SERVICE PRECAUTIONS - DISCHARGE HEADLIGHT
Before checking the discharge headlight related parts, be sure to read the following warnings and precautions carefully, and then perform necessary operations.
| WARNING | Do not touch the socket and the connector while the headlights are on. High voltage is applied to the bulb socket and connector during headlight operation. The operator may be burnt or dead due to an electric shock by high voltage. Do not attempt to use a tester to check them. If the bulb socket and connectors should be inspected using a tester, the operator may be burnt or dead due to an electric shock by high voltage. Do not turn ON the headlights while the controller or the bulb is removed. If the headlights are turned ON with the controller or bulb removed, the operator may get burned by the high temperature of the bulb. The operator may be burnt or dead due to an electric shock by high voltage. Before service work, turn the lighting switch OFF and disconnect the battery terminal and the controller connector in a dry place. Do not touch the components with wet hands. If you work on the components with wet hands or in wet conditions, the operator may be burnt or dead due to an electric shock by high voltage. |
| WARNING | Do not illuminate the bare headlight bulb. (Do not illuminate the headlight using other than the vehicle power supply.) If the headlight bulb illuminates without fitting it in the headlight unit, it may burst due to rise in its internal pressure. |
| CAUTION | When reusing the controller with the discharge headlight damaged, observe the inspection procedures for the related parts of the discharge headlight before determining the reusability of the controller. If you fail to observe "How to check discharge headlight components," the vehicle may be damaged. |
VISUAL CHECK OF CONTROLLER (CASE)
If any of the check items below are found, replace the controller.
| Items to be checked | Why the controller should be replaced |
|---|---|
| Obvious deformation (warping, twisting, dents, nicks, chipped edges) of controller case | The printed circuit board or the element(s) may be cracked |
| Damaged connector (chipped or cracked plastics, or deformed terminal) | The damaged part(s) may cause poor connection or short circuit. |
CONTROLLER REPLACEMENT
PROBABLE CAUSES
- Burned-out daytime running light bulb
- Malfunction of the daytime running light relay
- Malfunction of the ETACS-ECU
- Damaged harness wires and connectors
LIN - LIGHTING CONTROL SENSOR (LIGHT SENSOR)
| Item No. | Scan tool display | Check conditions | Normal conditions |
|---|---|---|---|
| 7001 | RLS IG1 | When the ignition switch is in the "LOCK" or "ACC" position | OFF |
| When the ignition switch is in the "ON" or "START" position | ON | ||
| 7002 | RLS Light sensor sensitivity | When the customize value of lighting control sensor sensitivity is set to Level 1 (fast) | Level 1 bright |
| When the customize value of lighting control sensor sensitivity is set to Level 2 (slightly fast) | Level 2 bright | ||
| When the customize value of lighting control sensor sensitivity is set to Level 3 (normal) | Level 3 | ||
| When the customize value of lighting control sensor sensitivity is set to Level 4 (slightly slow) | Level 4 dark | ||
| When the customize value of lighting control sensor sensitivity is set to Level 5 (slow) | Level 5 dark | ||
| 7004 | RLS Radio ACC | When the ignition switch is in the "LOCK" or "START" position | OFF |
| When the ignition switch is in the "ACC" or "ON" position | ON | ||
| 7007 | RLS Vehicle speed | Perform a test run of the vehicle. | The values displayed on the speedometer and the scan tool MB991958 are almost the same. |
| 7009 | RLS Low beam "ON" request | When the lighting control sensor area is bright | OFF |
| When the lighting control sensor area is dark | ON | ||
| 7010 | RLS judgment illuminance output | When the lighting control sensor area changes from dark to bright | The value displayed on the scan tool MB991958 increases. |
| When the lighting control sensor area changes from bright to dark | The value displayed on the scan tool MB991958 decreases. | ||
| 7011 | RLS Taillight "ON" request | When the lighting control sensor area is bright | OFF |
| When the lighting control sensor area is dark | ON | ||
| 7012 | RLS Tunnel detect output | When the lighting control sensor area is bright | OFF |
| When the lighting control sensor area is dark | ON | ||
| 7014 | RLS specification | EU | |
| 7015 | RLS ECU Diagnostic Version | ||
| 7016 | RLS ECU Hardware Version | ||
| 7017 | RLS ECU Software Version | ||
| 7018 | RLS ECU Part number | 8634A001 | |
| 7019 | RLS ECU Serial number |
DATA LIST REFERENCE TABLE
Scheme 60
- Inspect for rusted or faulty headlight assemblies.
