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Autopapyrus · Toyota Avensis (2nd generation, T250)
https://autopapyrus.com/guides/toyota/avensis/right-headlight-assembly-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Toyota Avensis (2nd generation, T250): Right Headlight Assembly Replacement

On the Avensis T250, the right headlight is attached with several bolts to the body reinforcement and is covered at the front by the bumper. You get to the fasteners by moving or removing the front bumper. Exact torque specs were not found in open sources. The headlight and bumper fasteners are lightly loaded, so tighten them moderately and do not strip the threads.

Difficulty: Medium Time: 1-2 hours Steps: 14 Tools: socket set and ratchet (8, 10, 12 mm), Phillips and flat-head screwdrivers, plastic trim clip removers, thin flat-head screwdriver for connectors, masking tape, container for fasteners

Part

  • 🔩 Right front headlight assembly (Toyota Avensis T250, right side, matched to your type: halogen or xenon, with or without leveling adjuster). Also get a set of plastic bumper clips and pins, since some of them break during removal
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes and 3 more. See manuals →

Step by step

14 steps
  1. Shut off the engine, turn off the ignition and switch off the lights. For safety, disconnect the negative battery terminal. Get a container for fasteners and tape for labeling ready.
  2. Open the hood. Remove the upper plastic cover (air intake or shroud) above the radiator. It is held by plastic clips, so pry them out with a trim clip remover.
  3. Raise the front of the car and set it on jack stands, or work over a pit. Remove the plastic engine undercover at the front. Remove the fasteners that hold the lower edge of the bumper to the undercover.
  4. Remove the screws and pull out the clips that hold the bumper to the fender liners in both wheel wells. Pull the liners back to reach the side fasteners of the bumper.
  5. At the front top, under the grille and above the bumper, remove the screws and clips that hold the bumper to the radiator support. The number and location vary by trim level, so go by the fasteners you can see.
  6. Disconnect the fog light connectors, if equipped, and the headlight washer hoses, if installed. Label the connectors with tape.
  7. Pull the bumper sides forward to free it from the guides at the fenders. Remove it with a helper and do not pull on the corner, to avoid tearing the mounts and scratching the paint. Set the bumper aside on a soft pad.
  8. Disconnect the connectors of the right headlight: the main connector for the low and high beam bulb, the turn signal and the parking light. If there is a leveling adjuster or a xenon ballast, disconnect those too. Press the latch on each connector until it clicks.
  9. Remove the headlight mounting bolts. They are on the top and side of the frame and reinforcement, usually with a 10 mm head. Check the number of bolts on the car, most often there are three. Hold the headlight with your hand so it does not fall.
  10. Carefully slide the headlight forward, releasing the locking tabs at the bottom and at the side by the fender. Do not scratch the fender: cover its edge with tape.
  11. Transfer the bulbs and dust covers to the new headlight if they are not included. Do not touch the glass of a halogen bulb with your fingers. If the headlight has an adjustment screw or leveling adjuster, match its position to the old headlight.
  12. Place the new headlight on the locating pins and install the bolts. Tighten them moderately, without heavy force, and check the gaps with the fender and hood before final tightening. Connect the connectors, reconnect the battery terminal and check the parking light, low beam, high beam and turn signal.
  13. Install the bumper in reverse order: guide the side edges into the guides, then secure the top, the wheel wells, the lower part, the undercover and the cover. Replace broken clips with new ones. Connect the fog lights and washers before final fastening.
  14. After replacement, check and adjust the beam aim on an alignment machine or using markings on a wall. A new headlight almost always needs adjustment.

Common mistakes and warnings

  • If the car has xenon headlights, the ballast produces high voltage. Before starting, turn off the lights and ignition, disconnect the battery terminal and wait a few minutes. Do not touch the ballast or bulb contacts while the lights are on. Do not force the bumper removal: plastic tabs break easily in the cold, so work in a warm garage if possible.