2004 Avensis, Problems With Hid

[pero-zdero]

First of all, Hello to everyone,

I am new at your forum, as you can see this is my first post, but I have been reading your posts and following whats going on at the forum, for what I can understand, since English is my second language. I've been planning on writing for a while, but didn't have much time on my hands, so here it is.

Another thing is that I don't live in UK, but in Southeastern Europe and Toyota is pretty new on market here, and even if I asked a question on a forum, i wouldn't receive adequate answer, so that is another reason why I seek for answers outside my own country.

I own a 2004 avensis 2.0 D4D, with sol package, and of course it came with factory installed xenon lights. The car was bought in 2005 with some discount since it was already a year old, but new, with less then 50km on the clock.

The problem as of last year is that the lights on this car are terrible, if I might say that word at all. From what I found out on this forum a lot of people complained on poor performance of avensis headlight, but I couldn't find that one of them solved the problem, and with some research I found out what could cause that problem.

At these pictures, which are not of mine car, you will see how the problem is solved, and you might find someone in your area that does the same think for a lot less then taking it to a local dealership. I am planning on taking my car to this guy, and will post pictures of before and after.

In the first picture (mind the date, it is taken in November 2010) this is exactly how bright are mine lights.

The second picture is of a projector inside a headlight, which will be taken out from this headlight and replaced with a newer model.

The third picture is comparison of a new projector (on the left) vs. the old (at the right)

The fourth picture is the housing of an old projector, which is apparently the culprit of our problems, it turns out, it is burnt and matted, and it does not reflect the light properly.

The fifth picture is fitting the new projector in headlight.

And the picture number six is the final product, and how bright the light is after the "transplantation"

and last, but not least picture number 7 is the picture of high beams, since this guy converted his original D2S bulb into H1 which has low and high beam in it. plus he is left with halogen H1 high beam. (might not be legal for UK, since you have much stricter MOT) , but you can leave it to D2S and H1 high beam.

Hope you enjoyed the detailed post, and mind any mistakes in grammar.

[9BarStrata]

Very informative post, thanks for that.

In your research have you seen anyway of cleaning the projector without having to dismantle the whole headlight?

[pero-zdero]

Very informative post, thanks for that.

In your research have you seen anyway of cleaning the projector without having to dismantle the whole headlight?

Yeah, that would be a nice thing to do if you have a little dust on,or inside your projector(I mean on a projector glass), I can tell you from my personal experience, since I have changed the D2S bulb on my avensis by myself.

First of all, changing the D2S bulb(in my case) required taking out the whole assembly headlight, which included removing the front bumper, once you remove the bumper half of work is done, because the headlamp is just sitting there on 2 screws, and in one clamp. If you look at the picture from the attach. under number 1 you will see how much space there is left once you remove the aluminum cover, however, there is still housing of a projector that is on your way, and the space left is as big as metal part of the bulb(number 2 on the picture).

So if you can squeeze some cloth with glass cleaner in there, I'll take my hat down!

[nocter]

did you buy the projector or did you buy a new headlamp? I am guessing that a new headlamp will have the projector part..

[NeoXon]

Hi pero-zdero!

Thanks for your post, it helped a lot in understanding the problem I unfortunately also happen to have.

I still have a few more questions though. How could you take apart the headlight itself? As far as I know it is glued together. On your second picture the front glass (actually plastic) part is already taken off. How did you manage to remove it, because it is glued to that black housing that holds the H.I.D. projector and the distance beam headlight in its place (seen on 2nd picture).

Also, does the Xenon's lens easily come off from the housing with just !Removed! off that 3 screws? Is there any adhesive sealant or anything between the housing and the lens? I thought it was totally sealed, too.

And my most important question: if the main problem comes from the matted mirror foil of the projector, do you think if it is enough to bring the projector's housing to a good specialist who can refurbish the mirror foil for some 10 Euros?

