Toyota FJ Cruiser (GSJ 10, 15 series). Instruction - part 294

LIGHTING  –  HEADLIGHT ASSEMBLY

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ADJUSTMENT

1.

PREPARE VEHICLE FOR HEADLIGHT AIMING 
ADJUSTMENT
(a) Prepare the vehicle:

•

Ensure that there is no damage or deformation of 
the body around the headlights.

•

Fill the fuel tank.

•

Fill the oil to the specified level.

•

Fill the coolant to the specified level.

•

Inflate the tires to the appropriate pressure.

•

Place the spare tire, tools and jack in their 
original positions.

•

Unload the trunk.

•

Sit a person of average weight (68 kg, 150 lb) in 
the driver seat.

2.

PREPARE FOR HEADLIGHT AIMING (for Using a 
Tester)
(a) Prepare the vehicle for headlight aim check.
(b) Adjust the headlight in accordance with headlight 

tester instructions.

3.

PREPARE FOR HEADLIGHT AIMING (for Using a 
Screen)
(a) Prepare the vehicle in accordance with the following 

conditions:
•

Place the vehicle in a location that is dark 
enough to clearly observe the cutoff line. The 
cutoff line is a distinct line, below which light from 
the headlights can be observed and above which 
it cannot.

•

Place the vehicle at a 90

° angle to the wall.

•

Keep a 7.62 m (25 ft) distance between the 
center of the headlight bulb and the wall.

•

Place the vehicle on a level surface.

•

Bounce the vehicle up and down to settle the 
suspension.
NOTICE:
A distance of 7.62 m (25 ft) between the 
vehicle (the center of the headlight bulb) and 
the wall is necessary for proper aim 
adjustment. If unable to secure a distance of 
7.62 m (25 ft), set a distance of exactly 3 m 
(9.84 ft) to check and adjust the headlight 
aim. (Since the target zone changes 
depending on the distance, follow the 
instructions shown in the illustration.)

(b) Prepare a piece of thick white paper (approximately 

2 m (6.6 ft) high x 4 m (13.1 ft) wide) to use as a 
screen.

(c) Draw a vertical line down the center of the screen (V 

line).

90

q

7.62 m (25 ft) 
3 m (9.84 ft)

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LIGHTING  –  HEADLIGHT ASSEMBLY

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(d) Set the screen, as shown in the illustration.

HINT:
•

Stand the screen perpendicular to the ground.

•

Align the V line on the screen with the center of 
the vehicle.

(e) Draw base lines (H line, V LH and V RH lines) on 

the screen, as shown in the illustration.
HINT:
•

The base lines differ for "low-beam inspection" 
and "high-beam inspection".

•

Mark the headlight bulb center marks on the 
screen. If the center mark cannot be observed on 
the headlight, use the center of the headlight 
bulb.

(1) H Line (Headlight height):

Draw a horizontal line across the screen so that 
it passes through the center marks. The H line 
should be at the same height as the headlight 
bulb center marks of the low-beam headlights.

(2) V LH Line and V RH Line (Center mark 

positions of left-hand (LH) and right-hand (RH) 
headlights):
Draw two vertical lines so that they intersect the 
H line at each center mark (aligned with the 
center of the low-beam headlight bulbs).

Aligning distance 7.62 m (25 ft):

Aligning distance 3 m (9.84 ft):

V RH Line

90°

7.62 m (25 ft)

V LH Line

V Line

V RH Line

90°

3 m (9.84 ft)

V LH Line

V Line

H Line

90°

7.62 m (25 ft)

H Line

90°

3 m (9.84 ft)

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V LH Line

V Line

V RH Line

H Line

Ground

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LIGHTING  –  HEADLIGHT ASSEMBLY

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4.

INSPECT HEADLIGHT AIMING
(a) Cover the headlight on the opposite side or 

disconnect its connector, to prevent light from the 
headlight not being inspected from affecting the 
headlight aiming inspection.
NOTICE:
Do not keep the headlight covered for more than 
3 minutes. The headlight lens is made of 
synthetic resin, and may easily melt or be 
damaged due to heat.

