low beam TOYOTA AVENSIS 2003 Service Repair Manual

MO
NEW MODEL OUTLINE

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Sedan and Liftback Models
Wagon Model
Headlight
(High Beam)
Clearance Light Turn
Signal Light
Headlight Cleaner Headlight
(Low Beam)
MO-7
EXTERIOR
Front View

The front view is dynamically expressive, with innovative headlights and\
a front bumper design
that has a sense of stability with upper and lower thickness.

The headlight low beams feature projectors and have an innovative shape.\
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010B5±11
D25082
Rubber Attachment
D27697
: SUPPORT POSITION, PAN
TOGRAPH JACK POSITION
: CENTER OF VEHICLE GRAVITY
(unload condition)
: JACK POSITION
±
INTRODUCTION REPAIR INSTRUCTION
01±19
AVENSIS REPAIR MANUAL (RM1018E)
VEHICLE LIFT AND SUPPORT LOCATIONS
1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP
(a) As a rule, the vehicle must be unloaded when jacking up. Never jack up o\
r lift up the vehicle loaded
with things of heavy weight.
(b) When removing any parts of heavy weight like the engine and transmission, the center of gravity of the vehicle moves. Place a balance weight so as to keep it from rolling,\
or hold the jacking support
location using the mission jack.
2. NOTICE FOR USING 4 POST LIFT
(a) Follow the instruction manual for a safety operation.
(b) Do not damage tires or wheels with a free wheel beam.
(c) Using a wheel stopper, fix the vehicle.
3. NOTICE FOR USING JACK AND SAFETY STAND
(a) Work in the flat place using a wheel stopper at all times.
(b) Use a safety stand with a rubber attachment, as shownin the illustration.
(c) Support the specified location with a jack and safety stand accurately.
(d) When jacking up the front wheels, release the parking
brake and place wheel stoppers only behind the rear
wheels. When jacking up the rear wheels, place wheel
stoppers only in front of the front wheels.
(e) Do not work or leave the vehicle supported only by a jack. Be sure to support the vehicle with a safety stand.
(f) When jacking up only the front wheels or only the rear wheels, place wheel stoppers to both sides of the wheels that contact ground.
(g) When jacking down the vehicle with its front wheels jacked up, release t\
he parking brake and place wheel stoppers only in front of the rear wheels. When jacking down the v\
ehicle with its rear wheels
jacked up, place wheel stoppers only behind the front wheels.
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B00540
A75980
Disconnect Wire
from Terminal B
Generator
Voltmeter
Battery Ammeter
19±16
±
STARTING & CHARGING CHARGING SYSTEM (1AZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that it fits properly in the ribbed grooves.
HINT:
Check with your hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
5. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
6. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that there is no abnormal noise from the generator while the engin\
e is running.
7. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on\
.
(b) Start the engine and check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warn\
ing light circuit. 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an amme-
ter and voltmeter as shown in the illustration.
(1) Disconnect the wire from terminal B of the generatorand connect it to the negative (±) lead of the amme-
ter.
(2) Connect the positive (+) lead of the ammeter to ter- minal B of the generator
(3) Connect the positive (+) lead of the voltmeter to ter- minal B of the generator.
(4) Ground the negative (±) lead of the voltmeter.
(b) Check the charging circuit. (1) Keep the engine speed at 2,000 rpm, check thereading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 12.9 to 14.9 V
HINT:

If the voltmeter reading is more than standard voltage, re-
place the voltage regulator.

If the voltmeter reading is less than the standard voltage,
check the voltage regulator and generator as follows:
9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights and\
turn the heater blower switch to the ºHIº position.
(b) Check the reading on the ammeter. Standard amperage: 30 A or more
HINT:

If the ammeter reading is less than standard amperage, repair the genera\
tor.

If the battery is fully charged, the indication will sometimes be less t\
han standard amperage.
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B00540
A75980
Disconnect Wire
from Terminal B
Generator
Voltmeter
Battery Ammeter
±
STARTING & CHARGING CHARGING SYSTEM (1AZ±FSE)
19±19
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that it fits properly in the ribbed grooves.
HINT:
Check with your hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
5. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
6. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that there is no abnormal noise from the generator while the engin\
e is running.
7. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on\
.
(b) Start the engine and check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warn\
ing light circuit. 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an amme-ter and voltmeter as shown in the illustration.
(1) Disconnect the wire from terminal B of the generatorand connect it to the negative (±) lead of the amme-
ter.
(2) Connect the positive (+) lead of the ammeter to ter- minal B of the generator
(3) Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
(4) Ground the negative (±) lead of the voltmeter.
(b) Check the charging circuit. (1) Keep the engine speed at 2,000 rpm, check thereading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 12.9 to 14.9 V
HINT:

If the voltmeter reading is more than standard voltage, re-
place the voltage regulator.

If the voltmeter reading is less than the standard voltage,
check the voltage regulator and generator as follows:
9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights and\
turn the heater blower switch to the ºHIº position.
(b) Check the reading on the ammeter. Standard amperage: 30 A or more
HINT:

If the ammeter reading is less than standard amperage, repair the genera\
tor.

