Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSTOYOTA2002HIGHLANDER 4WD L4-2.4L (2AZ-FE)REPAIR AND DIAGNOSISLIGHTING AND HORNSHEADLAMPSERVICE AND REPAIR
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)
Headlamp: Service and Repair
2002 Toyota Highlander 4WD L4-2.4L (2AZ-FE)SECTION Service and Repair
REPLACEMENT
1. REMOVE RADIATOR GRILLE
2. REMOVE FRONT FENDER LINER LH
3. REMOVE FRONT FENDER LINER RH
4. REMOVE FRONT BUMPER COVER
5. REMOVE HEADLAMP UNIT LH
a. Remove the 2 bolts.
b. Disconnect the connectors.
c. Disconnect the pin.
d. Pull out the head lamp unit forward, then disconnect the bracket of body side.
6. INSTALL HEADLAMP PROTECTOR RETAINER UPPER LH
HINT: When only the installation part of the headlamp unit LH is damaged, it can be repaired inexpensively by using a bracket provided for repair. In this case, however, the headlamp assembly LH itself should not be damaged.
a. Cut off the part shaded in the illustration and properly it with sandpaper.
NOTE: After roughly cutting off the part, place the headlamp protector retainer UPR LH against the bosses and gradually file any interfering part until the proper condition for installation is made.
b. Install the headlamp protector retainer UPR LH with the 2 screws.
7. INSTALL HEADLAMP PROTECTOR RETAINER LWR LH
HINT: When only the installation part of the headlamp unit LH is damaged, it can be repaired inexpensively by using a bracket provided for repair. In this case, however, the headlamp assembly LH itself should not be damaged.
a. Cut off the part shaded in the illustration and properly it with sandpaper.
NOTE: After roughly cutting off the part, place the headlamp protector retainer LWR LH against the bosses and gradually file any interfering part until the proper condition for installation is made
b. Install the headlamp protector retainer LWR LH with the 2 screws.
8. INSTALL HEADLAMP BRACKET LWR LH
HINT: When only the installation part of the headlamp unit LH is damaged, it can be repaired inexpensively by using a bracket provided for repair. In this case, however, the headlamp assembly LH itself should not be damaged.
a. Cut off the part shaded in the illustration and properly it with sandpaper.
NOTE: After roughly cutting off the part, place the headlamp bracket LWR LH against the bosses and gradually file any interfering part until the proper condition for Installation Is made.
b. Install the headlamp bracket LWR LH with the screw.
9. HEADLIGHT AIM ONLY
1. REMOVE RADIATOR GRILLE
2. REMOVE FRONT FENDER LINER LH
3. REMOVE FRONT FENDER LINER RH
4. REMOVE FRONT BUMPER COVER
5. REMOVE HEADLAMP UNIT LH
a. Remove the 2 bolts.
b. Disconnect the connectors.
c. Disconnect the pin.
d. Pull out the head lamp unit forward, then disconnect the bracket of body side.
6. INSTALL HEADLAMP PROTECTOR RETAINER UPPER LH
HINT: When only the installation part of the headlamp unit LH is damaged, it can be repaired inexpensively by using a bracket provided for repair. In this case, however, the headlamp assembly LH itself should not be damaged.
a. Cut off the part shaded in the illustration and properly it with sandpaper.
NOTE: After roughly cutting off the part, place the headlamp protector retainer UPR LH against the bosses and gradually file any interfering part until the proper condition for installation is made.
b. Install the headlamp protector retainer UPR LH with the 2 screws.
7. INSTALL HEADLAMP PROTECTOR RETAINER LWR LH
HINT: When only the installation part of the headlamp unit LH is damaged, it can be repaired inexpensively by using a bracket provided for repair. In this case, however, the headlamp assembly LH itself should not be damaged.
a. Cut off the part shaded in the illustration and properly it with sandpaper.
NOTE: After roughly cutting off the part, place the headlamp protector retainer LWR LH against the bosses and gradually file any interfering part until the proper condition for installation is made
b. Install the headlamp protector retainer LWR LH with the 2 screws.
8. INSTALL HEADLAMP BRACKET LWR LH
HINT: When only the installation part of the headlamp unit LH is damaged, it can be repaired inexpensively by using a bracket provided for repair. In this case, however, the headlamp assembly LH itself should not be damaged.
a. Cut off the part shaded in the illustration and properly it with sandpaper.
NOTE: After roughly cutting off the part, place the headlamp bracket LWR LH against the bosses and gradually file any interfering part until the proper condition for Installation Is made.
b. Install the headlamp bracket LWR LH with the screw.
9. HEADLIGHT AIM ONLY
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.