Headlight Bulb Replacement for a Kei Car That Requires This Much Disassembly (Daihatsu Copen L880K)

I received a request from another auto shop to replace the high beam bulb for a Daihatsu Copen.

When a request comes from another shop, it usually means the job is difficult, but this time it exceeded my expectations.

This job was to replace the high beam bulb, but it required removing the entire headlight unit. While headlight unit removal in many cases only requires detaching the front bumper, with this Copen, the front fender also needed to be removed. The front fender’s mounting bolts are also located behind the cowl top panel where the wiper motor is housed, so the wipers and cowl top panel had to be removed as well. The disassembly at the turning point looked like this:

With its cute exterior design and the constraints of using existing components, I suppose this level of serviceability is the best that could be achieved.

I experienced an imported car level of difficulty on a domestic Japanese car, which made me realize how manufacturing priorities are determined.