Or do I absolutely need to replace the whole projector? If so, where can I get one and what brand fits into my Avensis 2's headlight? I think my H.I.D. bulb is still fine, so I wouldn't like to get a new one, if it's not absolutely necessary.

Maybe it would be also helpful if you addeded some more information on the reassembly process especially where adhesisive sealant (eg. silicone) must be added (I think I saw one on the 5th picture).

Thanks again for the great pictures and description! :)

[pero-zdero]

did you buy the projector or did you buy a new headlamp? I am guessing that a new headlamp will have the projector part..

I was maybe a little bit confusing in the first post, and some of You thought that I was the one who is doing all the work, but no, I just did a research and found a guy who does this for living.

He is the one that is supplying the projector and does all the work, he is charging 150€ for the projector and 50€ for the labor. Like I said I will be taking my car to him in near future (he lives 600km from my house) and I don't want to go there just for the headlamp.

Hi pero-zdero!

Thanks for your post, it helped a lot in understanding the problem I unfortunately also happen to have.

I still have a few more questions though. How could you take apart the headlight itself? As far as I know it is glued together. On your second picture the front glass (actually plastic) part is already taken off. How did you manage to remove it, because it is glued to that black housing that holds the H.I.D. projector and the distance beam headlight in its place (seen on 2nd picture).

Also, does the Xenon's lens easily come off from the housing with just !Removed! off that 3 screws? Is there any adhesive sealant or anything between the housing and the lens? I thought it was totally sealed, too.

And my most important question: if the main problem comes from the matted mirror foil of the projector, do you think if it is enough to bring the projector's housing to a good specialist who can refurbish the mirror foil for some 10 Euros?

Or do I absolutely need to replace the whole projector? If so, where can I get one and what brand fits into my Avensis 2's headlight? I think my H.I.D. bulb is still fine, so I wouldn't like to get a new one, if it's not absolutely necessary.

Maybe it would be also helpful if you addeded some more information on the reassembly process especially where adhesisive sealant (eg. silicone) must be added (I think I saw one on the 5th picture).

Thanks again for the great pictures and description! :)

NeoXon, as You can see, I am not the one who is doing all the work, but I do have some knowledge about it since I talked to this guy over the phone, and he was pleasant to tell me how he does it (not in details, off course, he has some secrets up his sleeve).

The cover lens (the plastic) is removed by putting the hole headlamp in a oven, at particular temp. for a couple of minutes. After that everything is about unscrewing and drilling holes from what I understand.

Regarding Your question about refurbishing, I guess it could be done, and You will still have original projector, however, imagine having all this work done and finding out that refurbishing don't do the trick!

You will be angry, right!

That's why I said in the first post, maybe You can find someone in your area who does this work, instead of taking it to Toyota dealership (and they will sell you a new headlamp for 400€).

He also mentioned that another problem in avensis headlamp (and all older models of xenon lights) is in the little metal piece between the projector and housing (it doesn't ventilate well) and causes all the matting.

Here is how the Yaris looks like after having projectors installed.

[NeoXon]

He also mentioned that another problem in avensis headlamp (and all older models of xenon lights) is in the little metal piece between the projector and housing (it doesn't ventilate well) and causes all the matting.

So in other words installing a new non-Toyota projector is better not only because a refurbished Toyota projectoor may not work as nicely as a new one, but because the ventilation problem, which is the root cause of the matting, is still there. Does installing a new projector solve the ventilation problem? I mean the small little metal piece between the new projector and the housing is still there and causes problems, right?

If it turns out that this is a fault in how Toyota designed the headlamp, we should be able to get it replaced free of charge, am I right? Driving without proper light at night can be even more dangerous, if not directly contributing to a fatal hit in the night, than that fuel pump problem that resulted in the latest recall of D4 engines.

I think I will contact Toyota tomorrow with this problem and see what they say. I have heard too many times about this problem already, so I guess it can't be a result of misusing the headlamps.

