Chrysler Front Wheel Drive Cars 6-CYL 1988-1995 Repair Information

Headlights

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REMOVAL & INSTALLATION



Sealed Beam

If vehicle is equipped with headlamp doors turn the headlight switch ON. Open the hood and locate the power distribution center. This center is located in the front of the left front strut tower. Remove the cover from the center and remove the Headlamp Close Relay. This will prevent the headlamp doors from closing to provide easier servicing. Turn the headlight switch to OFF, then perform this repair.

  1. Remove the headlight bezel.
  2.  
  3. Unhook the spring from the headlight retaining ring if so equipped.
  4.  
  5. Unscrew the retaining ring and remove it.
  6.  

Do not disturb the two long aiming screws. Conventional and Halogen headlamp sealed beams units are interchangeable in pairs, but it is recommended that they not be mixed together (one halogen and one conventional). It is fine to upgrade from conventional bulbs to halogen, but do not change from halogen bulbs to conventional bulbs, especially if the vehicle came equipped with halogen bulbs.

  1. Unplug the old sealed beam from the engine electrical wiring harness.
  2.  
  3. Extract the old bulb from its mounting bracket.
  4.  

To install:
  1. Connect the replacement bulb and install it into the receptacle (check operation of headlight before completing repair).
  2.  
  3. Install the retaining ring and secure it in place with the retaining screws. Connect the spring.
  4.  
  5. Install the headlight bezel.
  6.  

Aero Headlamp

Aero headlamp systems use replaceable halogen bulbs that are mounted in aerodynamic, molded plastic lens reflector assemblies.

Lens fogging is a normal condition and does not require service, as moisture will vent from tubes behind the lens on Aero headlamp-type system.

EXCEPT PREMIER AND MONACO

See Figures 1, 2 and 3

It may be necessary to remove the entire headlamp assembly if enough access cannot be gained otherwise.

  1. Locate and remove the wire connector behind the headlamp assembly in the engine compartment. It may be necessary to remove certain items in the engine compartment to gain access to the bulb wires.
  2.  
  3. Rotate the bulb retaining ring counterclockwise 1 / 4 turn and remove the ring, bulb and bulb holder from the lens assembly. The bulb holder has alignment notches.
  4.  

Do not touch the bulb with bare fingers or any possibly oily surface, since reduced bulb life may result!

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Fig. Fig. 1: To remove the light bulb, first unplug the headlight electrical connector, then ...



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Fig. Fig. 2: ... remove the light bulb socket retaining ring



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Fig. Fig. 3: Rotate the light bulb socket 1/4 turn counter-clockwise, then pull it straight out of the lens assembly

To install:
  1. Wearing gloves or holding the replacement bulb with a cloth rag to keep oil off of the bulb surface, insert the bulb into the rear hole of the headlamp assembly. Make certain that the alignment grooves and tabs line up, push the light bulb into the assembly until seated flush, then turn the bulb clockwise 1 / 4 turn.
  2.  
  3. Plug the electrical light bulb wiring harness into the new light bulb. Install any items removed from the engine compartment.
  4.  

PREMIER AND MONACO

See Figures 4, 5 and 6

Unlike the other vehicles covered by this information, the removal and installation of the headlamp bulbs in the Premier and Monaco models requires the extraction of the entire headlamp lens assembly.

  1. Remove the grille-to-headlamp assembly attaching screws.
  2.  
  3. Disconnect the headlamp aiming cable from the aiming screw end.
  4.  
  5. Remove the headlamp assembly attaching bolts from above and behind the lamp assembly and separate the lamp assembly from the vehicle.
  6.  
  7. Unplug the headlamp wire connector.
  8.  

Do not touch the bulb with bare fingers or any possibly oily surface, since reduced bulb life may result!

