MG
Moderator
Please see T-SB-0002-22 (Link Needed)
Introduction:
Some 2016 – 2018 model year RAV4 Hybrid vehicles may exhibit a condition in which the halogen low beam headlamp bulb lifetime is shorter than customer expectation. Follow the Repair Procedure in this bulletin to address this condition and enhance headlamp durability.
Warranty Information:
Install Wire, Engine Room Main and Bulb (Both Sides)
APPLICABLE WARRANTY:
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure:
1. Confirm the condition exists. Does the vehicle exhibit a condition in which the halogen low beam headlamp bulb lifetime is shorter than customer expectation?
YES — Continue to step 2.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
2. Replace BOTH headlamp bulbs.
3. Confirm proper operation of BOTH headlamps. Does the vehicle exhibit proper headlamp operation?
YES — Continue to step 4.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
4. Confirm headlight aim is visually correct and there are NO signs of damage or alterations to the wiring or headlamps.
5. Modify the right-hand and left-hand engine room main wires.
A. Carefully remove the white clip from each harness using a cutting tool.
B. Attach two NEW clips to the right-hand engine room main wire, P/N 82115-42690.
(1) Position the right-hand engine room main wire with the part number sticker facing you and the male connector on the left side as shown in Figure 2.
(2) Orient the NEW clips so that the open end is facing AWAY from you as shown.
(3) The left-side clip should be 1 in. to the right of the end of the corrugated tubing.
(4) The right-side clip should be 0.5 in. to the left of the end of the corrugated tubing.
(5) Trim the clips AFTER installation.
C. Attach two NEW clips to the left-hand engine room main wire, P/N 82115-42700.
(1) Position the left-hand engine room main wire with the part number sticker facing you and the male connector on the left side as shown in Figure 4.
(2) Orient the NEW clips so that the open end is facing TOWARD you as shown.
(3) The left-side clip should be 1 in. to the right of the end of the corrugated tubing.
(4) The right-side clip should be 0.5 in. to the left of the end of the corrugated tubing.
(5) Trim the clips AFTER installation.
6. Install the left-hand engine room main wire on the driver side.
A. Unplug the headlamp bulb from the vehicle wire harness.
B. Unclip the vehicle wire harness from the headlamp assembly
C. Plug the left-hand engine room main wire into the headlamp bulb.
D. Attach the white clip that is closest to the headlamp bulb to the mounting point the original vehicle side harness was removed from.
E. Attach the second white clip to the mounting point located approximately 1.5 in. below the previous mounting location.
F. Attach the original vehicle wire harness clip that was removed to the NEW location as shown.
G. Connect the vehicle wire harness electrical connector to the NEW left-hand engine room main wire.
7. Install the right-hand engine room main wire on the passenger side.
A. Unplug the headlamp bulb from the vehicle wire harness.
B. Unclip the vehicle wire harness from the headlamp assembly
C. Plug the right-hand engine room main wire into the headlamp bulb.
D. Attach the white clip that is closest to the headlamp bulb to the mounting point the original vehicle side harness was removed from.
E. Attach the second white clip to the mounting point located approximately 1.5 in. below the previous mounting location.
F. Attach the original vehicle wire harness clip that was removed to the NEW location as shown.
G. Connect the vehicle wire harness electrical connector to the NEW right-hand engine room main wire.
8. Verify normal operation of ALL affected systems.
Introduction:
Some 2016 – 2018 model year RAV4 Hybrid vehicles may exhibit a condition in which the halogen low beam headlamp bulb lifetime is shorter than customer expectation. Follow the Repair Procedure in this bulletin to address this condition and enhance headlamp durability.
Warranty Information:
Install Wire, Engine Room Main and Bulb (Both Sides)
APPLICABLE WARRANTY:
This repair is covered under the Toyota Basic Warranty. This warranty is in effect for 36 months or 36,000 miles, whichever occurs first, from the vehicle’s in-service date. Warranty application is limited to occurrence of the specified condition described in this bulletin.
Repair Procedure:
1. Confirm the condition exists. Does the vehicle exhibit a condition in which the halogen low beam headlamp bulb lifetime is shorter than customer expectation?
YES — Continue to step 2.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
2. Replace BOTH headlamp bulbs.
3. Confirm proper operation of BOTH headlamps. Does the vehicle exhibit proper headlamp operation?
YES — Continue to step 4.
NO — This bulletin does NOT apply. Continue diagnosis using the applicable Repair Manual.
4. Confirm headlight aim is visually correct and there are NO signs of damage or alterations to the wiring or headlamps.
5. Modify the right-hand and left-hand engine room main wires.
A. Carefully remove the white clip from each harness using a cutting tool.
B. Attach two NEW clips to the right-hand engine room main wire, P/N 82115-42690.
(1) Position the right-hand engine room main wire with the part number sticker facing you and the male connector on the left side as shown in Figure 2.
(2) Orient the NEW clips so that the open end is facing AWAY from you as shown.
(3) The left-side clip should be 1 in. to the right of the end of the corrugated tubing.
(4) The right-side clip should be 0.5 in. to the left of the end of the corrugated tubing.
(5) Trim the clips AFTER installation.
C. Attach two NEW clips to the left-hand engine room main wire, P/N 82115-42700.
(1) Position the left-hand engine room main wire with the part number sticker facing you and the male connector on the left side as shown in Figure 4.
(2) Orient the NEW clips so that the open end is facing TOWARD you as shown.
(3) The left-side clip should be 1 in. to the right of the end of the corrugated tubing.
(4) The right-side clip should be 0.5 in. to the left of the end of the corrugated tubing.
(5) Trim the clips AFTER installation.
6. Install the left-hand engine room main wire on the driver side.
A. Unplug the headlamp bulb from the vehicle wire harness.
B. Unclip the vehicle wire harness from the headlamp assembly
C. Plug the left-hand engine room main wire into the headlamp bulb.
D. Attach the white clip that is closest to the headlamp bulb to the mounting point the original vehicle side harness was removed from.
E. Attach the second white clip to the mounting point located approximately 1.5 in. below the previous mounting location.
F. Attach the original vehicle wire harness clip that was removed to the NEW location as shown.
G. Connect the vehicle wire harness electrical connector to the NEW left-hand engine room main wire.
7. Install the right-hand engine room main wire on the passenger side.
A. Unplug the headlamp bulb from the vehicle wire harness.
B. Unclip the vehicle wire harness from the headlamp assembly
C. Plug the right-hand engine room main wire into the headlamp bulb.
D. Attach the white clip that is closest to the headlamp bulb to the mounting point the original vehicle side harness was removed from.
E. Attach the second white clip to the mounting point located approximately 1.5 in. below the previous mounting location.
F. Attach the original vehicle wire harness clip that was removed to the NEW location as shown.
G. Connect the vehicle wire harness electrical connector to the NEW right-hand engine room main wire.
8. Verify normal operation of ALL affected systems.