REMOVAL & INSTALLATION
See Figures 1 through 6
- Loosen or remove the headlight retaining ring by rotating it counterclockwise or remove the headlight trim piece. Do not disturb the adjusting screw settings.
- Pull the headlight bulb forward and disconnect the wiring assembly plug from the bulb.
- Connect the wiring assembly plug to the new bulb. Place the bulb in position, making sure that the locating tabs of the bulb are fitted in the positioning slots.
- Install the headlight retaining ring.
- Place the headlight trim ring or door into position, and install the retaining screws.
See Figure 7
- Turn the headlight switch OFF .
- Open the hood and locate the bulb which is in the rear of the headlamp body.
- Bend back and lift up on the two black tabs retaining while holding the lamp to the van.
- Disengage the electrical connection by grasping the wires and snapping the connector rearward.
- Remove the bulb retaining ring by rotating it counterclockwise (when viewed from the rear) about 1 / 8 of a turn and sliding the ring off the base.
- Remove the bulb by pulling it straight back out.
- Insert the bulb into the socket with the flat side of the base facing forward. Turn the base slightly to the left or right, if necessary to align grooves in the forward part of the base with the locating tabs inside the socket.
- When the tabs are aligned, push the bulb into the socket until the mounting face on the base contacts the rear face of the socket.
Bulbs No. 9004 and 9007 are similar, but not interchangeable.
- Install the retaining ring and rotate it clockwise. A stop will be felt when the ring is full engaged.
- Engage the electrical connector by pushing it on until it snaps and locks into position.
- Install the lamp in the grille and engage the two black locking tabs.
- Turn the lights ON to check for proper operation.
- Loosen the screws retaining the headlight door, then pull forward and up to disengage the lower locating tabs.
- Loosen the retaining screws and remove the retaining ring. Do not touch the adjusting screws.
- Pull the headlight assembly forward, disengage the wiring and remove the bulb.
- Engage the electrical connector, install the bulb and tighten the screws.
- Install the retaining ring and screws.
- Install the headlight door and tighten the screws.
AIMING THE HEADLIGHTS
See Figures 8 through 12
The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made.
Headlight adjustment may be temporarily made using a wall, as described below, or on the rear of another vehicle. When adjusted, the lights should not glare in oncoming car or truck windshields, nor should they illuminate the passenger compartment of vehicles driving in front of you. These adjustments are rough and should always be fine-tuned by a repair shop which is equipped with headlight aiming tools. Improper adjustments may be both dangerous and illegal.
For most of the vehicles covered by this information, horizontal and vertical aiming of each sealed beam unit is provided by two adjusting screws which move the retaining ring and adjusting plate against the tension of a coil spring. There is no adjustment for focus; this is done during headlight manufacturing.
Because the composite headlight assembly is bolted into position, no adjustment should be necessary or possible. Some applications, however, may be bolted to an adjuster plate or may be retained by adjusting screws. If so, follow this procedure when adjusting the lights, BUT always have the adjustment checked by a reputable shop.
Before removing the headlight bulb or disturbing the headlamp in any way, note the current settings in order to ease headlight adjustment upon reassembly. If the high or low beam setting of the old lamp still works, this can be done using the wall of a garage or a building:
- Park the vehicle on a level surface, with the fuel tank about 1 / 2 full and with the vehicle empty of all extra cargo (unless normally carried). The vehicle should be facing a wall which is no less than 6 feet (1.8m) high and 12 feet (3.7m) wide. The front of the vehicle should be about 25 feet from the wall.
- If aiming is to be performed outdoors, it is advisable to wait until dusk in order to properly see the headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible by closing shades or hanging cloth over the windows.
- Turn the headlights ON and mark the wall at the center of each light's low beam, then switch on the brights and mark the center of each light's high beam. A short length of masking tape which is visible from the front of the vehicle may be used. Although marking all four positions is advisable, marking one position from each light should be sufficient.
- If neither beam on one side is working, and if another like-sized vehicle is available, park the second one in the exact spot where the vehicle was and mark the beams using the same-side light. Then switch the vehicles so the one to be aimed is back in the original spot. It must be parked no closer to or farther away from the wall than the second vehicle.
- Perform any necessary repairs, but make sure the vehicle is not moved, or is returned to the exact spot from which the lights were marked. Turn the headlights ON and adjust the beams to match the marks on the wall.
- Have the headlight adjustment checked as soon as possible by a reputable repair shop.