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Accessing/removing 2012 PiP passenger headlight assembly?

Discussion in 'Gen 1 Prius Plug-in 2012-2015' started by Coyotefred, Jun 26, 2017.

  1. Coyotefred

    Coyotefred Member

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    Hello!

    I've just finished several unpleasant hours attempting to seat/secure the passenger-side lowbeam headlight bulb. I've replaced these bulbs before, so I know how to do it and what it should "feel" like. I just can't get the bulb/socket to seat/lock into the housing. The driver's side unlocks and locks into place easily.

    I removed the 2 bolts/moved the coolant reservoir to the side for better access, but still no success. It's difficult to see the part of the housing where the bulb/socket screws in to, but it looks a bit dirty/grimey/sooty(?). I've tried to clean it out a bit with a pick/toothbrush, but it makes no difference.

    The reason I tackled it in the first place was that it was obvious the passenger lowbeam was poor compared to the driver's side; when I inspected it, the bulb/socket was ajar/loose in the housing. When I removed the bulb, it looks perfectly normally (no obvious evidence of overheating, etc.). But I can't see whether anything in the housing might have melted, etc. creating the problem.

    Incidentally, I've been running H9 bulbs after doing the "H11 to H9 conversion"); I seem to recall some discussion about heating concerns...

    In any case, it seems at this point I need to remove that passenger headlight assembly and inspect the housing more closely. I'd like to give it the old "college try" before shelling out what is sure to be several hundred dollars at the dealership. I haven't found any instructions on how to access/remove the assembly...there are some online links/videos, but they all apply to different Prius models (if I've missed something please post). I've removed the 2 obvious bolts securing the housing, but it looks as if I need to somehow remove the entire front bumper/panel to remove it.

    'Any advice/insights? Thanks for your time and help...
     
  2. Prodigyplace

    Prodigyplace Senior Member

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    Perhaps a short subscription to the Toyota TechInfo? 2 days for $15 seems reasonable.
     
  3. bisco

    bisco cookie crumbler

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    i did this a few months ago. drivers side easy, passenger side made me !@$%&*!

    i finally got it in after many tries, and i have gorilla hands. it's too tight, and the wires are to short.

    i got a good visual from the drivers side, so i could picture the orientation of the ears as i flubbed around on the passenger side.

    all the best!(y)
     
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  4. Coyotefred

    Coyotefred Member

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    I'm not familiar with this service/database. I assume it's some kind of service resource? At the service cost I'm likely looking at, $15 is a pretty decent gamble...I was just hoping someone else on the forum might have done this already...

     
  5. bisco

    bisco cookie crumbler

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    it's the toyota service manual online. it should have the step by step for removing anything.
     
  6. Rebound

    Rebound Senior Member

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    There's a good video on YouTube by a guy named cardologist (or something like that) and he pulls the front bumper off a Prius to pull the headlight housings.

    Here, I found it:


    Looks easy.
     
    bisco, Raytheeagle and Coyotefred like this.
  7. Coyotefred

    Coyotefred Member

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    Absolutely perfect...just what I need. I really appreciate your taking the time to track it down. Hopefully I can get to it tonight. I'll post back if I find anything interest/relevant to others as far as the problem. Thanks again!

     
  8. bisco

    bisco cookie crumbler

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    can't wait to see what the problem is.
     
  9. Coyotefred

    Coyotefred Member

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    Well the first stage of surgery is complete, and the problem obvious. The video located/posted by Rebound is excellent and right on the money. My 'fastener remover tool' from Autozone stinks, however...a screwdriver did much better although I still broke a few, so I'll be replacing those. You don't need to totally remove the bumper, as shown in the first picture. The key, as the video shows, are those small metal tabs that must be bent back a bit to allow the lip of the assembly to moved out.

    Once the assembly is out, you can obviously see the issue. It wasn't my bit clumsy hands/poor technique after all...that bulb wasn't going anywhere. I've posted a picture of the (relatively) intact driver's side for comparison (3rd picture). Obviously that inner "ring" of material is some kind of 'meltable' material rather than metal...perhaps that is standard.

    I made the H11 to H9 "conversion" in late 2014 I think and have been running Sylvania H9s ever since. The fact that the driver's side seems relatively normal--and the fact that many others appear to have made this conversion without issues--would suggest the problem was "user error" (me) in not getting the bulb properly/snuggled installed. But after this, I may play it safe by going back to the stock H11s just in case...

    I'm guessing I'm looking at replacing the entire headlight assembly...it doesn't look like the melted section/piece can be removed/replaced on its own.

    But a good cautionary tale I suppose of making sure those bulbs are securely tightened in there!

    https://goo.gl/photos/pFRngd5z5RPVVE5b8

    https://goo.gl/photos/ouc8CYu8ATvzyaQZ8

    https://goo.gl/photos/A1qAo59CRQ5WSA6o6
     
  10. bisco

    bisco cookie crumbler

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    well done! wow, i guess you're lucky there wasn't a fire.
    yeah, i stuck with the elevens, but only because the amazon descriptions were confusing, and i didn't want to have to send the nines back.
     
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  11. xliderider

    xliderider Senior Member

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    I ran H9 bulbs for about a year and a half before installing HIDs with no problems.

    Yes, the plastic mounting area melted due to an improperly seated bulb, unfortunately.

    A replacement headlight assembly should be available on ebay for less than $150.
     
  12. Coyotefred

    Coyotefred Member

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    Any ideas which model(s) and/or year(s) of Prius run the same headlight assembly? I'm seeing listings for the part for 2012-15 PiPs...any idea whether any other Prius models in the same years run this assembly?

     
  13. xliderider

    xliderider Senior Member

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    Searching for "plug in prius headlight assembly", I see several listings on eBay for the passenger side headlight. Match the pictures in the listing/item description to your actual headlight. It is my understanding that the plug in Prius headlight covers have a blue tint vs. the clear covers of the non-plug in models. Additionally, if I recall correctly, there might be differences in whether the PiP headlights have LED DRLs in them or not that changed over the model years.
     
  14. Coyotefred

    Coyotefred Member

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    Hey thanks. I did a little digging, and I believe the headlight assembly 81130-47550, interchange part number TO2519136. Searching with these part numbers brought up the right product....found one for around $130...
     
  15. Rebound

    Rebound Senior Member

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    The LED DRL is below the headlamp. It's not part of the headlamp assembly.
     
  16. xliderider

    xliderider Senior Member

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    Ok, maybe it's the v wagon I'm thinking about then.
     
  17. Rebound

    Rebound Senior Member

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    There was the Base and Advanced PiP's, and the advanced one had leather-like seats and LED headlights, not just theLED DRL's.