[pero-zdero]

So in other words installing a new non-Toyota projector is better not only because a refurbished Toyota projectoor may not work as nicely as a new one, but because the ventilation problem, which is the root cause of the matting, is still there. Does installing a new projector solve the ventilation problem? I mean the small little metal piece between the new projector and the housing is still there and causes problems, right?

If it turns out that this is a fault in how Toyota designed the headlamp, we should be able to get it replaced free of charge, am I right? Driving without proper light at night can be even more dangerous, if not directly contributing to a fatal hit in the night, than that fuel pump problem that resulted in the latest recall of D4 engines.

I think I will contact Toyota tomorrow with this problem and see what they say. I have heard too many times about this problem already, so I guess it can't be a result of misusing the headlamps.

You might be right, but as I mentioned, this also happens with other xenon manufacturers, you can see how many other non-Toyota cars he was working on, and I think they were made by HELLA or Bosch.

You should contact your Toyota dealer, and ask them about your problem, maybe they will replace Your headlight free of charge.

Another thing that I would like to POINT OUT, I am NOT this guy's promoter of any kind. In search to find a solution to MY PROBLEM which is not being able to SEE AT NIGHT! I found someone who replaces the projectors, and I will be taking my car to him. If You can solve your problem by taking your car to Toyota dealership, please do so, I know that I wasn't able to do so (too expansive, 400euros for each headlamp, plus 200euros for each bulb total of 1200euros). For that much money I could do 6 replacement at this guy.

[Sam29]

Just a question, can we replace the whole headlight unit from face lift model to this mk2 avensis?

Cheers.

[pero-zdero]

Just a question, can we replace the whole headlight unit from face lift model to this mk2 avensis?

Cheers.

Honestly, I have no idea! We need to ask somebody who works on Toyota's.

[NeoXon]

Just a question, can we replace the whole headlight unit from face lift model to this mk2 avensis?

Cheers.

Why would you like to do that? Did Toyota fix this projector matting problem in facelift Avensis II models (produced from 2006-2008)? If that is the case maybe it really is a good idea to change the headlight to that one. I know someone who had his car's headlights changed still back in 2005 on his 03 Avensis, because of this matting of the projector, he still had the same problem some years later. So Toyota produced faulty headlights still in 2005, 2 years after Avensis II went to market. Hmmm, not so nice.

[Sam29]

Just a question, can we replace the whole headlight unit from face lift model to this mk2 avensis?

Cheers.

Why would you like to do that? Did Toyota fix this projector matting problem in facelift Avensis II models (produced from 2006-2008)? If that is the case maybe it really is a good idea to change the headlight to that one. I know someone who had his car's headlights changed still back in 2005 on his 03 Avensis, because of this matting of the projector, he still had the same problem some years later. So Toyota produced faulty headlights still in 2005, 2 years after Avensis II went to market. Hmmm, not so nice.

That was my point, simply change the whole unit.

But two questions.

First has Toyota sorted this problem in face lift model ? (my understanding of it is >2007 and 2006 is old mk2)

If answer is yes, can it be fitted in mk2 (2003-06) avensis?

Cheers.

[pero-zdero]

Easy for both of you to say. You can search fot it on eBay, find it for the price of 100 pounds with delivery at your door, and have it replaced in a hour and a half and have your problems solved.

But for us who live in part of the world where eBay won't deliver, and even if they do, I will be charged at customs for more then the headlamp are worth, we need to improvise, my previous posts show you how!

[NeoXon]

Easy for both of you to say. You can search fot it on ebay, find it for the price of 100 pounds with delivery at your door, and have it replaced in a hour and a half and have your problems solved.

But for us who live in part of the world where ebay won't deliver, and even if they do, I will be charged at customs for more then the headlamp are worth, we need to improvise, my previous posts show you how!