- These conditions must be corrected before a satisfactory adjustment can be made.
- Inspect tire inflation, and adjust if necessary.
- If the fuel tank is not full, place a weight in the trunk of the vehicle to simulate weight of a full tank [3 kg (6.6 pounds) per gallon].
- There should be no other load in the vehicle other than driver or substituted weight of approximately 68 kg (150 pounds) placed in driver's position.
- Turn the headlight leveling switch to the switch position "0." < Vehicles with headlight manual leveling system >
- Thoroughly clean headlight lenses.
- Place the vehicle on a level floor, perpendicular to a flat screen 7.62 m (25.0 ft) away from the bulb center-marks on the headlight lens.
- Rock vehicle sideways to allow vehicle to assume its normal position.
- Bounce the front suspension through three (3) oscillations by applying the body weight to hood or bumper.
- Set the distance between the screen and the bulb center marks of the headlight as shown in the illustration.
- Four lines of adhesive tape (or equivalent markings) are required on screen or wall: Position a vertical tape or mark so that it is aligned with the vehicle center line. Measure the distance from the center-marks on the headlight lens to the floor [reference value: 679.5 mm (26.75 inches)]. Transfer the measurement to the screen. Horizontal tape or mark on the screen is for reference of vertical adjustment. Measure the distance from the center line of the vehicle to the center of each headlight. Transfer the measurement to the screen. Vertical tape or mark on the screen with reference to the center line of each headlight bulb.
Scheme 61
- The low-beam headlight will project on the screen upper edge of the beam (cut-off).
- Turn the adjusting screw to achieve the specified low-beam cut-off location on the aiming screen.
Standard value < Vehicles without discharge headlight >
(Vertical direction) Horizontal line (H) ± 50.5 mm (± 2.0 inches) (± 0.38 degrees angle)
(Horizontal direction): ± 126.4 mm (± 5.0 inches) (± 0.95 degrees angle) from the axis, which is 266.1 mm (10.5 inches) (2 degrees angle) rightward from the vertical line (V)
Scheme 62
Standard value < Vehicles with discharge headlight >
(Vertical direction) 53.2 mm (2.1 inches) (0.4 degrees) below horizontal line (H). ± 50.5 mm (± 2.0 inches) (± 0.38 degrees angle)
(Horizontal direction): Elbow point intersects the vertical line (V). ± 126.4 mm (± 5.0 inches) (± 0.95 degrees angle)
Scheme 63
| CAUTION | Do not cover a headlight for more than three minutes to prevent the plastic headlight lens deformation. |
Note. High-beam pattern should be correct when the low-beams are adjusted properly.
LUMINOUS INTENSITY MEASUREMENT
- Set the headlights to high-beam.
- Using a photometer, and following its manufacturer's instruction manual, measure the headlight center intensity and check to be sure that the limit value is satisfied.
Limit: 40, 000 cd or more {When a screen is set 18.3 m (60 feet) ahead of the vehicle}
Note. When measuring the intensity, maintain an engine speed of 2, 000 r/min, with the battery fully charged. There may be special local regulations pertaining to headlight intensity. Be sure to make any adjustments necessary to satisfy such regulations. If an illuminometer is used to make the measurements, convert its values to photometer values by using the following formula.
