Lighting - HID Headlamp Protector Kit
BODYBO005-05
REVISED
Title:
HID HEADLAMP PROTECTOR KIT
Models:
'04 - '05 RX 330
July 25, 2005
TSIB REVISION NOTICE:
^ April 5, 2006: Step 5 has been added to the "Disassemble Headlamp Assembly" section, and a note has been added after step 2B in the "Install Brackets" section.
^ September 26, 2005: The "Production Change Information" section has been removed because the "Applicable Vehicles" section has been updated to include all 2004 - 2005 model year RX 330 vehicles equipped with High Intensity Discharge (HID) headlamps. The OFP has been updated in the "Installation Reimbursement Procedure" section. The "Disassemble Headlamp Assembly" and "Applying DataDots" sections have been updated.
Previous versions of this TSIB should be discarded.
Introduction
To address the High Intensity Discharge (HID) theft issue that has affected some Lexus customers and dealers in the Eastern Area, Lexus has developed a kit that will register the HID headlight components to the customer's vehicle by using a DataDot(R) application system. In addition, the kit will include special mounting brackets to help secure the light assemblies into the vehicle. This bulletin provides instructions on how to install this kit and register the components.
Applicable Vehicles
^ All 2004 - 2005 model year RX 330 vehicles equipped with High Intensity Discharge (HID) headlamps.
Parts Information
Installation Reimbursement Procedure
Required Tools & Material
Components
Remove Headlamp Assembly
1. Remove the front bumper cover.
A. Remove the 3 screws and 2 attaching clips.
B. Remove the 2 screws and 2 clips.
C. Partially remove the splash shield.
HINT:
Do NOT remove the splash shield completely. Partially remove the splash shield so the bumper cover can be removed.
D. Put protective tape under the front fender to prevent damage.
If the vehicle is equipped with headlamp washers, go to step E; otherwise, go to step F.
E. Vehicles equipped with headlamp washer:
a. Remove the washer hose clip.
b. Using a screwdriver, pull out the front washer nozzle.
NOTE:
Tape the screwdriver tip before use to prevent scratches to the painted surface.
F. Disconnect the fog lamp connectors.
G. Remove the 2 screws and 3 clips.
H. Using a taped screwdriver, disengage the 4 claws and remove the bumper cover.
2. Remove both the LH and RH headlamp assemblies.
A. Remove the 3 screws.
B. Pull the headlamp assembly forward, and then release the headlamp bracket.
C. Disconnect the connectors and remove the headlamp assembly.
Disassemble Headlamp Assembly
1. Remove the headlamp socket cover.
A. Disconnect the headlamp socket cover as shown in the illustration.
B. Remove the headlamp socket cover from the headlamp wire.
2. Disconnect the headlamp socket as shown in the illustration.
3. Remove the headlamp cover No. 1.
A. Remove the 4 screws and dispose of headlamp cover No. 1.
B. Remove the headlamp gasket and dispose of it.
4. Remove the headlamp light control ECU.
A. Remove the 2 screws and the sub-assembly headlamp light control ECU and dispose of the 2 screws.
B. Remove the original wire fitting bracket and dispose of it.
5. Install the NEW wire fitting bracket. Be sure to route the braided shielded cable and power cable exactly as illustrated.
Applying Data Dots
HINT:
To ensure maximum adhesion to the polypropylene and other headlamp surfaces, prepare areas of the light control ECU and headlight assembly for DataDot application as follows:
^ Use a medium grit sandpaper or a 60-grit emery cloth to scuff polypropylene surfaces of the headlamp assembly to be marked.
^ Scuff in an up/down and side-to-side pattern (crosshatch), NOT a circular pattern.
^ Clean the scuffed areas with a damp cloth and then dry.
NOTE:
^ The DataDot system uses a clear, water-based adhesive mixed with the DataDots. The DataDot adhesive will dry almost clear.
^ Excess material, spills, or runs must be cleaned up with water and a paper cloth towel before the material dries.
^ Stir bottle before application to assure maximum DataDot application. Stir the dots from the bottom of the pod to make sure the DataDots are well distributed in the adhesive.
CAUTION:
Headlamp mounting tabs break easily.
1. Apply the DataDots to the LH and RH headlamp assemblies.
A. Apply the DataDots to the scuffed area of the headlamp assembly as shown in the illustration.
B. Apply the DataDots to the scuffed area of the headlamp assembly as shown in the illustration.
NOTE:
Wait for the DataDot adhesive to "touch dry."
^ The DataDot adhesive is dry-to-the-touch in approximately 20 minutes.
^ The DataDot adhesive fully cures in 72 hours.
