This procedure covers removal and replacement of the LED headlight module assembly on 2019-2024 Toyota RAV4 2.5L I4 FWD models, including disconnecting the electrical connectors and properly seating the new module.

Warnings

Tools required

Parts

• LED Headlight Module Assembly × 1 — Use OEM specification for left or right side
• Headlight module seal/gasket (if damaged) × 1 — Usually included with new module

Preparation

1. Ensure vehicle is parked on level surface with engine off and cooled
2. Turn ignition to OFF position and remove key
3. Open hood and prop securely
4. Disconnect negative battery terminal and wait 3 minutes for system capacitors to discharge
5. Identify which headlight module requires replacement (driver or passenger side)

Procedure

1. 1

   Remove front wheel well liner clips (if additional access needed)
   For improved access on some trim levels, turn steering wheel fully to opposite side of repair. Remove 2-3 plastic push clips from front section of wheel well liner to create access opening behind headlight assembly. This step is optional but recommended for easier connector access.
2. 2

   Access headlight module area
   Locate the LED headlight module at the rear of the headlight assembly in the engine bay. You will see a large electrical connector with a gray locking tab and the module housing secured by mounting bolts. Remove any plastic engine covers if they obstruct access to the headlight area.
3. 3

   Disconnect headlight module electrical connector
   Press down firmly on the gray locking tab of the main LED module connector while pulling the connector body straight back away from the module. Do not pull on wires. The connector requires significant force to release but should not require prying tools. If multiple connectors are present (for adaptive lighting), disconnect all connectors before proceeding.
   ⚠Ensure locking tab is fully depressed before pulling connector to avoid breaking the tab mechanism.
4. 4

   Remove rubber weather seal/dust cover
   Rotate the rubber dust cover on the rear of the headlight module counterclockwise approximately 1/4 turn and pull it off. This cover protects the module mounting area from moisture and debris. Inspect the seal for cracks or deterioration.
5. 5

   Remove LED module mounting bolts
   Using an 8mm socket with extension, remove the 3 mounting bolts securing the LED headlight module to the headlight housing. These bolts are arranged in a triangular pattern around the module. Keep bolts organized for reinstallation.
   ⚠Support the module with one hand while removing the final bolt to prevent it from falling into the engine bay.
   Torque spec

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

   Extract LED headlight module
   Carefully pull the LED module straight out from the headlight housing. The module may be snug in the housing and require gentle wiggling while pulling. Avoid tilting or rotating the module excessively during removal as this can damage the mounting tabs or seal groove.
7. 7

   Inspect headlight housing and mounting surface
   With module removed, inspect the headlight housing opening for any debris, moisture, or corrosion. Check the seal seating surface for damage. Wipe clean with a lint-free cloth if needed. Verify the mounting bolt holes in the housing are clean and threads are undamaged.
8. 8

   Prepare new LED module for installation
   Remove new LED module from packaging carefully. Verify the module has the gasket/seal properly seated in its groove. Do not touch the LED elements or expose circuit boards to contaminants. If transferring any components from old module (check service bulletin), do so now.
   ℹ️Some modules come pre-assembled with bulbs and seals; others may require component transfer. Verify with parts supplier before discarding old module.
9. 9

   Install new LED headlight module
   Align the new module with the headlight housing opening, ensuring the seal is properly positioned. Insert the module straight into the housing without tilting. The module should seat flush against the housing with mounting bolt holes aligned. Rotate module slightly if needed for proper indexing.
10. 10

    Install and torque module mounting bolts
    Thread all 3 mounting bolts by hand first to ensure proper alignment. Tighten bolts in a star/alternating pattern to ensure even seating. Use torque wrench to tighten mounting bolts to specification. Verify module sits flush and secure in housing.
    Torque spec

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

    Reinstall rubber weather seal
    Position the rubber dust cover over the rear of the module assembly, aligning any tabs or orientation features. Press firmly and rotate clockwise approximately 1/4 turn until it locks into place. Verify the seal is seated completely around its perimeter.
12. 12

    Reconnect electrical connector(s)
    Align the main electrical connector with the module socket and push firmly until you hear/feel a distinct click. The gray locking tab should snap into the locked position. Gently tug on the connector body to verify it is secure. Reconnect any additional connectors if equipped with adaptive lighting.
13. 13

    Reinstall wheel well liner clips and engine covers
    If wheel well liner was partially removed, reinstall all push clips by aligning and pressing firmly until seated. Reinstall any engine covers or components that were removed for access. Ensure all fasteners are secure.
14. 14

    Reconnect battery and initialize system
    Reconnect the negative battery terminal. Some RAV4 models may require headlight system initialization through the multi-information display or auto-leveling calibration. Consult owner's manual for specific initialization procedures if equipped with adaptive headlights.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify rubber weather seal is properly installed to prevent moisture intrusion
3. Double-check that all mounting bolts are torqued to specification
4. Confirm no tools or parts were left in engine bay
5. Close hood after final verification

Verification

• Turn ignition to ON position (engine off) and activate headlights to verify proper operation
• Test low beam, high beam, and daytime running light functions
• Check for any error messages on instrument cluster related to headlight system
• Verify headlight auto-leveling functions properly if equipped (watch for initial calibration movement)
• Inspect for any light leakage around module seal indicating improper seating
• Test turn signals and any integrated marker lights in the headlight assembly
• At night or in dark area, verify proper beam pattern and alignment (schedule alignment if pattern seems off)
• Monitor for 24-48 hours to ensure no error codes appear related to headlight system

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