TOYOTA AVENSIS 2003 Service Repair Manual

650ST±01
I35226
Headlamp No.2 BulbBulb Socket
Socket Cover
Bulb Socket Back Cover
Headlamp No.1 Bulb
Front Turn Signal Lamp Bulb
Clearance Lamp Bulb
Halogen Headlamp:
Discharge Headlamp:
Headlamp No.2 Bulb
Clearance Lamp Bulb
Bulb Socket
Back Cover
Front Turn Signal Lamp Bulb
Socket Cover
Discharge Headlamp Bulb
Headlamp Protector Retainer
±
LIGHTING HEADLAMP UNIT LH
65±15
AVENSIS REPAIR MANUAL (RM1018E)
HEADLAMP UNIT LH
COMPONENTS
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650SU±01
I35241
I35242
I35243
I35254
65±16
±
LIGHTINGHEADLAMP UNIT LH
AVENSIS REPAIR MANUAL (RM1018E)
REPLACEMENT
1.REMOVE FRONT SPOILER COVER LH (See page 76±3)
2.REMOVE FRONT SPOILER COVER RH (See page 76±3)
3.REMOVE FRONT BUMPER COVER (See page 76±3) 4. REMOVE HEAD LIGHT ASSY
(a) Disconnect the connector.
(b) Remove the 2 screws.
(c) Remove the headlamp assy and disengage the claw asshown in the illustration.
5. REMOVE HEADLAMP, NO.1 BULB (HALOGEN HEAD LAMP)
(a) Release the lock of the set spring and remove the head- lamp bulb No.1.
6. REMOVE DISCHARGE HEADLAMP BULB (DISCHARGE HEAD LAMP)
(a) Rotate the bulb socket cover in the direction of the arrow
and pull it of backward of the vehicle.
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I35255
I35244
I35229
I35245
I36703
±
LIGHTING HEADLAMP UNIT LH
65±17
AVENSIS REPAIR MANUAL (RM1018E)
(b) Release the lock of the set spring and remove the dis-
charge headlamp bulb.
7. REMOVE HEADLAMP, NO.2 BULB
(a) Remove the headlamp socket cover.
(b) Release the lock of the set spring and remove the head- lamp bulb No.2.
8. REMOVE CLEARANCE LAMP BULB
(a) Remove the clearance lamp socket and the clearance lamp bulb as shown in the illustration.
(b) Remove the clearance lamp bulb from the clearance lamp socket.
9. REMOVE FRONT TURN SIGNAL LAMP BULB
(a) Remove the front turn signal lamp socket and the front turn signal lamp bulb as shown in the illustration.
10. REMOVE HEADLAMP PROTECTOR RETAINER
HINT:
When only the installation part of the headlamp unit assy LH is
damaged, it can be repaired inexpensively by using a head-
lamp protector retainer. In this case, however, the headlamp
unit assy LH itself should not be damaged.
(a) Cut off the part shaded in the illustration and file it smooth.
NOTICE:
After cutting off the part roughly, place the headlamp pro-
tector retainer against the bosses, and gradually file any in-
terfering part until the proper condition for installation is
made.
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I36704
65±18
±
LIGHTINGHEADLAMP UNIT LH
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the headlamp protector retainer with the 2 screws.
11.HEADLIGHT AIM ONLY (See page 65±19)
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650SV±01
I33423
V LH LineV RH LineV Line
Ground
H Line
±
LIGHTING HEADLAMP UNIT LH
65±19
AVENSIS REPAIR MANUAL (RM1018E)
ADJUSTMENT
1. HEADLIGHT AIM ONLY
HINT:

Perform aiming adjustment with Low±beam.

Since the Low±beam light and the High±beam light is a
unit, if aiming on either side is connect, the other side
should also be connect.
However, check both beams just to make sure.
(a) Prepare vehicle in the following conditions.

Check that any damage or deformation does not exist on
the body around the headlights.

Fuel tank is full.

The tire inflation pressure is at the specified level.

Vehicle is parked at a level surface.

A person having an average weight sits in the driver's
seat.

Vehicle is bounced up and down to stabilize the suspen-
sion to the normal position.
(b) Prepare a thick white paper (Draw base lines).
HINT:

Stand the paper perpendicular as against a wall.

The base lines differ for ºLow±beam inspectionº and
ºHigh±beam inspectionº.
(1) V line (Vehicle Center position) Draw a vertical line down the center of the paper in
order to align it with the center of the vehicle.
(2) H line (Headlight height)
Draw horizontal line across the paper at the same
height from the ground as the center mark for the
Low±beam lights.
(3) V LH line, V RH line (Center mark position of right and left headlights)
Draw vertical lines, for left & right, at the same posi-
tion as the center mark for the Low±beam lights.
HINT:
Follow the same procedures when adjusting the High±beam
lights.
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I35248
V LH Line
V RH Line
V Line90
3 m (9.84 ft)
I37308
Low Beam:V LH Line
V RH Line
30mm
(1.18 in.) 84 mm
(3.3 in.)
H Line6mm
(0.23 in.)
I37102
High Beam:V LH Line
V RH Line
H Line
I35802Adjusting Bolt A
Adjusting Bolt B
65±20
±
LIGHTING HEADLAMP UNIT LH
AVENSIS REPAIR MANUAL (RM1018E)
(c) Check the headlight aiming. (1) Align the paper with the center of the vehicle.

Make a distance of 3 m ( 9.84 ft) between the head-
lights and the paper, and put the paper against a
wall with the H line being at the same height as the
center mark.

