headlamp TOYOTA AVENSIS 2003 Service Repair Manual

5006X−01
Steering
Column
Protector No.1
F44781
Horn Button Assy
Steering Wheel Assy
Spiral Cable Sub −Assy
Steering Column Cover
Headlamp Dimmer Switch AssySteering Column Assy
Steering
Sliding Yoke
Sub− Assy
Steering Intermediate
Shaft Assy No.2
Column Hole Cover Silencer Sheet
Steering Column Cover LWR
Windshield Wiper
Switch Assy
N

m (kgf
cm, ft
lbf): Specified torque
OIL Pressure Power Steering:
Steering Intermediate
Shaft Assy No.2
Steering
Sliding Yoke
Sub−Assy
35 (360, 26)
Column Hole Cover
Silencer Sheet
LHD Steering Position Type:
LHD Steering Position
Type: w/ Instrument Cluster
Finish Panel Assy
Floor Shift
Parking Lock Cable
Assy (A/T Transaxle)
Instrument Panel
Hole Cover
5 (51, 44 in.




lbf)
18 (184, 13)
18 (184, 13)
Instrument Panel
Airbag Assy
18 (184, 13)
18 (184, 13)
18 (184, 13)
25 (255, 18)
50 (510, 37)
35 (360, 26)
35 (360, 26)
28 (286, 21)
35 (360, 26)
28 (286, 21)
25 (255, 18)
25 (255, 18)
−
STEERING COLUMN STEERING COLUMN ASSY
50−5
STEERING COLUMN ASSY
COMPONENTS
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F44779
Horn Button Assy
Steering Wheel Assy
Headlamp Dimmer Switcn Assy
Spiral Cable
Windshield Wiper Switch Steering Column Cover
Steering Column Assy
Steering
Intermediate
Shaft Assy
No.2
Steering Sliding
Yoke sub−assy
Column Hole Cover Silencer Sheet
N
m (kgf
cm, ft
lbf): Specified torque Steering Sliding
Yoke sub
−assy
Steering Intermediate
Shaft Assy No.2
LHD Steering Position Type:
Electric Power Steering:
35 (360, 26)
35 (360, 26)
35 (360, 26)
Column Hole Cover Silencer Sheet
Steering Column Cover
LW R
Floor Shift Parking Lock
Cable Assy (A/T Transaxle)
Instrument Panel Airbag Assy
18 (184, 13)
Steering
Column
Protector
No.1
Instrument
Panel
Hole Cover
18 (184, 13)
18 (184, 13)
5 (51, 44 in.




lbf)
25 (255, 18)
18 (184, 13)
18 (184, 13)
LHD Steering Position Type: w/ Instrument Cluster
Finish Panel Assy
50 (510, 37)
25 (255, 18)
Steering Column
Protector No.1
35 (360, 26)
M/T Transaxle:25 (255, 18)
−
STEERING COLUMN STEERING COLUMN ASSY
50−7
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F44783
MatchmarksSST
F44784
50±10
±
STEERING COLUMN STEERING COLUMN ASSY
AVENSIS REPAIR MANUAL (RM1018E)
5. REMOVE STEERING WHEEL ASSY
(a) Remove the steering wheel assy set nut.
(b) Place matchmarks on the steering wheel assy and steer- ing main shaft assy.
(c) Using SST, remove the steering wheel assy. SST 09950±50013 (09951±05010, 09952±05010, 09953±05020, 09954±05021)
6.REMOVE INSTRUMENT PANEL UNDER COVER SUB±ASSY NO.1 (See page 71±11)
7.REMOVE INSTRUMENT PANEL HOLE COVER (See page 60±54)
8.REMOVE INSTRUMENT PANEL AIR BAG ASSY (See page 60±54)
9. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.1 (ELECTRIC POWER STEERING) (See page 71±11)
10. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (ELECTRIC POWER
STEERING) (See page 71±11)
11. REMOVE INSTRUMENT PANEL REGISTER ASSY CTR (ELECTRIC POWER STEERING) (See page 71±11)
12. REMOVE STEERING COLUMN COVER LWR
(a) Remove the 3 screws and steering column cover LWR.
13. REMOVE STEERING COLUMN COVER W/INSTRUMENT CLUSTER FINISH PANEL ASSY
(a) Disengage the 2 clips and remove the steering column cover w/instrument cluster finish panel assy.
14.REMOVE COMBINATION METER ASSY (ELECTRIC POWER STEERING) (See page 71±11)
15. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.1 (ELECTRIC POWER STEERING) (See page 71±11)
16. REMOVE INSTRUMENT PANEL REGISTER ASSY NO.2 (ELECTRIC POWER STEERING) (See page 71±11)
17. REMOVE GLOVE COMPARTMENT DOOR ASSY (ELECTRIC POWER STEERING)
(See page 71±11)
18.REMOVE FRONT PILLAR GARNISH LH (ELECTRIC POWER STEERING) (See page 71±11)
19.REMOVE FRONT PILLAR GARNISH RH (ELECTRIC POWER STEERING) (See page 71±11)
20. DISCONNECT PASSENGER AIRBAG CONNECTOR (ELECTRIC POWER STEERING) (See page 71±11)
21. REMOVE INSTRUMENT PANEL SUB±ASSY UPPER W/INSTR PNL PASS L/DOOR AIR BAG ASSY (ELECTRIC POWER STEERING) (See page 71±11)
22.REMOVE HEADLAMP DIMMER SWITCH ASSY (See page 65±27)
23.REMOVE WINDSHIELD WIPER SWITCH ASSY (See page 66±24)
24.REMOVE SPIRAL CABLE SUB±ASSY (See page 60±26)
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H42657
H42659
60±14
±
SUPPLEMENTAL RESTRAINT SYSTEM SUPPLEMENTAL RESTRAINT SYSTEM
AVENSIS REPAIR MANUAL (RM1018E)
10. INSTRUMENT PANEL AIRBAG ASSY (VEHICLE IN- VOLVED IN COLLISION AND AIRBAG IS NOT
DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
(b) Do a visual check of the instrument panel airbag assy re- moved from the vehicle:

Cuts, minute cracks or marked discoloration on the
instrument panel airbag assy.
HINT:

Never repair it in order for reuse or replacement.

There should be no interference between the horn button
assy and steering wheel assy, and the clearance should
be uniform all the around when the new horn button assy
is installed on the steering wheel assy.
CAUTION:
For removal and installation procedures of the horn button
assy, see ºReplacementº on page 60±54, and be sure to fol-
low the correct procedure.
11. AIRBAG SENSOR ASSY CENTER (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
12. AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS NOT DEPLOYED)
(a)Do a diagnostic system check (See page 05±1184).
13. AIRBAG SENSOR ASSY CENTER (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS
DEPLOYED)
(a)Replace the airbag sensor assy center (See page 60±62).
14. AIRBAG FRONT SENSOR (VEHICLE NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
15. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
(b) When the headlamp of the vehicle or its periphery is damaged, check if t\
here is any damage to the airbag front sensor. If there are any defects as mentioned below, replace the airbag front sensor with
a new one:
If there are any defects as mentioned below, replace the airbag front sensor with a new one:

Cracks, dents or chips in the case.

Cracks, dents, chips and scratches in the connector.

Peeling off of the label or damage to the serial number.
16. AIRBAG FRONT SENSOR (VEHICLE INVOLVED IN COLLISION AND AIRBAG IS DEPLOYED)
(a)Replace the airbag front sensor assy (See page 60±64).
17. SIDE AIRBAG SENSOR ASSY (VEHICLES NOT INVOLVED IN COLLISION)
(a)Do a diagnostic system check (See page 05±1184).
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650T2±01
I35251
I35252Claw
±
LIGHTING HEADLAMP DIMMER SWITCH ASSY
65±27
AVENSIS REPAIR MANUAL (RM1018E)
HEADLAMP DIMMER SWITCH ASSY
REPLACEMENT
1. SEPARATE STEERING COLUMN COVER LWR
(a) Remove the 3 screws and steering column cover LWR.
2. REMOVE HEADLAMP DIMMER SWITCH ASSY
(a) Disconnect the connector.
(b) Release the claw and pull out the headlamp dimmer
switch assy.
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650T5±01
I35250
65±30
±
LIGHTING HEADLAMP LEVELING ECU ASSY
AVENSIS REPAIR MANUAL (RM1018E)
HEADLAMP LEVELING ECU ASSY
REPLACEMENT
1. REMOVE GLOVE COMPARTMENT DOOR ASSY (LHD STEERING POSITION TYPE) (See page 71±11)
2.REMOVE FUSE BOX OPENING COVER (RHD STEERING POSITION TYPE) (See page 71±11)
3. REMOVE LIGHT CONTROL ECU
(a) Disconnect the connector.
(b) Remove the bolt and headlamp leveling ECU assy.
4. INSTALL LIGHT CONTROL ECU
(a) Install the headlamp leveling ECU assy with the bolt.
(b) Connect the connector.
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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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