TOYOTA AVENSIS 2005 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
± LIGHTINGHEADLAMP UNIT LH
65±15
AVENSIS REPAIR MANUAL (RM1018E)
HEADLAMP UNIT LH
COMPONENTS

650SR±01


7 8
9 654 3 2 1
10 11 12 13 14 15 16 17I33101
I35771
± LIGHTINGLIGHTING SYSTEM
65±9
AVENSIS REPAIR MANUAL (RM1018E)
INSPECTION
1. HEADLAMP DIMMER SWITCH ASSY
(a) Inspect light control switch continuity.
(1) Check that there is continuity between the terminals
at each switch position as shown in the chart.
Standard:
Switch operationTester connectionSpecified condition
OFF±No continuity
TAIL14 ± 16Continuity
HEAD13 ± 16 ± 14Continuity
(b) Inspect headlight dimmer switch continuity.
(1) Check that there is continuity between the terminals
at each switch position as shown in the chart.
Standard:
Switch operationTester connectionSpecified condition
FLASH7 ± 8 ± 16Continuity
LOW BEAM16 ± 17Continuity
HI BEAM7 ± 16Continuity
(c) Inspect turn signal switch continuity.
(1) Check that there is continuity between the terminals
at each switch position as shown in the chart.
Standard:
Switch operationTester connectionSpecified condition
Right turn2 ± 3Continuity
Neutral±No continuity
Left turn1 ± 2Continuity
(d) Inspect front fog light switch continuity.
(1) Check that there is continuity between the terminals
at each switch position as shown in the chart.
Standard:
Switch operationTester connectionSpecified condition
OFF±No continuity
Front fog switch ON10 ± 11Continuity
Rear fog switch ON10 ± 12Continuity
2. HAZARD WARNING SIGNAL SWITCH ASSY
(a) Check that there is continuity between the terminals at
each switch position as shown in the chart.
Standard:
Switch operationTester connectionSpecified condition
OFF1 ± 4No continuity
ON1 ± 4Continuity
Illumination circuit8 ± 9Continuity

I30905
I30905
E64835
65±10
± LIGHTINGLIGHTING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
(b) Inspect illumination operation.
(1) Connect the positive (+) lead from the battery to the
terminal 8 and negative (±) lead to the terminal 9,
then check that the illumination comes on.
3. FRONT DOOR COURTESY LAMP SWITCH ASSY
(a) Check that there is continuity between the terminal and the switch body when the switch is operated.
Standard:
ON (When shaft is pressed): No continuity
OFF (When shaft is not pressed): Continuity
4. REAR DOOR COURTESY LAMP SWITCH ASSY
(a) Check that there is continuity between the terminal and the switch body when the switch is operated.
Standard:
ON (When shaft is pressed): No continuity
OFF (When shaft is not pressed): Continuity
5. BACK DOOR LOCK ASSY (WAGON MODELS)
(a) Inspect back door courtesy lamp switch operation.
(1) Check that there is continuity between the terminal
1 and the terminal 2 when the back door is open and
closed.
Standard:
Back door is open: No continuity
Back door is closed: Continuity
6. BACK DOOR LOCK ASSY (LIFTBACK MODELS)
(a) Inspect back door courtesy lamp switch operation.
(1) Check that there is continuity between the terminal
1 and the terminal 2 when the back door is open and
closed.
Standard:
Back door is open: No continuity
Back door is closed: Continuity
7. HEADLAMP RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity

B16200
B16200
B16200
E64835
E68131
± LIGHTINGLIGHTING SYSTEM
65±11
AVENSIS REPAIR MANUAL (RM1018E)
8. TAIL LAMP RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity
9. FOG LAMP RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity
10. REAR FOG LAMP RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity
11. RUNNING LIGHT RELAY
(a) Inspect relay continuity.
Standard:
ConditionTester connectionSpecified condition
Always1 ± 2Continuity
Always3 ± 5No continuity
Apply B+ between
the terminal 1 and 23 ± 5Continuity
12. TRANSPONDER KEY AMPLIFIER
(a) Inspect key cylinder operation.
(1) Connect the battery positive (+) lead to the terminal
2 and the battery negative (±) lead to the terminal
6, and check that the indicator light comes on.

