TOYOTA AVENSIS 2002 Repair Manual

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
± LIGHTINGHEADLAMP 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.

650T3±01
I35231
I35231
AB
A
65±28
±
LIGHTING HEIGHT 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)

650T4±01
I35240
I35240
A
B
A
±
LIGHTING HEIGHT 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)

650T0±02
E60618
±
LIGHTIN GLICENSE PL ATE LAMP ASSY
65±25
AVENSIS RE PAIR MANUAL (RM1018E)
LICENSE PL ATE LAMP ASSY
REPLACEMENT
1. REMOV E BACK DOOR TRIM BOARD ASSY ( See page LIFTBACK 75±40, W AGON 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 as shown 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.

650NC±02
± LIGHTINGLIGHTING 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 identified 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 halogen bulbs (for headlamp
and fog lamp), as they have pressurized gas inside and can be easily broken.
(d) Touching the HV socket of the discharge headlight with the headlight dimmer switch 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.

650SQ±01
65±2
±
LIGHTING LIGHTING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
PROBLEM SYMPTOMS TABLE
1. HEADLIGHT SYSTEM
SymptomSuspect AreaSee page
Only one headlamp comes on.
1. Bulb
2. H±LP LL, H±LP RL fuse
3. Light control computer (w/ HID)
4. Harness or connector±
±
±
±
Headlamp does not come on (All).
1. H±LP LL, H±LP RL fuse
2. H±HP relay
3. Headlamp dimmer switch assy
4. Harness or connector
5. Integration relay (w/ Daytime running light system)±
±
65±9 ±
±
ºHI±Beamº does not come on (All).
1. Bulb
2. H±LP HI LH, H±LP HI RH fuse
3. DIM relay (w/ Daytime running light system)
4. Headlamp dimmer switch assy
5. Harness or connector
6. Integration relay (w/ Daytime running light system)±
±
±
65±9 ±
±
ºHI±Beamº does not come on (One side).1. Bulb
2. Harness or connector±
±
ºFlashº does not come on.
(Headlamp and Hi±Beam is normal)1. Headlamp dimmer switch assy
2. Harness or connector
3. Integration relay (w/ Daytime running light system)65±9
±
±
Headlamp is dark.1. Bulb
2. Harness or connector±
±
Tail lamp does not come on (All).
1. TAIL fuse
2. TAIL relay
3. Headlamp dimmer switch assy
4. Harness or connector
5. Integration relay (w/ Daytime running light system)±
±
65±9 ±
±
Only one tail lamp comes on.1. Bulb
2. Harness or connector±
±
Rear combination light does not come on.1. Bulb
2. Harness or connector±
±
Daytime running light system does not operate.
1. Headlamp dimmer switch assy
2. Ignition switch
3. Harness or connector
4. Integration relay65±9±
±
±
2. FOG LAMP SYSTEM
SymptomSuspect AreaSee page
Front fog lamp does not come on with light control switch in TAIL
or HEAD position.
1. FR FOG fuse
2. FR FOG relay
3. Headlamp dimmer switch assy
4. Harness or connector±
±
65±9 ±
Only one front fog lamp does not come on.1. Bulb
2. Harness or connector±
±
Rear fog lamp does not come on with light control switch in HEAD
position.
1. RR FOG fuse
2. RR FOG relay
3. Headlamp dimmer switch assy
4. Harness or connector±
±
65±9 ±
Only one rear fog lamp does not come on.1. Bulb
2. Harness or connector±
±

±
LIGHTING LIGHTING SYSTEM
65±3
AVENSIS REPAIR MANUAL (RM1018E)
3. TURN SIGNAL AND HAZARD WARNING SYSTEM
SymptomSuspect AreaSee page
ºHazardº and ºTurnº do not come on.
1. HAZARD fuse
2. GAUGE2 fuse
3. IG1 relay
4. Ignition switch
5. Turn signal flasher relay
6. Harness or connector±
±
±
±
65±5
±
Hazard warning light does not come on.
(Turn is normal)1. Hazard warning switch
2. Harness or connector65±9±
Turn signal does not come on.
(Hazard is normal)1. Headlamp dimmer switch (turn signal switch)
2. Harness or connector65±9±
Turn signal does not come on in one direction.1. Headlamp dimmer switch (turn signal switch)
2. Harness or connector65±9±
Only one bulb does not come on.1. Bulb
2. Harness or connector±
±
4. ILLUMINATED ENTRY SYSTEM
SymptomSuspect AreaSee page
Illumination lamp of Multiplex body ECU control does not come
on.
1. Ignition switch
2. Door courtesy switch
3. Door lock position switch
4. Harness or connector
5. Integration relay±
65±9
05±1534 ±
±
Illumination lamp of Multiplex body ECU control does not go off.
1. Ignition switch
2. Door courtesy switch
3. Door lock position switch
4. Harness or connector
5. Integration relay±
65±9
05±1534 ±
±
5. HEADLIGHT BEAM LEVEL CONTROL SYSTEM (W/O HID)
SymptomSuspect AreaSee page
Headlight beam level control system does not operate (All).
1. TAIL relay
2. Headlamp leveling switch
3. Harness or connector±
65±9 ±
Headlight beam level control system does not operate (One side).
1. Headlamp leveling switch
2. Headlight beam level control actuator
3. Harness or connector65±9
65±5±
6. HEADLIGHT BEAM LEVEL CONTROL SYSTEM (W/ HID)
SymptomSuspect AreaSee page
Headlight beam level control system does not operate (All).
1. GAUGE2 fuse
2. Ignition switch
3. Speed sensor signal circuit
4. Height control sensor sub±assy
5. Headlamp leveling ECU assy
6. Harness or connector±
±
±
65±9
65±5 ±
Headlight beam level control system does not operate (One side).
1. Headlamp leveling ECU assy
2. Headlight beam level control actuator
3. Harness or connector65±5
65±5±
Beam level warning light comes on.
1. Height control sensor sub±assy
2. Headlamp leveling ECU assy
3. Harness or connector65±9
65±5±