If the DataDots are inadvertently spilt, please wipe up with a damp cloth immediately.
To speed up drying time, apply hot air from a heat gun held a distance of 8 in. (20.3 cm).
2. Apply the DataDots to the B-pillar.
A. Stick a PIN code label next to the VIN label on the B-pillar.
B. Apply DataDots to the B-pillar around the VIN label.
NOTE:
Do NOT put DataDots on the VIN label, which might make the label unreadable.
Please discard the applicator and pod after use. Reusing an applicator will "cross contaminate" (mix up) the DataDots between vehicles (only 1 DataDot kit per vehicle).
Wait for the DataDot adhesive to "touch dry."
^ The DataDot adhesive is dry-to-the-touch in approximately 20 minutes.
^ The DataDot adhesive fully cures in 72 hours.
If the DataDots are inadvertently spilt, please wipe up with a damp cloth immediately.
To speed up drying time, apply hot air from a heat gun held a distance of 8 in. (20.3 cm).
C. Apply one DataDot sticker to the outside surface (front) corner of each headlamp.
D. Apply one DataDot window decal to both the driver's door and front passenger's door window glass.
DataDot PIN Registration
Each DataDot kit has a unique PIN that must be registered with the VIN of the vehicle being marked.
An online database operated by DataDot(TM) USA is available for easy registration of the DataDot PIN and the vehicle VIN. This information will be validated by DataDot and then passed on to a national database for law enforcement agencies.
Access to the Lexus PIN registration database is secured through the use of the standard Lexus dealer code.
Upon entering registration data, the online database does an immediate check to make certain the DataDot submission is a valid one (PIN and VIN are the correct length and are not a duplicate).
Registration Steps:
1. Obtain the PIN barcode label out of the DataDot kit and stick it on the repair order.
2. Logon to the DataDot on-line registration database found.
NOTE:
On first visit to this web address, it may be helpful to save it to your computer's "favorites" or to another location on your desk top.
3. Follow the on-screen prompts and enter the required information.
A. Dealer Code: Enter your Lexus dealer code.
B. Date DataDots Applied: Enter the date applied.
C. Vehicle VIN: Enter the complete VIN of the vehicle that DataDots were applied to.
D. DataDot PIN: Enter the PIN from the labels supplied with the DataDot kit (Example: LXS123456789).
4. Once entered, hit Next to continue to submission screen.
5. If the data entered is correct, select submit and print the "Confirmation Form" and attach it to the Repair Order.
NOTE:
For questions or problem support, contact DataDot(TM) USA.
Process Headlamp Housing
1. Cut out the headlamp housing bosses on which the light control ECU was mounted.
NOTE:
Be careful NOT to drop chips of the headlamp housing boss in the headlamp housing.
Install Brackets
1. Install the headlamp bracket No. 1 to body with 2 bolts and 2 nuts.
NOTE:
Do NOT completely tighten the bolts and nuts because headlamp bracket No. 1 and bracket B need to be installed with some clearance.
2. Install the wire fitting bracket, bracket A, and headlamp light control ECU to headlamp cover No. 1.
A. Install a new wire fitting bracket to the headlamp light control ECU. Do NOT secure the wire harness.
B. Install bracket A and the headlamp light control ECU to a new headlamp cover No.1 with 3 new bolts by using a Torx Socket Wrench (T20).
NOTE:
Be sure to attach the wire harness to the wire fitting as shown in the illustration.
3. Install the headlamp cover No. 1 assembly to the headlamp assembly.
A. Install the headlamp cover No. 1 assembly with a new gasket and the 4 screws.
Torque: 1.47 - 1.96 N.m (15 - 20 kgf.cm, 13 - 17 in.lbf)
NOTE:
Do NOT let headlamp cover No.1 pinch the wires.
B. Connect the headlamp socket.
C. Install the headlamp socket cover to the headlamp assembly.
4. Install the bracket B to bracket A with 2 bolts by using a Torx Driver (T25).
Install Headlamp Assembly
1. Install the headlamp assembly.
A. Set the headlamp assembly in place without tightening bolts and connecting wires
B. Adjust the location of headlamp bracket No. 1. Keep clearance between bracket B and the headlamp bracket No. 1 and Torx bolt assembly as shown in the illustration.
C. Remove the headlamp assembly and tighten the bolts and nuts installing headlamp bracket No. 1.
D. Install the headlamp assembly with the 3 bolts.
E. Connect bracket B and headlamp bracket No.1 with the Torx bolt by using a Torx Socket Wrench (T30).
2. Install the front bumper cover and headlamp washer nozzle, if equipped.
HINT:
Installation is in the reverse order of removal.
3. Verify headlamps are aimed correctly.