Toyota Avalon (XX50): Headlight Assembly

Toyota Avalon (XX50) 2019-2022 Service & Repair Manual / Vehicle Exterior / Lighting (ext) / Headlight Assembly

Adjustment

ADJUSTMENT

CAUTION / NOTICE / HINT

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PROCEDURE

1. PREPARE VEHICLE FOR HEADLIGHT AIM ADJUSTMENT

(a) Prepare the vehicle:

Ensure that there is no damage or deformation to the vehicle body around the headlights.
Fill the fuel tank.
Make sure that the oil is filled to the specified level.
Make sure that the engine coolant is filled to the specified level.
Inflate the tires to the appropriate pressure.
Unload the trunk and vehicle, ensuring that the spare tire, tools and jack are in their original positions.
Sit a person of average weight (68 kg, 150 lb) in the driver's seat.

2. PREPARE FOR HEADLIGHT AIMING (Using a headlight aim test machine)

(a) Adjust the headlight aim in accordance with the headlight aim test machine instructions.

3. PREPARE FOR HEADLIGHT AIMING (Using a screen)

(a) Prepare the vehicle:

Place the vehicle in a location that is dark enough to clearly observe the cutoff line. The cutoff line is a distinct line, below which light from the headlights can be observed and above which it cannot.
Place the vehicle at a 90° angle to the wall.
Create a 7.62 m (25 ft.) distance between the vehicle (center marks of the headlights) and the wall.
Make sure that the vehicle is on a level surface.
Position the front wheels straight ahead.
Bounce the vehicle up and down to settle the suspension.

NOTICE:

A distance of 7.62 m (25 ft.) between the vehicle center marks of the headlights and the wall is necessary for proper aim adjustment. If sufficient space is not available, secure a distance of exactly 3 m (9.84 ft.) to allow for checking and adjustment of headlight aim. (The size of the target zone will change with the distance, so follow the instructions in the illustration.)

*A	w/o Cornering Light	*B	w/ Cornering Light
*a	Center Mark	-	-

(b) Prepare a piece of thick white paper (approximately 2 m (6.56 ft.) (height) x 4 m (13.1 ft.) (width)) to use as a screen.

(d) Set the screen as shown in the illustration.

HINT:

Stand the screen perpendicular to the ground.
Align the V line on the screen with the center of the vehicle.

(e) Draw base lines (H, V LH, and V RH lines) on the screen as shown in the illustration.

*a	V LH Line
*b	V Line
*c	V RH Line
*d	H Line
*e	Ground

HINT:

Mark the headlight center marks on the screen.

*A	w/o Cornering Light	*B	w/ Cornering Light
*a	Center Mark	-	-

(1) H Line (Headlight height):

Draw a horizontal line across the screen so that it passes through the center marks. The H line should be at the same height as the center marks of the headlights.

(2) V LH Line, V RH Line (Center mark position of left-hand (LH) and right-hand (RH) headlights):

Draw 2 vertical lines so that they intersect the H line at each center mark (aligned with the center marks of the headlights).

4. INSPECT HEADLIGHT AIMING (w/o Cornering Light)

(a) Cover the headlight on the opposite side to prevent light from the headlight that is not being inspected from affecting the headlight aiming inspection.

NOTICE:

Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, which may melt or be damaged due to excessive heat.

(b) Start the engine.

HINT:

If the alignment distance is 7.62 m (25 ft.):
The low beam cutoff line should be between 101 mm (3.97 in.) above or below the H line as well as 101 mm (3.97 in.) left or right of the V LH or RH line (SAE J599).
If the alignment distance is 3 m (9.84 ft.):
The low beam cutoff line should be between 39 mm (1.56 in.) above or below the H line as well as 39 mm (1.56 in.) left or right of the V LH or RH line (SAE J599).

5. INSPECT HEADLIGHT AIMING (w/ Cornering Light)

(a) Cover the headlight on the opposite side to prevent light from the headlight that is not being inspected from affecting the headlight aiming inspection.

NOTICE:

Do not keep the headlight covered for more than 3 minutes. The headlight lens is made of synthetic resin, which may melt or be damaged due to excessive heat.

(b) Start the engine.

