UPPER RETAINER
HINT:
- If only the installation area of the headlight is damaged, use a bracket for a low-cost repair.
- Ensure that other areas of the headlight are not damaged.
1. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.
  NOTE: After cutting off the shaded portion, place the headlight protector upper retainer against the bosses and gradually file away the shaded portion until installation is possible.
  
  Fig 1: Identifying Cutting Portion Of Headlight Protector Upper Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the headlight protector upper retainer with the 2 screws.
INSTALL HEADLIGHT PROTECTOR
HINT:
- If only the installation area of the headlight is damaged, use a bracket for a low-cost repair.
- Ensure that other areas of the headlight are not damaged.
  
  Fig 2: Identifying Headlight Protector Upper Retainer Screws
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
1. Cut off the portion indicated by the hatched lines in the illustration and smooth the surface with sandpaper.
  NOTE: After cutting off the shaded portion, place the headlight protector against the bosses and gradually file away the shaded portion until installation is possible.
  
  Fig 3: Identifying Cutting Portion Of Headlight Protector Upper Retainer
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Install the headlight protector with the 2 screws.
INSTALL HEADLIGHT UNIT (See INSTALLATION )
INSTALL FRONT BUMPER COVER (See INSTALLATION )
INSTALL RADIATOR GRILLE (See INSTALLATION )
INSTALL NO. 1 RADIATOR GRILLE GARNISH (See INSTALLATION )

Fig 4: Identifying Headlight Protector Screws
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
PREPARE VEHICLE FOR HEADLIGHT AIMING ADJUSTMENT (See DISASSEMBLY )
PREPARE FOR HEADLIGHT AIMING (for Using a Tester) (See DISASSEMBLY )
PREPARE FOR HEADLIGHT AIMING (for Using a Screen) (See DISASSEMBLY )
INSPECT HEADLIGHT AIMING (See ADJUSTMENT )
ADJUST HEADLIGHT AIMING (See ADJUSTMENT )