  1. Rotate the socket counterclockwise 1 / 4 turn and pull the socket from the back of the lens assembly.
  2.  



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Fig. Fig. 4: Remove the bezel retaining screws to loosen the headlamp assembly-Premier and Monaco



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Fig. Fig. 5: Detach the headlamp wire connector-Premier and Monaco



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Fig. Fig. 6: Once the headlamp assembly has been removed from the vehicle, the various light bulbs can easily be removed-Premier and Monaco

To install:
  1. Wearing gloves or holding the replacement bulb with a cloth rag to keep oil off of the bulb surface, insert the bulb into the rear hole of the headlamp assembly. Make certain that the alignment grooves and tabs line up, push the light bulb into the assembly until seated flush, then turn the bulb clockwise 1 / 4 turn.
  2.  
  3. Plug the headlamp wire connector back into the headlamp bulb.
  4.  
  5. Install the assembly into the vehicle and secure in place with the mounting bolts.
  6.  
  7. Connect the headlamp aiming cable to the aiming screw end.
  8.  
  9. Install the grille-to-headlamp assembly attaching screws.
  10.  

MANUAL OPERATION OF POWER HEADLAMP DOORS



See Figure 7

A manual over-ride hand wheel permits the power headlamp doors to be opened in case of motor failure or to service the headlamps. The wheel is located on the top of the headlamp door drive motor. To gain access to the wheel, open the hood and go in through the flap located in the sight shield behind the bumper fascia. The wheel must be turned a number of turns to remove play and then open the doors.



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Fig. Fig. 7: The power headlamp drive mechanism-note the location of the manual actuating wheel on the top of the drive motor

  1. Disconnect the negative battery cable.
  2.  
  3. Locate the manual override knob. On Daytona, they are located under access shields behind the bumper facia and under the center of the front bumper on LeBaron and other models.
  4.  
  5. Remove the protective cover boot.
  6.  
  7. Rotate the manual override knob to raise the headlight cover(s).
  8.  
  9. Connect the negative battery cable.
  10.  

ALIGNMENT



Aiming Preparation

Headlamps should be adjusted with a special alignment tool, state regulations may vary this procedure, use the following procedure for temporary adjustments only.

Perform the following items before attempting to aim the headlamps:



Verify the headlamp dimmer and high beam indicator operation
 
Inspect and correct all components that could interfere with the proper headlamp alignment
 
Verify proper tire inflation on all wheels
 
Clean headlamp lenses and make sure that there are no heavy loads in the trunk or hatch luggage area
 
The fuel tank should be full. Add 6.5 lbs. (3 kg) of weight over the fuel tank for each estimated gallon of missing fuel.
 

Alignment Screen Preparation

See Figures 8 and 9

  1. Position the vehicle on a level surface perpendicular to a flat wall 25 ft. (7.62 m) away from the front of the headlamp lens.
  2.  
  3. From the floor up 5 ft. (1.3 m), tape a line on the wall at the centerline of the vehicle. Sight along the centerline of the vehicle (from the rear of the vehicle forward) to verify accuracy of the the line placement.
  4.  
  5. Rock the vehicle side to side and up and down (on front bumper assembly) a few times to allow the suspension to stabilize.
  6.  



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Fig. Fig. 8: Headlamp alignment screen low beam pattern



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Fig. Fig. 9: Sealed high beam alignment pattern

  1. Measure the distance from the center of the headlamp lens to the floor. Transfer measurements to the alignment screen with tape. Use this mark for the up/down adjustment reference.
  2.  
  3. Measure distance from the centerline of the vehicle to the center of each headlamp being aligned. Transfer measurements to screen with tape to each side of the vehicle centerline. Use this mark for left/right adjustment reference.
  4.  

Headlight Adjustment

See Figures 10 through 14

A properly aimed low beam headlamp will project the top edge of high intensity pattern on the the alignment screen from 2 in. (50mm) above to 2 in. (50mm) below the headlamp centerline. The side-to-side outboard edge of high intensity pattern should be from 2 in. (50mm) left to 2 in. (50mm) right of the headlamp centerline.

The preferred headlamp alignment is "0'' for the up/down adjustment and "0'' for the left/right adjustment.

The high beams on a vehicle with a Aero headlamps cannot be aligned. The high beam pattern should be correct when the low beams are aligned properly. The high beam pattern on vehicles with multiple sealed beam headlamps should be aligned with the low beam lamp either disconnected or covered (do not cover illuminated headlamp for more than 15 seconds).

To adjust headlamps, adjust the alignment screws to achieve the specified high intensity pattern-refer to the illustrations.



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