DIY HEADLIGHT REMOVAL AND HEADLIGHT BLACKOUT GUIDE AKA Baked Headlight

I didnt see a DIY guide on removing the headlight, or maybe I didnt search enough, but here it is. I also didnt see a blackout guide either, the chrome was just getting to me, I liked the blackout look a lot better. and some cars colors schemes would be much nicer with modified headlights. Lets see them!!







a headlight removal guide is helpful if You need to access the back of the headlight for HID install (installing a ballast)
I am not responsible for you screwing up your car following this guide. I tried to be as thorough as possible. Please read and follow all instructions given. Use Common Sense. Nothing is too hard to perform in this guide. As in any blackout guide, there is a possibility that condensation may occur in your headlight. Pictures taken with iphone, I will try to answer questions politely but I dont guarantee my level of patience if its already been covered. Mods done to 2010 Prius 3. Should be same for all Gen3 Prius.

Tools:
3x Flat head screwdriver (3) you will end up destroying 2-
10mm socket
Phillips Screwdriver
Primer,
Paint,
Oven,
Oven mitts


1) Open the hood, set the parking brake.

2) Locate the side of the bumper near the wheelwell. You will see a 10mm screw and a flathead screwdriver clip. Remove the screw and turn the flathead screw to the vertical posn.
Repeat on opposite side of bumper.





3) Under the bumper, you will see a plastic push pin . pop this out with a flathead screw driver.
Repeat on opposite side of bumper.



4) Pull the bumper away gently, there is a bracket that will have tabs. You wont damage these tabs if you pull gently, they will pop out.
Repeat on opposite side of bumper.





5) You will see a 10mm bolt to the front on the bumper bracket, remove this,
Repeat on opposite side of bumper.




5) in the front of the engine bay, you will see an air deflector. Under are some push pins and 10mm bolts , remove these. Pull the bumper slightly out to give some room to remove the headlight.
Repeat on opposite side.


6) Remove the 10mm screws on the top portion of the headlight.
Repeat on opposite side


7) Locate the metal tab to the medial portion of the headlight. Holding in the headlight.
Bend this up with a flathead screwdriver. (It is the tab in the middle of this picture)


8) While pulling the bumper away, Pull the headlight straight out. It should pull free quite easily with a little wiggling.
(Sorry no pic)

9) Disconnect all connections to lights. Remove lights and keep them in a safe place. DO NOT TOUCH THE LOW AND HIGH BEAM BULBS.




YOU ARE NOW DONE REMOVING THE HEADLIGHTS.,

 

10) Preheat oven to 215 degrees. I used an old towel on top of a cookie sheet. Now might be a good time to explain this to wife.



11) Locate screws on the back of the headlights, remove these and keep in a safe place. There are six or seven of these (I cant remember)
(Sorry lost this pic)

12) Place headlight in the oven, try not to let the headlight touch the sides of the oven, just in case. .






13)”bake” for 10-15 min.


14) Remove headlight from oven, it should be hot enough that you will need oven mitts. If you can physically hold the headlight with your bare hands it is probable not yet hot enough to pull apart too easily.



15)Using one or two flathead screwdrivers or a putty knife, start prying apart the clear outer shield from the black housing.There will be black glue all over these screwdrivers which will be very difficult to remove.





When there is enough space to get fingers in there, use your hands and continue using gradual constant pressure to separate the light. It should be a little difficult pulling it apart. Be careful not to break any tabs and NOT to get any black glue anywhere on the chrome or clear shield as it will be difficult to remove.





You will now have a black housing with the chrome lighting housing and the clear shield with the bezel attached.








16) locate 3 screws on the back of the outer bezel. Remove them and keep in a safe place







17) If you want, you can remove the orange reflector at this point. Remember that there is just chrome under there. And very shiny.











18) mask any areas you don’t want to spray. Here, I masked off the Orange reflector area. In Hindsight, I should have masked off the Ring surrounding the Low beam projector.







19) Primer the bezel housing. Remember not to go too heavy, 2 – 3 light coats should do it, each coat, I sprayed from a different angle to get the whole housing covered, there are a lot of nooks and crannies in this housing. Let dry 45-60min. wet sand here if you wish.






20) Paint the housing any color you wish. I chose gloss black, which is standard fare I think. Again 2-3 light coats and then one heavy coat should work, let dry, preferably overnight. Member sfv41901 has suggested baking these bezels again, just to ensure the paint is cured.







21) Replace the outer housing to the clear shield. Preheat oven to 215 degrees.




22) Place the shield back into the black light housing. This step requires a little maneuvering. I found it easiest to work from the “front” the light to the back. Align up all the tabs. Press as hard as you can to get the headlight aligned correctly.,



23) Bake headlight again for 10-15 min. to soften the glue. Same directions as above



24)After removing the headlight from the oven, again, squeeze the headlight together as hard as you can to get the headlight resealed and aligned.
Replace the screws, to tighten, Again, I found it easiest to work from front to back, and retighten screws often. Ensure that they are aligned and tight.



25) Reassembly and replacement of headlight, is opposite of disassembly and removal.





Good luck and show off them headlights!!

 

Let the flaming commence!!

 

Yes, yellow vinyl overlay

So I removed the high beam bulbs and yes, I noted a faint paint smell still. I will leave them out for a week or so to let the paint dry some more.
added suggestion to the DIY guide, thanks for the headsup

 

They are called Velox Flight. U can find them at costco or discount tire/. Americas tire. Pretty much BBS knockoffs.

Just make sure you DONT paint the rear bezel and you will be fine. You DO need chrome reflector for the high beam.