(b) Start the engine.

NOTICE:
Engine rpm must be 1,500 or more.

(c) Turn on the headlight and make sure that the cutoff 

line falls within the specified area, as shown in the 
illustration.

HINT:
•

Since the low-beam light and the high-beam light 
are a unit, if the aim on one is correct, the other 
should also be correct. However, check both 
beams just to make sure.

•

Alignment distance is 7.62 m (25 ft):
The cutoff line is 101 mm (3.97 in.) above and 
below the H line as well as to the left and right of 
the V line with low-beam (SAE J599).

Aligning distance 7.62 m (25 ft):

Aligning distance 3 m (9.84 ft):

H Line

H Line

H Line

V RH Line

V LH Line

Low Beam:

High Beam:

V RH Line

V LH Line

Low Beam:

High Beam:

40 mm 
(1.57 in.)

101 mm 
(3.97 in.)

101 mm 
(3.97 in.)

40 mm 
(1.57 in.)

53 mm 
(2.08 in.)

21 mm 
(0.82 in.)

40 mm 
(1.57 in.)

40 mm 
(1.57 in.)

101 mm 
(3.97 in.)

101 mm 
(3.97 in.)

Cutoff Line

Cutoff Line

H Line

40 mm 
(1.57 in.)

101 mm 
(3.97 in.)

101 mm 
(3.97 in.)

40 mm 
(1.57 in.)

40 mm 
(1.57 in.)

40 mm 
(1.57 in.)

101 mm 
(3.97 in.)

101 mm 
(3.97 in.)

V RH Line

V LH Line

V RH Line

V LH Line

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LIGHTING  –  HEADLIGHT ASSEMBLY

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•

Alignment distance is 3 m (9.84 ft):
The cutoff line is 40 mm (1.57 in.) above and 
below the H line as well as to the left and right of 
the V line with low-beam (SAE J599).

•

Alignment distance is 7.62 m (25 ft):
The cutoff line is 101 mm (3.97 in.) above and 
below the H line as well as to the left and right of 
the V line with high-beam (SAE J599).

•

Alignment distance is 3 m (9.84 ft):
The cutoff line is 40 mm (1.57 in.) above and 
below the H line as well as to the left and right of 
the V line with high-beam (SAE J599).

•

Alignment distance is 7.62 m (25 ft):
The cutoff line is 53 mm (2.08 in.) below the H 
line with low-beam.

•

Alignment distance is 3 m (9.84 ft):
The cutoff line is 21 mm (0.82 in.) below the H 
line with low-beam.

5.

ADJUST HEADLIGHT AIMING
(a) Adjust the aiming vertically.

Adjust the headlight aim to within the specified 
range by turning aiming screw A with a screwdriver.
NOTICE:
The final turn of the aiming screw should be 
made in the clockwise direction. If the screw is 
tightened excessively, loosen it and then 
retighten it, so that the final turn of the screw is 
in the clockwise direction.

(b) Perform low-beam aim adjustment.

HINT:
The headlight aim moves down when the aiming 
screw is turned clockwise, and moves up when the 
aiming screw is turned counterclockwise.

(c) Adjust the aim horizontally.

Adjust the headlight aim to within the specified 
range by turning aiming screw B with a screwdriver.
NOTICE:
The final turn of the aiming screw should be 
made in the clockwise direction. If the screw is 
tightened excessively, loosen it and then 
retighten it, so that the final turn of the screw is 
in the clockwise direction.

REASSEMBLY

1.

INSTALL FRONT TURN SIGNAL LIGHT BULB
(a) Install the front turn signal light bulb into the light 

socket.

(b) Turn the front turn signal light socket and bulb, in 

the direction indicated by the arrow in the 
illustration, to install them.

A

B

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