Standard Procedure - Headlamp Unit Alignment - Export; Removal - Chrysler PT Cruiser Service & Repair Manual

PT
HEADLAMP UNIT (Continued)
(6) A small dot is molded into each headlamp lens
signifying the center of the low-beam headlamp.
Measure the distance from the center of the head-
lamp to the floor. Transfer measurement to the align-
ment screen (with tape). Use this line for up/down
adjustment reference.
HEADLAMP UNIT ALIGNMENT
The headlamp low beam pattern has a distinct hor-
izontal cutoff line which is used to visually align the
headlamps. A properly aimed headlamp will have the
top of the horizontal cut off line of the low beam pat-
tern aligned with the horizontal line on the wall (Fig.
13). The high beams on a vehicle with aero head-
lamps cannot be aligned. The high beam pattern
should be correct when the low beams are aligned
properly.
To adjust headlamp unit alignment, rotate align-
ment screw to achieve the specified low beam hot
spot pattern.
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT - EXPORT
VEHICLE PREPARATION FOR HEADLAMP UNIT
ALIGNMENT
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Verify that the headlamp leveling switch is in
the "0" position.
(3) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(4) Verify proper tire inflation.
(5) Clean headlamp lenses.
(6) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(7) Fuel tank should be FULL. Add 2.94 kg (6.5
lbs.) of weight over the fuel tank for each estimated
gallon of missing fuel.
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 10 meters (32.8 ft.) away from front
of headlamp lens (Fig. 14).
(2) Place 75 kg in the driver's seat to simulate the
ride height of the vehicle when driven.
(3) If necessary, tape a line on the floor 10 meters
(32.8 ft.) away from and parallel to the wall.
(4) From the floor up 1.27 meters (5 ft.), tape a
vertical line on the wall at the centerline of the vehi-
cle. Sight along the centerline of the vehicle (from
rear of vehicle forward) to verify accuracy of the line
placement.
(5) Rock vehicle side-to-side three times and allow
suspension to stabilize.
LAMPS/LIGHTING - EXTERIOR
(6) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(7) Measure the distance from the center of head-
lamp low beam dot on the lens to the floor. Transfer
measurement to the alignment screen (with tape).
Use this line for up/down adjustment reference.
(8) Place a tape line 130 mm below and parallel to
the center of headlamp line.
(9) 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 vehicle centerline. Use these lines for left/
right adjustment reference.
HEADLAMP UNIT ALIGNMENT
A properly aimed low beam headlamp will project a
high intensity light pattern on the screen with the
horizontal cut-off line aligned with the tape line 100
mm (3.94 in.) below the headlamp centerline (Fig.
14). The intersection of the horizontal and 15 degree
cut-off lines in the projected pattern should align to
the intersection of the headlamp centerline vertical
tape line and the tape line 100 mm (3.94 in.) below
the headlamp horizontal centerline. The high beams
on a vehicle with aero headlamps cannot be aligned.
The high beam pattern should be correct when the
low beams are aligned properly.
To adjust headlamp unit alignment, rotate the
alignment screws (horizontal and vertical) to
achieve the specified low beam spot pattern. The
alignment screws are located in the front of the head-
lamp unit, just below the lens.

REMOVAL

(1) Raise vehicle on a hoist.
(2) Remove wheel and tire.
(3) Remove splash shield as necessary to access
headlamp housing.
(4) Remove grille.
(5) Remove the two fascia bolts from behind the
grille (Fig. 15) and (Fig. 16).
(6) Remove fasteners attaching fender to fascia on
the side being worked on.
(7) Remove the three fasteners holding the lower
fascia to the lower radiator crossmember.
(8) Remove four nuts attaching headlamp housing
(Fig. 17).
(9) Remove headlamp housing by lowering the fas-
cia as necessary (Fig. 18) and (Fig. 19).
(10) Disconnect wire connector.
8L - 13