E68137
E68137
65±12
± LIGHTINGLIGHTING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
13. MAP LAMP ASSY
(a) Check the continuity between the terminals at each
switch position as shown in the chart.
Standard:
Switch operationTester connectionSpecified condition
OFF±No continuity
DOOR2 ± 4Continuity
ON3 ± 4Continuity
14. ROOM LAMP ASSY NO.2
(a) Check the continuity between the terminals at each
switch position as shown in the chart.
Standard:
Switch operationTester connectionSpecified condition
OFF±No continuity
DOOR2 ± 4Continuity
ON3 ± 4Continuity
15. COURTESY LAMP ASSY
(a) Check that the continuity exists between the terminals.
Standard: There is continuity
16. LUGGAGE COMPARTMENT LAMP ASSY NO.1
(a) Check that the continuity exists between the terminals.
Standard: There is continuity
17. GLOVE BOX LAMP ASSY
(a) Check that the continuity exists between the terminals when switch is operated.
Standard:
ON (When shaft is pressed): No continuity
OFF (When shaft is not pressed): Continuity
18. LH VISOR ASSY
(a) Inspect vanity light continuity.
(1) Check that the continuity exists between the terminal 1 and the terminal 2 when the light is oper-
ated.
Standard:
OFF (closed): No continuity
ON (opened): Continuity
19. RH VISOR ASSY
(a) Inspect vanity light continuity.
(1) Check that the continuity exists between the terminal 1 and the terminal 2 when the light is oper-
ated.
Standard:
OFF (closed): No continuity
ON (opened): Continuity

E68132
E68133
E65594
Free Pushed in4
2
13
± LIGHTINGLIGHTING SYSTEM
65±13
AVENSIS REPAIR MANUAL (RM1018E)
20. HEADLAMP LEVELING SWITCH
(a) Connect the battery positive (+) lead to the terminal 1 and
the battery negative (±) lead to the terminal 5.
(b) Measure the resistance between the terminal 2 and the
battery negative (±) lead when headlamp leveling switch
is operated.
(c) Measure the resistance between the terminal 4 and the
battery negative (±) lead when headlamp leveling switch
is operated.
Standard:
Switch positionResistance (
)
01.0 ± 1.2
11.6 ± 1.9
22.3 ± 2.6
32.9 ± 3.3
43.5 ± 3.9
54.1 ± 4.6
(d) Inspect switch illumination.
(1) Connect the battery positive (+) lead to the terminal
3 and the battery negative (±) lead to the terminal
5, and check that the illumination comes on.
21. STOP LAMP SWITCH ASSY (W/O CRUISE CONTROL)
(a) Check the continuity between each of the terminals when switch is operated.
Standard:
ON (When shaft is pushed): No continuity
OFF (When shaft is not pushed): Continuity
22. STOP LAMP SWITCH ASSY (W/ CRUISE CONTROL)
(a) Check the continuity between the terminals at each
switch position as shown in the chart.
Standard:
Switch positionTester connectionSpecified condition
Switch pin free1 ± 2No continuity
Switch pin free3 ± 4Continuity
Switch pin pushed in1 ± 2Continuity
Switch pin pushed in3 ± 4No continuity
23. BACK UP LAMP SWITCH ASSY
(a) Check the continuity between each of the terminals when switch is operated.
Standard:
ON (When shaft is pushed): Continuity
OFF (When shaft is not pushed): No continuity