If you ask me, it is a problem for me as well. I've just bought this car for some 7000 euros and I am not willing to spend 1100 euros on new headlamps! Finally I was able to find a place where they fix both headlamps for 90 euros. But I still need to remove the bumpers and the headlights and bring them to this guy who refurbishes the mirror foil on the projector. Still better than having to disassemble the headlight unit by myself though (and possibly accidentally melting down the whole thing in the oven).

[pero-zdero]

If you ask me, it is a problem for me as well. I've just bought this car for some 7000 euros and I am not willing to spend 1100 euros on new headlamps! Finally I was able to find a place where they fix both headlamps for 90 euros. But I still need to remove the bumpers and the headlights and bring them to this guy who refurbishes the mirror foil on the projector. Still better than having to disassemble the headlight unit by myself though (and possibly accidentally melting down the whole thing in the oven).

Great, would you please take pictures before and after the treatment. I would love to see how it came out. Good luck!

[pero-zdero]

All right people, I have found the solution to my problems, and as of couple of days ago I am able to see while driving at night.

Here are the pictures before and after...

As soon as I get a chance I will post a picture of the projectors shinning on the road.

[Sam29]

I would like to hear the solution and kindly put step by step tutorial.

Cheers.

[pero-zdero]

I would like to hear the solution and kindly put step by step tutorial.

Cheers.

Simply said, I took my car to a shop, told the guy that I want H1 5000K, and came back 10-12 hours later, and the pictures are the result.

In my first post you are able to see how the new projector looks, and these pictures are just how its done on my car.

[Sam29]

I would like to hear the solution and kindly put step by step tutorial.

Cheers.

Simply said, I took my car to a shop, told the guy that I want H1 5000K, and came back 10-12 hours later, and the pictures are the result.

In my first post you are able to see how the new projector looks, and these pictures are just how its done on my car.

So you cleaned the reflectors and then used HID on your cars for these results?

[pero-zdero]

So you cleaned the reflectors and then used HID on your cars for these results?

Not really. Since the housing of the projector was burnt and was not reflecting light toward the road, I have had the whole projector replaced with a new one, the one that has a solenoid built in, and when you turn on high beams, the high beam comes from that bulb also. I didnt take picture of the projector, but I have seen it, and it is the same as on this picture (this is from the first avensis that he was working on)

the one on the right is the original Toyota projector, and the other one is a replacement.

On this picture you can see the fitting of a new projector inside a headlight.

Again, these pictures were taken back in november of 2010, and are not of mine car, the ones in post on top of page are of mine car.

[bmwe30m3]

hello every1 ive problems with my headlights can u please tell me where did u get the new projecters from beacuse ive checked mine and 1 is melted thanx

[pero-zdero]

And finally here are some pictures on the road.

Low beam

High beam

The high beam is paired with the H1 halogen light and that is why it looks a little bit yellowish....

Just to add, I am totally happy with how it looks now, too bad I don't have pictures of before, but trust me, I was not able to see much.

[Andre-K]

I wonder if I have the same problem, or is it something else...

My left headlight is yellowish, weaker than it should - the strange thing is that both headlights seem to be almost equally bright/white the first 1-4 seconds after ignition .. later, the left fades away.

I did replace the bulb. Is the ballast bad ?

- I had many aftermarket HID's - never seen a ballast/bulb behave like this.

[pero-zdero]

I really dont know, but as you can see my lights were awful before, and I changed the whole projector, and bulb, didnt touch the ballast, and so far, so good (knock on wood).

Once you disassemble the front of your car (in order to remove the headlamp) you should take out the ballast from your right headlamp and place it on your left one, just to eliminate the problem.

If it behaves like it used to, then you have faulty bulb, if it behaves normal, you have a faulty ballast ..... or you can just switch the bulbs...either way works fine...

I have post the picture in your thread.

[Andre-K]

yep, I understand the way of eliminating to find source of the problem, but were looking for a lazy method to determine what I needed to buy -before disassembling. :)

to loosen the bumper - do I need to lift the whole car, just a little ?, or no lifting at all ?