I = E x r 2
- I = intensity (cd)
- E = illumination (lux)
- r = distance (m) from headlights to illuminometer
HEADLIGHT AUTOMATIC-SHUTDOWN FUNCTION CHECK
Confirm that the headlights turn OFF in one second if the driver's door is opened when the ignition switch is OFF and the lighting switch is ON (HEAD position). If there is a malfunction, perform the troubleshooting (Refer to TROUBLE SYMPTOM CHART ).
HEADLIGHT AUTO LIGHT FUNCTION CHECK
Under the direct sunlight with the ignition switch ON and the lighting switch in the AUTO position, check that the headlight automatically illuminates when the lighting control sensor receiver is covered by hand. If there is any trouble, carry out the troubleshooting. (Refer to TROUBLE SYMPTOM CHART ).
Note. When covering the lighting control sensor receiver, be careful not to touch the windshield surface (where the lighting control sensor receiver is mounted). (The lighting control sensor receiver has limited resistance to oil.)
WELCOME LIGHT FUNCTION CHECK
When the lighting switch is in the OFF or AUTO position, unlock the door by the keyless entry system and check that the taillights or headlights turn on. If there is a malfunction, perform the troubleshooting (Refer to TROUBLE SYMPTOM CHART ).
Note. As for the vehicles with lighting control sensor, carry out the inspection in the dark place.
COMING-HOME LIGHT FUNCTION CHECK
After turning the ignition switch to the LOCK (OFF) position, check that passing operation lights up the headlights. If there is a malfunction, perform the troubleshooting (Refer to TROUBLE SYMPTOM CHART ).
CUSTOMIZATION FUNCTION
By operating the ETACS system or MMCS of scan tool MB991958, the following functions can be programmed. The programmed information is held even when the battery is disconnected.
| Adjustment item (scan tool display) | Adjustment item | Adjusting contents (scan tool display) | Adjusting contents |
|---|---|---|---|
| ACC power auto cut | Time to ACC power cut-off when the ignition switch is in the ACC position | Disable | No function |
| 30 min | 30 minutes (initial condition) | ||
| 60 min | 60 minutes | ||
| Turn power source | Adjustment of turn-signal light operation condition | ACC or IG1 | Operable with ACC or ON position |
| IG1 | Operable with ON position (initial condition) | ||
| Comfort flasher | With/without comfort flasher function | Disable | No function |
| Enable | With function (initial condition) | ||
| Comfort flasher switch time | Switch operation time to activate the comfort flasher function | Normal | 0.4 seconds (initial condition) |
| Long | 0.8 seconds | ||
| Sensitivity for auto light | Lighting control sensor sensitivity (illumination intensity) < vehicles with auto light > | Level 1 bright | High-high ambient brightness |
| Level 2 bright | High ambient brightness | ||
| Level 3 | Standard ambient brightness (initial condition) | ||
| Level 4 dark | Low ambient brightness | ||
| Level 5 dark | Low-low ambient brightness | ||
| Hazard answer back | Adjustment of the number of keyless hazard warning light answer back flashes | Lock: 1, Unlock: 2 | LOCK: Flashes once, UNLOCK: Flashes twice (initial condition) |
| Lock: 1, Unlock: 0 | LOCK: Flashes once, UNLOCK: No flash | ||
| Lock: 0, Unlock: 2 | LOCK: No flash, UNLOCK: Flash twice | ||
| Lock: 2, Unlock: 1 | LOCK: Flash twice, UNLOCK: Flash once | ||
| Lock: 2, Unlock: 0 | LOCK: Flash twice, UNLOCK: No flash | ||
| Lock: 0, Unlock: 1 | LOCK: No flash, UNLOCK: Flash once | ||
| Lock: 0, Unlock: 0 | No function | ||
| Headlight auto cut customize | Adjustment of headlight automatic shutdown function | Disable | No function |
| Enable (C-spec.) | With function (initial condition) | ||
| Welcome light | Disabling or enabling welcome light function < Vehicles with welcome light > | Disabled | No function |
| Small light | Tail light illuminates. (initial condition) | ||
| Head light | Headlight illuminates. | ||
| Coming home light | Disabling or enabling coming home light function | Disabled | No function |
| 15 sec | Headlight illuminates for 15 seconds. | ||
| 30 sec | Headlight illuminates for 30 seconds. (initial condition) | ||
| 60 sec | Headlight illuminates for 60 seconds. | ||
| 180 sec | Headlight illuminates for 180 seconds. |
CUSTOMIZATION FUNCTION TABLE
Scheme 64
Scheme 65
Scheme 66
Scheme 67
- As shown in the illustration, use the commercial tool to remove it.