HINT:

If the alignment distance is 7.62 m (25 ft.):
The low beam cutoff line should be between 20 mm (0.787 in.) above or below the H line as well as within 466 mm (1.53 ft.) right of the notch in the headlight beam pattern.
If the alignment distance is 3 m (9.84 ft.):
The low beam cutoff line should be between 8 mm (0.315 in.) above or below the H line as well as within 184 mm (7.24 in.) to the right of the notch in the headlight beam pattern.

6. ADJUST HEADLIGHT AIMING

(a) Adjust the aim vertically:

(1) Adjust the aim of each headlight to the specified range by turning each aiming screw with a screwdriver.

*A	w/o Cornering Light	*B	w/ Cornering Light
*a	Aiming Screw	-	-

NOTICE:

The final turn of the aiming screw should be made in the clockwise direction. If the screw is tightened excessively, loosen it and then retighten it, so that the final turn of the screw is in the clockwise direction.

HINT:

If it is not possible to correctly adjust headlight aim, check the headlight unit and headlight unit lens installation.
Confirm the direction of rotation of the aiming screw by observing it while it is being adjusted. Due to the position of the screwdriver, the direction of rotation of the adjusting screw can be different than the direction of rotation of the screwdriver being used to adjust it.

Components

COMPONENTS

ILLUSTRATION

*1	HEADLIGHT ASSEMBLY	-	-
	Nm (kgfcm, ft.*lbf): Specified torque	-	-

ILLUSTRATION

*A	w/ Cornering Light	-	-
*1	HEADLIGHT ECU SUB-ASSEMBLY	*2	HEADLIGHT GASKET
●	Non-reusable part	-	-

Disassembly

DISASSEMBLY

CAUTION / NOTICE / HINT

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PROCEDURE

1. REMOVE HEADLIGHT ECU SUB-ASSEMBLY (w/ Cornering Light)

Click here

2. REMOVE HEADLIGHT GASKET (w/ Cornering Light)

Click here

Inspection

INSPECTION

PROCEDURE

1. INSPECT HEADLIGHT ASSEMBLY LH (w/o Cornering Light)

(a) Apply auxiliary battery voltage to the headlight assembly LH and check that the lights illuminate.

OK:

Measurement Condition	Specified Condition
Auxiliary battery positive (+) → Terminal 4 (LO) Auxiliary battery negative (-) → Terminal 7 (E)	Lo beam headlight illuminates
Auxiliary battery positive (+) → Terminal 3 (HI) Auxiliary battery negative (-) → Terminal 7 (E)	Hi beam headlight illuminates
Auxiliary battery positive (+) → Terminal 1 (B) Auxiliary battery positive (+) → Terminal 4 (LO) Auxiliary battery negative (-) → Terminal 7 (E)	Daytime running light illuminates
Auxiliary battery positive (+) → Terminal 5 (B) Auxiliary battery negative (-) → Terminal 7 (E)	Parking light light illuminates
Auxiliary battery positive (+) → Terminal 2 (B) Auxiliary battery negative (-) → Terminal 7 (E)	Turn signal light illuminates
Auxiliary battery positive (+) → Terminal 6 (B) Auxiliary battery negative (-) → Terminal 7 (E)	Side marker light illuminates

If the result is not as specified, replace the headlight assembly LH.

*a	Component without harness connected (Headlight Assembly LH)

2. INSPECT HEADLIGHT ASSEMBLY RH (w/o Cornering Light)

(a) Apply auxiliary battery voltage to the headlight assembly RH and check that the lights illuminate.

OK:

Measurement Condition	Specified Condition
Auxiliary battery positive (+) → Terminal 4 (LO) Auxiliary battery negative (-) → Terminal 7 (E)	Lo beam headlight illuminates
Auxiliary battery positive (+) → Terminal 3 (HI) Auxiliary battery negative (-) → Terminal 7 (E)	Hi beam headlight illuminates
Auxiliary battery positive (+) → Terminal 1 (B) Auxiliary battery positive (+) → Terminal 4(LO) Auxiliary battery negative (-) → Terminal 7 (E)	Daytime running light illuminates
Auxiliary battery positive (+) → Terminal 5 (B) Auxiliary battery negative (-) → Terminal 7 (E)	Parking light light illuminates
Auxiliary battery positive (+) → Terminal 2 (B) Auxiliary battery negative (-) → Terminal 7 (E)	Turn signal light illuminates
Auxiliary battery positive (+) → Terminal 6 (B) Auxiliary battery negative (-) → Terminal 7 (E)	Side marker light illuminates

If the result is not as specified, replace the headlight assembly RH.

