Replace both left and right headlight assemblies on a 2019-2024 Toyota RAV4 with 2.5L I4 engine, including removal of front bumper cover for access.

Warnings

Tools required

Parts

• Driver side headlight assembly × 1 — 81110-42C60 or aftermarket equivalent
• Passenger side headlight assembly × 1 — 81170-42C60 or aftermarket equivalent
• Push-pin retaining clips (bumper cover) × 10 — 90467-07211 or similar

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently driven
3. Open hood and disconnect negative battery terminal, wait 2 minutes for airbag system to discharge
4. Photograph headlight assembly and bumper cover for reference
5. Gather all tools and replacement parts within reach
6. Place protective cloth over front fender to prevent scratches during work

Procedure

1. 1

   Disconnect battery and prepare vehicle
   Disconnect the negative battery terminal using a 10mm socket. Wait at least 2 minutes to allow the airbag system capacitors to fully discharge. This prevents SRS fault codes and electrical issues during headlight connector removal.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove front grille assembly
   Open the hood. Remove the upper grille by releasing 4 push-pin clips across the top edge. Use trim removal tool to carefully pry the grille forward from the center, then lift upward to release the lower tabs. Set grille aside in a safe location.
3. 3

   Remove bumper cover upper fasteners
   Locate and remove 6 push-pin clips along the top edge of the bumper cover (accessible with hood open). Remove 2 screws at each front corner near the wheel well using a 10mm socket. These secure the bumper cover to the fender liner.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
4. 4

   Remove wheel well liner fasteners
   Turn the steering wheel fully to one side for access. Remove 3 push-pin clips from the front portion of each wheel well liner where it meets the bumper cover. Pull the liner back slightly to access the hidden bumper mounting bolts behind it. Repeat on both sides.
5. 5

   Remove bumper cover lower fasteners
   From underneath the front of the vehicle, remove 6 push-pin clips along the lower edge of the bumper cover. Remove 2 bolts (10mm) at each outer lower corner where bumper meets wheel well area. The bumper is now ready to be removed.
6. 6

   Remove front bumper cover
   With an assistant supporting the bumper, gently pull the bumper cover straight forward. Start from one corner and work across to release the mounting tabs on each fender. Disconnect the fog light connectors (if equipped) by pressing the release tab and pulling straight out. Set the bumper cover in a safe location away from the work area.
   ⚠Bumper cover is flexible but can crack near mounting points if forced; use gentle even pressure
7. 7

   Disconnect headlight electrical connectors
   Locate the main headlight connector on the back of each headlight assembly. Press the locking tab and pull the connector straight back. For LED headlights, there may be 2-3 connectors per assembly including DRL and turn signal. Label connectors with tape if needed to ensure correct reassembly.
8. 8

   Remove driver side headlight mounting bolts
   Locate the three 10mm mounting bolts securing the driver side headlight assembly. Remove the upper bolt first, then the two lower bolts. Support the headlight assembly as you remove the final bolt to prevent it from falling.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Remove driver side headlight assembly
   Carefully pull the headlight assembly straight forward out of the mounting position. Wiggle gently if needed to release any remaining clips. Inspect the mounting area for any debris or damage. Set the old headlight aside.
10. 10

    Remove passenger side headlight mounting bolts
    Repeat the removal process for the passenger side. Remove the three 10mm mounting bolts (one upper, two lower) while supporting the headlight assembly. Note that the passenger side may have slightly different access angles.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Remove passenger side headlight assembly
    Pull the passenger side headlight assembly straight forward and out of the vehicle. Inspect both headlight mounting areas and clean any dirt or debris from the mounting surfaces and alignment pins.
12. 12

    Install new headlight assemblies
    Position each new headlight assembly into its mounting location, ensuring alignment pins seat properly into the body. Install the three mounting bolts for each side finger-tight initially. Once all bolts are started, torque each bolt to 27 Nm (20 lb-ft) in a star pattern to ensure even seating.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
13. 13

    Reconnect electrical connectors
    Reconnect all electrical connectors to each headlight assembly, ensuring each connector clicks into place securely. Verify connectors are fully seated by gently tugging on each connection. Route wiring to match original positions documented in preparation photos.
14. 14

    Reinstall front bumper cover
    With an assistant, position the bumper cover back onto the vehicle. Reconnect fog light connectors if equipped. Align the mounting tabs at each fender and push the bumper firmly into place until all tabs click. Install all push-pin clips and bolts in reverse order of removal, torquing cover screws to 11 Nm (8 lb-ft).
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
15. 15

    Reinstall grille and reconnect battery
    Position the front grille assembly back into place, engaging lower tabs first then pressing firmly until all upper clips seat. Reconnect the negative battery terminal and torque to 6 Nm (4 lb-ft). Do not overtighten to prevent terminal damage.
    ⚠Battery terminal bolt overtightening can crack terminal or strip threads
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all push-pin clips are fully seated and bumper cover is flush with fenders
2. Check that all electrical connectors are secure and wiring is not pinched
3. Ensure grille assembly is fully clipped in and aligned properly
4. Verify wheel well liners are properly positioned and secured

Verification

• Turn ignition to ON position (engine off) and verify both headlights illuminate in low beam mode
• Test high beam function on both sides
• Verify turn signals and daytime running lights function properly on both sides
• Check for any dashboard warning lights related to exterior lighting
• Inspect headlight aim and adjust if necessary using integrated adjustment screws
• Verify bumper cover gaps are even on both sides and all fasteners are tight
• Test drive vehicle and confirm no rattles or loose components from bumper area

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