HID Ballast

This procedure covers the removal and replacement of a failed HID ballast on a 2019-2024 Toyota RAV4 with factory HID headlights.

Warnings

Tools required

Parts

• HID ballast × 1 — Use OEM specification - verify driver or passenger side
• Push-pin retainers (if damaged) × 2 — 90467-07164 or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off headlights and remove key from ignition
3. Open hood and secure with prop rod
4. Identify which ballast has failed (driver or passenger side) by inspecting which headlight is not illuminating or flickering
5. Disconnect negative battery terminal and wait minimum 5 minutes for HID system capacitors to discharge

Procedure

1. 1

   Remove inner fender liner access panel
   Turn the front wheels away from the side being serviced for better access. Locate the inner fender liner plastic access panel behind the headlight assembly. Remove the push-pin retainers (typically 3-4) securing the access panel section. Pull the panel back to expose the rear of the headlight assembly.
2. 2

   Access the HID ballast
   Locate the HID ballast mounted to the rear of the headlight assembly or on the inner fender well. The ballast is a rectangular metal or plastic box approximately 4x6 inches. On RAV4, it is typically mounted vertically behind the headlight housing.
3. 3

   Disconnect ballast electrical connectors
   Press the release tab on the main power connector to the ballast and pull straight out. Disconnect the output connector that runs to the HID bulb by pressing the release tab and pulling away from ballast. Note the connector positions for reassembly.
4. 4

   Remove ballast mounting hardware
   Remove the mounting bolts securing the ballast to its bracket or headlight assembly using a 10mm socket. Most RAV4 ballasts use 2-3 bolts. Support the ballast while removing the final bolt to prevent it from dropping.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
5. 5

   Remove failed ballast
   Carefully pull the ballast away from its mounting location. Inspect the mounting bracket and connectors for any signs of corrosion, melting, or damage. Clean the mounting surface if necessary.
6. 6

   Install new ballast
   Position the new ballast in the mounting location, ensuring it is oriented correctly with connector ports accessible. Thread in the mounting bolts by hand first to prevent cross-threading, then tighten to specification using a torque wrench.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
7. 7

   Reconnect electrical connectors
   Connect the output connector from the ballast to the HID bulb connector first, ensuring it clicks into place. Then connect the main power connector to the ballast, again listening for a positive click. Gently tug on both connectors to verify they are fully seated.
8. 8

   Reinstall fender liner access panel
   Position the inner fender liner access panel back into place. Install all push-pin retainers, ensuring they are fully seated and flush with the panel surface. Replace any damaged retainers with new ones.
9. 9

   Reconnect battery and test
   Reconnect the negative battery terminal and tighten to specification. Do not overtighten as this can damage the terminal. Turn the ignition to ON position and activate the headlights to verify the new ballast functions correctly. HID headlights may flicker briefly during initial warm-up (10-15 seconds) which is normal.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify fender liner access panel is properly secured with all retainers installed
3. Check that headlight assembly is not loose or misaligned
4. Return wheels to straight position if turned for access

Verification

• Start engine and turn on headlights - both HID lights should illuminate within 15 seconds
• Verify no flickering occurs after initial warm-up period (30 seconds)
• Check for proper low beam and high beam operation on repaired side
• Inspect for any error messages or warning lights on instrument cluster
• Visually confirm no gaps in fender liner and all panels are secure

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