E68134
20

6

0
+45

±45
(Low) (High)
E68135
21.3

6
0

+45
±45
(Low)
(High)
65±14
± LIGHTINGLIGHTING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
24. HEIGHT CONTROL SENSOR SUB±ASSY FR RH
(a) Connect the 3 dry cell batteries (1.5 V) in series.
(b) Connect the positive (+) lead from the battery to the termi-
nal 1 and negative (±) lead from the battery to the terminal
3.
(c) Measure voltage between the terminal 2 and the terminal
3 when slowly move the link up and down.
Standard:
Link angleStandard voltage
+45
(High)4.5 V
0
(Normal)2.5 V
±45
(Low)0.5 V
25. HEIGHT CONTROL SENSOR SUB±ASSY REAR RH
(a) Connect the 3 dry cell batteries (1.5 V) in series.
(b) Connect the positive (+) lead from the battery to the termi-
nal 1 and negative (±) lead from the battery to the terminal
3.
(c) Measure voltage between the terminal 2 and the terminal
3 when slowly move the link up and down.
Standard:
Link angleStandard voltage
+45
(High)4.5 V
0
(Normal)2.5 V
±45
(Low)0.5 V

670SB±01
I36707
±
AUDIO & VISUAL SYSTEM REAR SPEAKER ASSY NO.2
67±15
AVENSIS REPAIR MANUAL (RM1018E)
REAR SPEAKER ASSY NO.2
REPLACEMENT
1. REMOVE REAR DOOR WINDOW REGULATOR HANDLE ASSY (W/O POWER WINDOW)
(See page 75±22)
2. REMOVE POWER WINDOW REGULATOR SWITCH ASSY REAR (W/ POWER WINDOW) (See page 75±22)
3.REMOVE REAR DOOR TRIM BASE LH (See page 75±22)
4.REMOVE REAR DOOR TRIM BOARD SUB±ASSY LH (See page 75±22)
5. REMOVE REAR SPEAKER ASSY NO.2
(a) Disconnect the connector.
(b) Remove the screw and the rear No.2 speaker assy.

670SA±01

I35188

I35189
(2)
(1)
(3)
H02440
Riveter
Mandrel
±
AUDIO & VISUAL SYSTEM REAR SPEAKER ASSY
67±13
AVENSIS REPAIR MANUAL (RM1018E)
REAR SPEAKER ASSY
REPLACEMENT
1.REMOVE REAR DOOR WINDOW REGULATOR HANDLE ASSY (See page 75±22)
2.REMOVE REAR DOOR TRIM BASE LH (See page 75±22)
3. REMOVE POWER WINDOW REGULATOR SWITCH ASSY REAR (W/ POWER WINDOW)
(See page 75±22)
4.REMOVE REAR DOOR TRIM BOARD SUB±ASSY LH (See page 75±22)
5. REMOVE REAR SPEAKER ASSY
(a) Disconnect the connector.
(b) Using a drill of less then
4 mm (0.16 in.), drill out the 3
rivet heads and remove the rear speaker assy from the
rear door panel.
(c) Gently and vertically put the drill to the rivet, and cut the
rivet flanges.
NOTICE:

Prizing the hole with a drill can lead to damage to the
rivet hole or breaking the drill.

Take care as the cut rivet is hot.
(d) Even if flange is taken off, continue drilling and push out remaining fragments with the drill.
(e) Using a vacuum cleaner, remove the drilled rivets and their dust from the inside of the rear door panel.
6. INSTALL REAR SPEAKER ASSY
(a) Using an air riveter or a hand riveter, install 3 new strike rivets to install the rear speaker assy on the rear door pan-
el.
NOTICE:

Install the new strike rivet in order shown in the il-
lustration to install the rear speaker assy.

Do not prize a riveter, as the riveter could be dam-
aged, loosened and the mandrel could be bent.

H02441
Riveter
Riveter
H02442
Riveter
67±14
± AUDIO & VISUAL SYSTEMREAR SPEAKER ASSY
AVENSIS REPAIR MANUAL (RM1018E)

Do not tilt the riveter or disconnect the rivet from the
materials while handling the riveter, as the materials
are not tightened firmly.

Install the rivet while there is no clearance between
the materials to tighten the materials firmly.
(b) Connect the connector.