- To insert the tool available in the market into the headlight assembly from the opening at the ignitor side, firstly remove the headlight control unit, the socket cover, the ignitor and the earth connector.
- Using the commercial tool, make the resin washer sag to push up the harness above the resin washer.
- Pull out the harness from the headlight assembly.
HEADLIGHT RELAY (LOW) CHECK - VEHICLES WITH DISCHARGE HEADLIGHT
| Battery voltage | Terminal number | Normal conditions |
|---|---|---|
| Not energized | 3 - 4 | No continuity |
| With current supply [terminal 2 (+), terminal 1 (-)] | Continuity exists (2 ohms or less) |
HEADLIGHT RELAY CONDITIONS (LOW)
Scheme 68
HEADLIGHT RELAY (HIGH) CHECK
| Battery voltage | Terminal number | Normal conditions |
|---|---|---|
| Not energized | 3 - 4 | No continuity |
| With current supply [terminal 2 (+), terminal 1 (-)] | Continuity exists (2 ohms or less) |
HEADLIGHT RELAY CONDITIONS (HIGH)
Scheme 69
DAYTIME RUNNING LIGHT RELAY CHECK - VEHICLES WITH DISCHARGE HEADLIGHT
| Battery voltage | Terminal number | Normal conditions |
|---|---|---|
| Not energized | 3 - 4 | No continuity |
| With current supply [terminal 2 (+), terminal 1 (-)] | Continuity exists (2 ohms or less) |
DAYTIME RUNNING LIGHT RELAY CONDITIONS
Scheme 70
HEADLIGHT LEVELING SWITCH CHECK
| Measured terminals | Switch position | Resistance value ohms |
|---|---|---|
| 4 - 6 | 0 | 750 |
| 1 | 1, 110 | |
| 2 | 1, 470 | |
| 3 | 1, 830 | |
| 4 | 2, 190 | |
| 5 - 6 | 0, 1, 2, 3, 4 | 2, 810 |
HEADLIGHT LEVELING SWITCH VALUES
Scheme 71
LIGHTING CONTROL SENSOR (LIGHT SENSOR) CHECK
Using the scan tool MB991958, check the LIN data list as follows.
- Under the direct sunlight, turn the ignition switch to the ON position and the lighting switch to the AUTO position.
- When the lighting control sensor receiver is covered by hand, and if the item No. 7009 (RLS Low beam "ON" request) and the item No. 7011 (RLS Taillight "ON" request) turn from OFF to ON, it is judged normal.
Note. Before inspection using the scan tool MB991958, wipe off the windshield clearly. Then check that there is no abnormality on the windshield surface where the lighting control sensor is mounted. When covering the lighting control sensor receiver, be careful not to touch the windshield surface (where the lighting control sensor receiver is mounted). (The lighting control sensor receiver has limited resistance to oil.)
REPAIR BRACKET PART NUMBER
| Part name | Part number |
|---|---|
| Headlight (LH) bracket kit | 8301B173 |
| Headlight (RH) bracket kit | 8301B174 |
REPAIR BRACKET PART NUMBERS