If the battery is fully charged, the indication will sometimes be less t\
han standard amperage.
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19±28
±
STARTING & CHARGING CHARGING SYSTEM (1CD±FTV)
AVENSIS REPAIR MANUAL (RM1018E)
HINT:

If the voltmeter reading is more than standard voltage, re-
place the voltage regulator.

If the voltmeter reading is less than the standard voltage,
check the voltage regulator and generator as follows:
10. INSPECT CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights and\
turn the heater blower switch to the ºHIº position.
(b) Check the reading on the ammeter. Standard amperage: 30 A or more
HINT:

If the ammeter reading is less than standard amperage, repair the genera\
tor.

If the battery is fully charged, the indication will sometimes be less t\
han standard amperage.
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B00540
A75980
Disconnect Wire
from Terminal B
Generator
Voltmeter
Battery Ammeter
19±6
±
STARTING & CHARGING CHARGING SYSTEM (1ZZ±FE/3ZZ±FE)
AVENSIS REPAIR MANUAL (RM1018E)
(b) Check that it fits properly in the ribbed grooves.
HINT:
Check with your hand to confirm that the belt has not slipped out
of the groove on the bottom of the pulley.
5. VISUALLY CHECK GENERATOR WIRING
(a) Check that the wiring is in good condition.
6. LISTEN FOR ABNORMAL NOISES FROM GENERATOR
(a) Check that there is no abnormal noise from the generator while the engin\
e is running.
7. INSPECT CHARGE WARNING LIGHT CIRCUIT
(a) Turn the ignition switch ON. Check that the charge warning light comes on\
.
(b) Start the engine and check that the light goes off.
HINT:
If the light does not operate as specified, troubleshoot the charge warn\
ing light circuit. 8. INSPECT CHARGING CIRCUIT WITHOUT LOAD
(a) According to the following procedure, connect an amme-ter and voltmeter as shown in the illustration.
(1) Disconnect the wire from terminal B of the generatorand connect it to the negative (±) lead of the amme-
ter.
(2) Connect the positive (+) lead of the ammeter to ter- minal B of the generator
(3) Connect the positive (+) lead of the voltmeter to ter-
minal B of the generator.
(4) Ground the negative (±) lead of the voltmeter.
(b) Check the charging circuit. (1) Keep the engine speed at 2,000 rpm, check thereading on the ammeter and voltmeter.
Standard amperage: 10 A or less
Standard voltage: 12.9 to 14.9 V
HINT:

If the voltmeter reading is more than standard voltage, re-
place the voltage regulator.

If the voltmeter reading is less than the standard voltage,
check the voltage regulator and generator as follows:
9. INSPECT CHARGING CIRCUIT WITH LOAD
(a) Keep the engine speed at 2,000 rpm, turn on the high beam headlights and\
turn the heater blower switch to the ºHIº position.
(b) Check the reading on the ammeter. Standard amperage: 30 A or more
HINT:

If the ammeter reading is less than standard amperage, repair the genera\
tor.

If the battery is fully charged, the indication will sometimes be less t\
han standard amperage.
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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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E68999
LH:
RH:
1
1 3
3
2
2
1
25
E68130
65±6
±
LIGHTING LIGHTING 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
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±
LIGHTING LIGHTING SYSTEM
65±7
AVENSIS REPAIR MANUAL (RM1018E)
(b) Connect the connector to the headlamp leveling ECU
assy, then turn the ignition switch ON and light control
switch into HEAD position. Inspect the wire harness side
connector from the back side as shown in the chart.
Standard:
Tester connectionConditionSpecified condition
2 ± body groundAlways5 V
3 ± body ground3 secs. after vehicle height change for 10 secs.1.0 to 13 V
4 ± body ground3 secs. after vehicle height change for 10 secs.1.0 to 13 V
5 ± body groundAlways0 to 5 V
6 ± body groundAlways0 to 5 V
10 ± body groundHeadlamp Switch is OFF
ON10 to 14 V
Below 1 V
11 ± body groundBeam level warning light OFF
ON10 to 14 V
Below 1 V
12 ± body groundTurn the vehicle wheelPuls generation
13 ± body groundAlways10 to 14 V
14 ± body groundAlways10 to 14 V
15 ± body groundAlways5 V
20 ± body groundAlwaysBelow 1 V
21 ± body groundAlwaysBelow 1 V
22 ± body groundAlwaysBelow 1 V
23 ± body groundAlwaysBelow 1 V
4. HEADLAMP AUTO LEVERING OPERATION CHECK
(a) Check that the initialization (determination of the initial position) for t\
he leveling motor is performed at
the engine±start.
(b) Check that the warning indicator in the combination meter assy illuminates for approximately 3 se- conds at the engine±start and then goes off.
(c) Check that the reflector works when:
Keeping the rear of the vehicle up or down while the engine is running with the vehicle stopped and
the headlamp dimmer switch in the HEAD position.
NOTICE:
Make sure to change the vehicle's height slowly.
5. FAIL±SAFE FUNCTION
(a) Headlamp Leveling Control ECU
HINT:
The Headlamp Leveling Control ECU performs the fail±safe when detecti\
ng following troubles. At this the
warning indicator light on the combination meter lights up.
Trouble AreaConditionHeadlight levering motor
1. Height control sensor
Signal level error

Out of voltageStop leveling operation
2. Headlamp leveling control ECU
Watchdock detection

High voltageStop leveling operation
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