Service Precautions Discharge Headlight: Notes

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.

CHECKING PROCEDURE FOR DISCHARGE HEADLIGHT RELATED PARTS (INSPECTION PROCEDURE WHEN REUSING THE CONTROLLER)

1 - 1 VISUAL CHECK OF CONTROLLER (CASE)

If any of the check items below are found, replace the controller.

CONTROLLER REFERENCE CHART

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.

1 - 2 CHECK OF WIRING HARNESS BETWEEN CONTROLLER AND BULB

If any of the check items below are found, replace the wiring harness between the controller and the bulb.

WARNING: If the wiring harness between the controller and the bulb is damaged, always replace it. Attempting to repair the wiring harness may cause a melted harness wire, or may result in a burn or death due to an electric shock by high voltage.

CONTROLLER REFERENCE CHART

Items to be checked	Why the controller should be replaced
Wiring harness shield damaged	Abnormal noise may cause.
Damaged connector (chipped or cracked plastics, or deformed terminal)	The damaged part(s) may cause poor connection or short circuit.

1 - 3 CHECK OF CONTROLLER OPERATION

If any of the abnormalities below are found, replace the controller.

NOTE: Ensure that the headlight control system and its circuit (power supply control at engine start and during steady illumination, high voltage generating circuit, etc.) are working normally. Then, check whether any internal breakage has occurred in the controller. However, some internal breakage may not be found.

CONTROLLER OPERATION CHART

Check item (Check of illumination operation)
With the headlight bulb in the cold state (with the light turned off for 10 minutes or more) and in warm state (after the light is illuminated for 15 minutes or more, it is turned off for 1 minute), turn ON and OFF the headlight several times, and then check that the headlight illuminates without fail.
Observe the headlights until they illuminate steadily (approximately five minutes after switching them on). Check that the headlights do not flash or flicker.
Turn on the headlights for thirty minutes. Check that the brightness is the same between right and left lights.
Turn on the headlights for thirty minutes. Check that the headlights do not flash or flicker for thirty minutes.

Troubleshooting procedure for discharge headlight (diagnostic procedure for malfunctions)
1. Check that the connectors are connected securely and the fuse has not been blown.
2. Before troubleshooting, read through the "Symptom chart" to understand what and how you should do. Follow all the procedures carefully.
3. The components should be checked with their connectors disconnected.