Headlight Assembly

This procedure covers the removal and replacement of the headlight assembly on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine, including proper alignment and electrical connection.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — 81110-42B80 (Left) or 81150-42B80 (Right)
• Push-type retainers (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key from vehicle
3. Allow engine to cool for at least 30 minutes if recently operated
4. Open hood and secure with prop rod

Procedure

1. 1

   Disconnect negative battery terminal
   Locate the battery in the engine compartment. Using a 10mm socket, loosen and remove the negative (-) battery terminal. Isolate the cable away from the battery post to prevent accidental reconnection during the repair.
2. 2

   Remove upper radiator cover panel
   Remove the plastic upper radiator cover panel that spans across the top of the radiator support. Remove the push-type retainers by prying up the center pin, then removing the entire retainer. Set aside for reinstallation.
3. 3

   Access headlight mounting area
   Locate the headlight assembly from above the radiator support. Identify the electrical connector at the rear of the headlight assembly and the three mounting bolts securing the assembly to the body.
4. 4

   Disconnect headlight electrical connector
   Press down on the locking tab of the main headlight electrical connector and pull firmly to disconnect. For models with active cornering or LED assemblies, there may be additional smaller connectors - disconnect all connectors leading to the headlight assembly.
5. 5

   Remove headlight assembly mounting bolts
   Using a 10mm socket with extension, remove the three headlight assembly mounting bolts. These are located at the top and sides of the headlight assembly accessible from above. Keep bolts organized for reinstallation.
6. 6

   Remove headlight assembly
   Carefully pull the headlight assembly forward and away from the vehicle. The assembly has alignment pins on the back that fit into grommets in the body - use gentle rocking motion if needed to disengage. Guide electrical connectors through the opening as you remove the assembly.
7. 7

   Install new headlight assembly
   Position the new headlight assembly near the mounting location. Feed electrical connectors through the opening first. Align the positioning pins on the rear of the assembly with the grommets in the body panel. Push assembly firmly into place ensuring proper seating against the fender and bumper cover.
8. 8

   Install mounting bolts
   Thread in all three headlight assembly mounting bolts by hand first to ensure proper threading. Once all bolts are started, torque each bolt to specification using a torque wrench in a cross pattern to ensure even seating of the assembly.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
9. 9

   Reconnect electrical connectors
   Reconnect all electrical connectors to the headlight assembly, ensuring each clicks firmly into place. Verify the locking tabs are fully engaged on all connectors.
10. 10

    Reinstall upper radiator cover
    Position the upper radiator cover panel back in place. Install the push-type retainers by inserting the body of the retainer first, then pressing down the center pin until it sits flush with the retainer body.
11. 11

    Reconnect battery
    Reconnect the negative battery terminal and tighten the terminal bolt securely using a 10mm socket.

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify headlight assembly is flush with fender and bumper cover with consistent gaps
3. Check that all mounting bolts are torqued to specification
4. Confirm upper radiator cover is properly secured with all retainers installed

Verification

• Turn ignition to ON position and verify all headlight functions: low beam, high beam, and turn signal
• Check for proper headlight aim - headlights should illuminate road ahead without blinding oncoming traffic
• Inspect headlight assembly fitment - gaps should be even around perimeter with no misalignment
• Verify no warning lights on instrument cluster related to headlight malfunction
• Test daytime running lights (DRL) if equipped by starting engine
• If headlight aim is off, use adjustment screws on back of headlight assembly to adjust beam pattern per manufacturer specifications

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