Align the center of the vehicle with the V line on the
paper, and ensure that the paper is at a 90  angle
in accordance to the V line.
(2) Start the engine.
(3) Turn on the headlights and check that the aim is with in the specified valves shown in the illustration.
NOTICE:

When covering the headlights, finish it within 3 mi-
nuites.

The headlight lens is made of synthetic resin, so it is
easily.
HINT:
When checking the aiming of the High±beam, shut off the Low±
beam or disconnect the Low±beam headlight connector.
(d) Adjust the aim in the vertical direction: Using a screwdriver, adjust the headlight aim within the
specified range by turning the aiming screw A.
NOTICE:

Adjust the headlight aim by turning the screw in the
tightening direction.

When the screw is tightened excessively, loosen it
once and re±tighten it to adjust the headlight aim.
HINT:
The optical axis aim moves downward when turning the screw-
driver clockwise, and it moves upward when turning the screw-
driver counterclockwise.
(e) Adjust the aim in the horizontal direction: Using a screwdriver, adjust the headlight aim within the
specified range by turning the aiming screw B.
NOTICE:

Adjust the headlight aim by turning the screw in the
tightening direction.

When the screw is tightened excessively, loosen it
once and re±tighten it to adjust the headlight aim.
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650T3±01
I35231
I35231
AB
A
65±28
±
LIGHTINGHEIGHT CONTROL SENSOR SUB±ASSY FR RH
AVENSIS REPAIR MANUAL (RM1018E)
HEIGHT CONTROL SENSOR SUB±ASSY FR RH
REPLACEMENT
1.REMOVE HEIGHT CONTROL SENSOR SUB±ASSY FR RH
(a)Disconnect the connector.
(b)Remove the 3 nuts and height control sensor sub±assy front RH.
2.INSTALL HEIGHT CONTROL SENSOR SUB±ASSY FR RH
(a)Install the height control sensor sub±assy front RH with the 3 nuts.
Torque:
A: 7.9 N
m (81 kgf
cm, 70 in.
lbf)
B: 5.8 N
m (59 kgf
cm, 51 in.
lbf)
(b)Connect the connector.
3.HEADLIGHT AIM ONLY (See page 65±19)
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650T4±01
I35240
I35240
A
B
A
±
LIGHTINGHEIGHT CONTROL SENSOR SUB±ASSY REAR RH
65±29
AVENSIS REPAIR MANUAL (RM1018E)
HEIGHT CONTROL SENSOR SUB±ASSY REAR RH
REPLACEMENT
1.REMOVE HEIGHT CONTROL SENSOR SUB±ASSY
REAR RH
(a)Disconnect the connector.
(b)Remove the 2 bolts, the nut and height control sensor sub±assy rear RH.
2.INSTALL HEIGHT CONTROL SENSOR SUB±ASSY REAR RH
(a)Install the height control sensor sub±assy rear RH with the 2 bolts and the nut.
Torque:
Bolt (A): 7.9 N
m (81 kgf
cm, 70 in.
lbf)
Nut (B): 5.8 N
m (59 kgf
cm, 51 in.
lbf)
(b)Connect the connector.
3.HEADLIGHT AIM ONLY (See page 65±19)
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650T0±02
E60618
±
LIGHTINGLICENSE PLATE LAMP ASSY
65±25
AVENSIS REPAIR MANUAL (RM1018E)
LICENSE PLATE LAMP ASSY
REPLACEMENT
1.REMOVE BACK DOOR TRIM BOARD ASSY (See page LIFTBACK 75±40, WAGON 75±45)
2. REMOVE LUGGAGE COMPARTMENT DOOR GARNISH SUB±ASSY OUTSIDE (SEDAN
MODELS) (See page 76±27)
3. REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE (LIFTBACK MODELS) (See page 76±28)
4.REMOVE BACK DOOR GARNISH SUB±ASSY OUTSIDE (WAGON MODELS) (See page 76±29)
5. REMOVE LICENSE PLATE LAMP ASSY
(a) Pull the license plate lamp assy to the side of vehicle asshown in the illustration and release the claw.
(b) Disconnect the connector and remove the license plate lamp assy.
(c) Remove the license plate lamp bulb.
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650NC±02
±
LIGHTING LIGHTING SYSTEM
65±1
AVENSIS REPAIR MANUAL (RM1018E)
LIGHTING SYSTEM
PRECAUTION
1. PRECAUTION OF HEADLIGHT BULB REPLACEMENT
(a) When any defects such as deformation, crack, dent, chipping, etc. are identi\
fied on the discharge
headlight (especially, on the light control ECU), replace it with a new one.
(b) Even if the operation seems to be normal, the fail±safe function may \
be defective.
(c) Be careful not to scratch on drop bulbs of the discharge headlamp and halo\
gen bulbs (for headlamp and fog lamp), as they have pressurized gas inside and can be easily broke\
n.
(d) Touching the HV socket of the discharge headlight with the headlight dimmer swit\
ch ON could gener- ate momentary high voltage of 20,000 V and lead to a serious injury.
(e) Never connect a tester to the high voltage socket of the discharge headlight \
for measurement, as this
leads to a serious injury because of high voltage.
(f) When performing operation related to the discharge headlight, keep it away from water including rain, turn off the light control switch, and disconnect the battery terminal and the \
connector of the light control
ECU in advance to avoid electric shock.
(g) When performing operation related to the discharge headlight, start it after\
assembling is completed
and never turn the lights on without a bulb installed.
(h) Do not turn the discharge headlight on using another power source except\
vehicle's.
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