Toyota Tercel 1984-1994 Repair Guide

Headlights

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REMOVAL & INSTALLATION



See Figures 1, 2, 3 and 4

Sealed Beam Type
  1. Remove the headlight bezel (trim) and/or the radiator grille, as necessary. It may also be necessary to remove the front turn signal/parking light on some models.
  2.  



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Fig. Fig. 1: On some models, it is necessary to remove the grille before removing the headlight bezel

  1. The headlight is held in place by a retainer secured by small screws. Identify these screws before applying any tools. Do not confuse the small retaining screws with the larger aiming screws.
  2.  



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Fig. Fig. 2: Apply some penetrating oil on the retaining screw threads. This will ease their removal as they are usually rusted

  1. Using a small screwdriver (preferably magnetic), remove the small screws in the head lamp retainer.
  2.  



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Fig. Fig. 3: The grease inside the connector helps prevent terminal corrosion

  1. The head lamp may be gently pulled free from its mount. Unplug the connector from the back of the headlight, then remove the unit from the car.
  2.  

To install:
  1. Place the new head lamp in position and connect the wiring harness. Make sure the headlight is right-side up.
  2.  



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Fig. Fig. 4: Make sure you install the headlight with the correct side up

  1. Turn on the headlights and check the new lamp for proper function. Check both high and low beams before final assembly.
  2.  
  3. Install the retainer.
  4.  
  5. Install the headlight bezel and/or grille
  6.  

Semi-Sealed Beam Type

See Figures 5 and 6

This type of light is replaced from behind the unit. The lens is not removed or loosened.

  1. Open and support the hood.
  2.  
  3. Unplug the wiring connector from the back the lamp. Be careful to release the locking tab completely before removal.
  4.  



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Fig. Fig. 5: On semi-sealed beams, depress the sides of the connector to release the lock tab

  1. Grasp the base of the bulb holder and collar, twist it, then carefully remove the bulb holder and bulb from the housing.
  2.  



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Fig. Fig. 6: Turn the bulb retaining ring, then remove the bulb

  1. Release the clip on the holder, then remove the bulb.
  2.  

To install:
  1. Install the new bulb in the holder and make sure the clip engages firmly.
  2.  

Hold the new bulb with a clean cloth or a piece of paper. DO NOT touch or grasp the bulb with your fingers. The oils from your skin will produce a hot spot on the glass envelope, shortening bulb life by up to 50 percent. If the bulb is touched accidentally, clean it with alcohol and a clean rag before installation.

  1. Install the holder and bulb into the housing. Note that the holder has guides which must align with the housing. When the holder is correctly seated, turn the collar to lock the holder in place.
  2.  
  3. Connect the wiring harness. Turn on the headlights and check the function of the new bulb on both high and low beam.
  4.  

AIMING



See Figures 7 and 8

The head lamps should be aimed using a special alignment tool, however this procedure may be used for temporary adjustment. Local regulations may vary regarding head lamp aiming, consult with your local authorities.

  1. Verify the tires are at their proper inflation pressure. Clean the head lamp lenses and make sure there are no heavy loads in the trunk. The gas tank should be filled.
  2.  

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  1. Position the vehicle on a level surface facing a flat wall 25 ft. (7.7 m) away.
  2.  
  3. Measure and record the distance from the floor to the center of the head lamp. Place a strip of tape across the wall at this same height.
  4.  
  5. Place strips of tape on the wall, perpendicular to the first measurement, indicating the vehicle centerline and the centerline of both head lamps.
  6.  
  7. Rock the vehicle side-to-side a few times to allow the suspension to stabilize.
  8.  
  9. Turn the lights ON, adjust the head lamps to achieve a high intensity pattern in the areas shown in the illustrations.
  10.  



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Fig. Fig. 7: Low-beam pattern alignment



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Fig. Fig. 8: High-beam pattern alignment

 
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