65±4
± LIGHTINGLIGHTING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
7. OTHERS
SymptomSuspect AreaSee page
Vanity light does not operate.1. Bulb
2. Harness s or connector±
±
Instrument panel illumination does not operate (All).
1. TAIL relay
2. PANEL fuse
3. Harness or connector
4. Integration relay (w/ DRL)±
±
±
±
Stop light does not operate (All).
1. STOP fuse
2. Stop light switch
3. Harness or connector±
±
±
Back up lamp does not come on (All).
1. GAUGE fuse
2. IG1 relay
3. Back up lamp switch assy (M/T)
4. Park/neutral position switch (A/T)
5. Harness or connector±
±
±
±
±

650ND±02
E15683
± LIGHTINGLIGHTING SYSTEM
65±5
AVENSIS REPAIR MANUAL (RM1018E)
ON±VEHICLE INSPECTION
1. INSPECT TURN SIGNAL FLASHER CIRCUIT
(a) Measure voltage between the terminal as shown in the
chart below.
Standard:
Tester connectionConditionSpecified condition
1 ± body groundTurn ignition switch ON10 to 14 V
1 ± body groundTurn ignition switch OFFNo voltage
4 ± body groundAlways10 to 14 V
7 ± body groundAlwaysContinuity
(b) Connect the connector to turn the signal flasher and the
ignition switch ON, and inspect the wire harness side con-
nector from the back side as shown in the chart.
Standard:
Tester connectionConditionSpecified condition
2 ± body groundHazard switch OFF  ON0V 10 to 14 V (60 to 120 time per minutes)
2 ± body groundTurn signal switch (right turn) OFF  ON0V 10 to 14 V (60 to 120 time per minutes)
3 ± body groundHazard switch OFF  ON0V 10 to 14 V (60 to 120 time per minutes)
3 ± body groundTurn signal switch (left turn) OFF  ON0V 10 to 14 V (60 to 120 time per minutes)
5 ± body groundTurn signal switch (left turn) OFF  ON10 to 14 V 0 V
6 ± body groundTurn signal switch (right turn) OFF  ON10 to 14 V 0 V
8 ± body groundHazard switch OFF  ON10 to 14 V 0 V

E68999
LH:
RH: 1
13
3 2
2
1
25
E68130
65±6
± LIGHTINGLIGHTING SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
2. INSPECT HEADLAMP ASSEMBLY (HEADLIGHT
BEAM LEVEL CONTROL ACTUATOR OPERATION)
(a) Disconnect the connector from the headlamp assy.
(b) Connect the positive (+) lead from the battery to the termi-
nal 3 of each of the headlight beam level control actuator
and negative (±) lead from the battery to the terminal 1 of
the each of the headlight beam level control actuator.
(c) Connect the positive (+) lead from the battery to the termi-
nal 1 of headlamp levering switch and negative (±) lead
from the battery to the terminal 5 of the headlamp levering
switch.
(d) Connect the terminal 2 of the headlamp leveling switch
and the terminal 2 of the each of headlight beam level
control actuator.
(e) Measure voltage between the terminal 2 of the headlamp
leveling switch and the battery negative (±) terminal when
headlamp levering switch is operated.
Standard:
Switch positionSpecified condition (V)
08.5 to 11.8
17.4 to 10.3
26.3 to 8.8
35.2 to 7.3
44.1 to 5.8
53.0 to 4.3
3. HEADLAMP LEVELING ECU ASSY
(a) Measure voltage between the terminal as shown in the
chart below.
Standard:
Tester connectionConditionSpecified condition
1 ± body groundTurn ignition switch ON10 to 14 V
1 ± body groundTurn ignition switch OFFNo voltage
10 ± body groundHeadlamp switch is HEADBelow 1 V
24 ± body groundAlwaysContinuity