Change the HID Headlights on a 2007 Prius

The Prius high intensity discharge (HID) headlights are gas lights similar to sodium lights in the street illumination. When the HID bulbs reach a certain number of hours, they start to automatically turn off when hot and come back on again after some minutes off. You can force the headlights to come on again by briefly turning them off to let them cool down and then turning them on again.. When the headlights start to fail this way it is time to change them. However, the Prius HID headlights are expensive and the Prius design makes changing them a non-trivial task. Your neighborhood electrician will probably say he cannot change those headlights. Toyota charges hundreds of dollars for the service plus hundreds of dollars for the light bulbs. This article describes how to order and change the Prius HID headlights in about 2 hours of work using simple tools. In time: the car accessories store in your town will probably not have the Prius headlights and the best choice is to order them online.

Steps

  1. Plan to spend 4 hours to complete the job -- between gathering the tools and cleaning up/putting everything back where you found. You might be done in about 1 hour if you are diligent, have all the tools ready and use a power drill and socket wrench). You don't need help from anybody. This is a very light job. Plan to change both HID light bulbs at the same time. If one of them failed the other will fail soon. To change one or both bulbs is the same amount of work (it might take 10 minutes longer for both).
  2. Get the Prius HID headlights online. The higher the temperature rated the more blue the lights will be (example: 8000K is much bluer than 4300K (bright yellowish).
    • D4C / D4S/ D4R HID Bulbs Pair
    • Heliolite Xenon 4300K Factory D4R HID replacement bulb
    • 8000K 8500K D4R D4S HID Light Bulbs Toyota Prius Avalon.
    • The D4C HID bulbs use the highest quality GE burner made in Hungary which will produce a super bright and sky blue color to replace your stock yellowish 4300K HID bulbs.
  3. Get the tools for the job. The WD-40 is to loosen screws, the combination wrench is 10 mm; If you have them, use a 10 mm socket wrench and a ratchet (both not shown in the picture) as they will make the job quicker.
  4. Raise the front of the car by driving the car on top of {{safesubst:#invoke:convert|convert}} thick plywood or similar wood. You could use other means like lifting with a jack and putting books under the front wheels. Make sure to lock the rear wheels to prevent the car from moving -- lock the rear wheels on both sides (front and back). You have to lie down under the front bumper of the car. Make sure the car is stable and is not going to move.
  5. Get six cups to put the screws of the different parts removed from the car. It makes things easier when putting everything back together.
  6. Remove the black plastic cover on top of the bumper/radiator. These are not regular screws, they are clips. Use a screwdriver on their side and pliers to remove them. Remove a total of 6 plastic clips and the black piece of plastic comes off.
  7. Begin removing the bumper of the car. Remove 3 plastic clips and 2 screws. These two screws are protected by rubber. It is easier if you remove the rubber ring (by hand) and use pliers to remove the screws. Using a screwdriver to remove the screw might damage the screw if the screw is stuck.
  8. Lie down under the bumper and remove a plastic protector held by 9 screws. It is the part shown in the middle of the picture.
  9. Remove the bumper protector (narrow black part under the bumper). Total of 7 screws.
  10. Bottom sides of the bumper: Remove screw right in front of both wheels (total two screws, one in each side of the car).
  11. Remove clip on top of front wheels (positioned at about 2 o'clock position).
  12. Partially pull out the wheel guard with your hands with help of a screwdriver and access the bumper screw hidden under it. Remove the screw with a screwdriver or socket wrench.
  13. At this point you should have all the bumper screws removed. A total of 6 screws and and 3 clip "screws" (plastic).
  14. It is time to pull out the bumper. Put a cardboard box under the bumper to hold it in place when it falls. Pull out the bumper by forcing out the plastic bumper from the pins where it is secured. When the bumper comes out, disconnect the fog light cables. Put the bumper away. The bumper is just around 8 lb in weight.
  15. Each headlight assembly (the eyes of the car) is hold by 3 screws (on top, inside and outside). Remove them.
  16. Remove the cables that feed the headlight assembly. No need to mark them for they are all different and only fit if they are in the correct place.
  17. Take the headlight assembly to a clean table to change the HID light bulbs.
  18. Remove the round black back of headlight bulbs. This is the finned plastic part on the headlight assembly. It has a very sticky O-ring to keep out moisture and may be very reluctant to turn. Notice the markings for lock and unlock directions. A small punch and hammer was helpful to loosen it initially and then continue the remaining small amount of rotation by hand.
  19. Remove HID bulb holder. Notice the "lock" arrow and twist the opposite direction before pulling up on the silver holder.
  20. Put clean gloves on. You are not supposed to touch the HID headlights because dirt or grease might make some regions of the glass overheat when in operation, decreasing the life of the HID bulb. See picture of original Prius (left) and OEM substitution bulb (right)
  21. Remove the old bulb; observe that the HID bulb fits only in the right orientation -- see grooves in its base. Install the new bulb. Close the assembly, making sure that the black cover fits well and the rubber seal is well positioned. This rubber seal prevents moisture from destroying the HID bulb inside.
  22. Go back to the car, reconnect all the cables. Before screwing the headlight assembly to the car make sure to test all the functions: low beam, high beam, and turn signal lights. The picture shows a comparison of intensity and color of the new light left, in the picture, with the old original Prius light. If not clear from the picture, the new light is stronger and more blue.
  23. Replace the HID light from the other side of the car
  24. Test both new headlights together. Test low/high beam and turn signals. Proceed if everything is working well.
  25. Screw down the headlight assemblies (3 screws for each).
  26. Put the bumper back near its final location and reconnect the fog lights. Test all the lights again.
  27. If you are not in a closed garage on a cold night you might want to run the car engine for 10 minutes to make sure you recharge the batteries. (You know how easy it is to deplete the Prius 12 V battery.)
  28. Put the bumper back into position. You might have to nudge with your hand to get it into place. See figure. Align the screw holders under the bumper with the bumper.
  29. Place the screws that fix the bumper located on top of the front wheel (behind the plastic protection).
  30. Replace the plastic protection on top of the wheel. If the plastic clip is loose now, press its wings with pliers (see picture).
  31. Replace the narrow black part under the bumper (7 screws).
  32. Replace the bumper screws on the right and left under the car.
  33. Place big black bumper/engine protector. See figure for correct position (front vs. back). Align the black part to the screw holder and place the 9 screws. The 5 coarse screws are in the front near the bumper and the 4 fine screws are in the back far from the bumper.
  34. On top of the bumper, place the 3 plastic screw clippers and the two screws with rubber bumpers.
  35. Replace the plastic guard on top of the radiator/bumper.


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Warnings

  • Test the lights for short periods when the car engine is off to prevent the need of a jump start.
  • Run the car with all lights off for 20 minutes before you start the job to prevent the battery from becoming depleted through this process.

Things You'll Need

  • Pair of new Prius HID light bulbs
  • 5 mm Screwdriver
  • Pliers
  • 10 mm combination or 10 mm hexagonal or 10 mm socket wrench
  • WD40 or equivalent
  • Clean gloves
  • A way to raise the front of the car (see text)
  • Lamps to illuminate the work area
  • Ratchet, power drill (optional)

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