*a	Component without harness connected (Headlight Assembly RH)

Installation

INSTALLATION

CAUTION / NOTICE / HINT

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PROCEDURE

1. INSTALL HEADLIGHT ASSEMBLY

(a) w/o Cornering Light:

(1) Connect the connector.

(2) Engage the guide to temporarily install the headlight assembly as shown in the illustration.

Install in this Direction

(3) Install the headlight assembly with the bolt (A) , bolt (B) and 3 screws.

Torque:

Bolt :

5.4 N·m {55 kgf·cm, 48 in·lbf}

*a	Bolt (A)
*b	Bolt (B)
*c	Screw

(b) w/ Cornering Light:

(1) Engage the guide to temporarily install the headlight assembly as shown in the illustration.

Install in this Direction

(2) Install the headlight assembly with the bolt (A) , bolt (B) and 3 screws.

Torque:

Bolt :

5.4 N·m {55 kgf·cm, 48 in·lbf}

*a	Bolt (A)
*b	Bolt (B)
*c	Screw

(3) Connect the connector and raise the connector lock lever to engage the claw and lock the connector as shown in the illustration.

*a	Connector Lock Lever
	Connect in this Direction

2. INSTALL FRONT BUMPER ASSEMBLY

Click here

3. PERFORM INITIALIZATION (w/ Cornering Light)

for Gasoline Model:

Click here

for HV Model:

Click here

4. ADJUST HEADLIGHT AIMING

Click here

Reassembly

REASSEMBLY

CAUTION / NOTICE / HINT

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PROCEDURE

1. INSTALL HEADLIGHT GASKET (w/ Cornering Light)

Click here

2. INSTALL HEADLIGHT ECU SUB-ASSEMBLY (w/ Cornering Light)

Click here

Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during headlight assembly removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced (for Gasoline Model)

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function When Necessary Procedures are not Performed
Front bumper assembly	Measurement of ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Intelligent Clearance Sonar System Intuitive Parking Assist System
Front bumper assembly	Front television camera view adjustment	Panoramic View Monitor System
Headlight assembly LH Headlight ECU sub-assembly LH	Synchronize the vehicle information	Lighting system (for Gasoline Model with Cornering Light)

Necessary Procedure After Parts Removed/Installed/Replaced (for HV Model)

Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function When Necessary Procedures are not Performed
Front bumper assembly	Measurement of ultrasonic sensor detection angle Ultrasonic sensor detection angle registration	Intelligent Clearance Sonar System Intuitive Parking Assist System
Front bumper assembly	Front television camera view adjustment	Panoramic View Monitor System
Headlight assembly LH Headlight ECU sub-assembly LH	Synchronize the vehicle information	Lighting system (for HV Model with Cornering Light)

HINT:

Use the same procedure for the RH side and LH side.
The following procedure is for the LH side.

PROCEDURE

1. REMOVE FRONT BUMPER ASSEMBLY

Click here

2. REMOVE HEADLIGHT ASSEMBLY

(a) Apply protective tape around the headlight assembly as shown in the illustration.

Protective Tape

(b) w/o Cornering Light:

(1) Remove the bolt (A) , bolt (B) and 3 screws.

*a	Bolt (A)
*b	Bolt (B)
*c	Screw

(2) Disengage the guide to separate the headlight assembly as shown in the illustration.

Remove in this Direction

(3) Disconnect the connector to remove the headlight assembly.

(1) Disengage the claw, pull down the connector lock lever as shown in the illustration and disconnect the connector.

*a	Connector Lock Lever
	Disconnect in this Direction

(2) Remove the bolt (A) , bolt (B) and 3 screws.

*a	Bolt (A)
*b	Bolt (B)
*c	Screw

(3) Disengage the guide to remove the headlight assembly as shown in the illustration.

Remove in this Direction

Hazard Warning Switch

Headlight Dimmer Switch

See More:

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