REMOVAL & INSTALLATION
Sealed Beam Headlights
See Figure 1
- Raise the headlights using the pop-up switch.
- Disconnect the negative battery cable.
- Unfasten the retaining screws, then remove the upper and the lower headlight bezels.
- Remove the headlight retaining ring screws, and the headlight retaining ring.
- Pull the headlight partially out, detach the connector, then remove headlight assembly from the vehicle.
- Attach the headlight electrical connector.
- Properly position the headlight and the retaining ring, then install the retaining screws.
- Install the headlight bezels and secure with the retaining screws.
- Connect the negative battery cable.
See Figures 2, 3, 4, 5, 6 and 7
- Open the vehicle's hood and secure it in an upright position.
- Disconnect the negative battery cable.
- If necessary, for 1995-98 vehicles, remove the air cleaner assembly and radiator reserve tank.
- Remove the socket cover by pulling it straight off, or turning it clockwise then pulling it off.
- For 1990-94 vehicles, remove the valve mounting spring and pull the valve out toward you, together with the connector.
- For 1995-98 vehicles, carefully twist the bulb and socket counterclockwise, then pull the assembly from the headlight housing.
- Holding the base of the bulb, detach it from the connector harness.
- Holding the base of the bulb, install it securely in the connector.
- Install the connector and bulb assembly in the housing and either twist to lock into position, or install the valve mounting spring, as applicable.
- Install the sealing cover by pushing it on and/or turning it counterclockwise. Make sure the cover is installed securely or the lens will be out of focus, or water may get into the light unit.
- Disconnect the negative battery cable and check the headlight operation.
MANUAL OPERATION OF CONCEALED HEADLIGHTS
If the headlight covers will not raise electrically, remove the fusible link from the relay box, then remove the boot on the rear area of the pop-up motor and turn the manual knob clockwise until the cover is open. Perform this procedure on both the left and right sides.
AIMING THE HEADLIGHTS
See Figures 8, 9, 10 and 11
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 guide, 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.