1996 CHRYSLER VOYAGER Service Manual

HEADLAMP ALIGNMENT
INDEX
page page
GENERAL INFORMATION
HEADLAMP ALIGNMENT................... 5
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION....... 5ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN.................... 5
GENERAL INFORMATION
HEADLAMP ALIGNMENT
The headlamps are equipped with a bubble level
for up/down headlamp alignment. The bubble is cen-
tered with the vehicle on a level surface. A horizontal
gauge and magnifying window is located next to the
bubble level for left/right alignment (Fig. 1). Aim on
every headlamp assembly is calibrated at the head-
lamp manufacturer. At the vehicle assembly plant,
the vertical aim is set by centering the bubble with
the vehicle on a level surface. Horizontal aim is con-
trolled by the mounting pads on each headlamp
mounting panel.
When the vehicle is to be used with a heavy load,
the bubble level can be used to compensate for the
altered ride height.
SERVICE PROCEDURES
HEADLAMP ALIGNMENT PREPARATION
(1) Verify headlamp dimmer switch and high beam
indicator operation.
(2) Inspect and correct damaged or defective com-
ponents that could interfere with proper headlamp
alignment.
(3) Verify proper tire inflation.
(4) Clean headlamp lenses.
(5) Verify that luggage area is loaded as the vehi-
cle is routinely used.
(6) 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.
ADJUSTMENTS
HEADLAMP/FOG LAMP ADJUSTMENT USING
ALIGNMENT SCREEN
ALIGNMENT SCREEN PREPARATION
(1) Position vehicle on a level surface perpendicu-
lar to a flat wall 7.62 meters (25 ft.) away from front
of headlamp lens (Fig. 2).
(2) If necessary, tape a line on the floor 7.62
meters (25 ft.) away from and parallel to the wall.
(3) From the floor up 1.27 meters (5 ft.), tape a
line on the wall at the center line of the vehicle.
Sight along the center line of the vehicle (from rear
of vehicle forward) to verify accuracy of the line
placement.
(4) Rock vehicle side-to-side three times and allow
suspension to stabilize.
(5) Jounce front suspension three times by pushing
downward on front bumper and releasing.
(6) Measure the distance from the center of head-
lamp lens to the floor. Transfer measurement to the
alignment screen (with tape). Use this line for
up/down adjustment reference.
(7) Measure distance from the center line of the
vehicle to the center of each headlamp being aligned.
Transfer measurements to screen (with tape) to each
Fig. 1 Magnifying Window and Bubble Level
NSLAMPS 8L - 5

side of vehicle center line. Use these lines for left/
right adjustment reference.
HEADLAMP ADJUSTMENT
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen 229 mm (9 in.)650 mm (2 in.) below the
headlamp center line. The center of the hot spot
should be 100 mm (4 in.)650 mm (2 in.) right of the
headlamp center line (Fig. 2). 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 alignment, rotate adjusting
screws to achieve the specified low beam hot spot
location (Fig. 3).
HEADLAMP ADJUSTMENT ± TOWN AND
COUNTRY
A properly aimed low beam headlamp will project
the center of the low beam hot spot on the alignment
screen 152 mm (6 in.)650 mm (2 in.) below the
headlamp center line. The center of the hot spot
should be 254 mm (10 in.)650 mm (2 in.) right of
the headlamp center line (Fig. 4). The high beams on
a vehicle with aero headlamps cannot be aligned. Thehigh beam pattern should be correct when the low
beams are aligned properly.
Fig. 2 Headlamp Alignment Screen
Fig. 3 Headlamp Bubble Level and Adjusters
8L - 6 LAMPSNS
ADJUSTMENTS (Continued)

To adjust headlamp alignment, rotate adjusting
screws to achieve the specified low beam hot spot
location (Fig. 3).
BUBBLE LEVEL CALIBRATION
(VERTICAL AIM)
After the headlamp alignment has been verified or
set and the bubble level is not centered, calibrate the
bubble level.
NOTE: Any calibration of the headlamp bubble
level must be done on a level surface and the head-
lamp cool. Do not operate the headlamps for a min-
imum of 20 minutes prior to beginning adjustments.
(1) Remove screws holding magnifying window to
top of headlamp module (Fig. 5).
(2) Position magnifying window to the side
between headlamp module and radiator closure
panel.
(3) Through slotted hole in magnifying window,
insert small screw driver into bubble level calibration
screw.(4) Rotate calibration screw in proper direction
until bubble is centered on the ªOº.
(5) Install magnifying window, making sure O-ring
seal is in place.
(6) If necessary, calibrate magnifying window.MAGNIFYING WINDOW CALIBRATION
(HORIZONTAL AIM)
After the headlamp alignment has been verified or
set and the magnifying window is not centered, cali-
brate the magnifying window.
(1) Loosen screws holding magnifying window to
top of headlamp module (Fig. 5).
(2) Using the calibration knob above headlamp
lens, rotate magnifying window until window is cen-
tered over the ªOº on the gauge below the window.
Fig. 4 Headlamp Alignment Screen ± T&C
NSLAMPS 8L - 7
ADJUSTMENTS (Continued)

(3) Tighten screws to hold magnifying window to
headlamp module. Do not over tighten.FOG LAMP ALIGNMENT
Prepare an alignment screen. Refer to the Align-
ment Screen Preparation paragraph in this section. A
properly aligned fog lamp will project a pattern on
the alignment screen 100 mm (4 in.) below the fog
lamp center line and straight ahead (Fig. 6). To
improve visual interpretation of the fog lamp pattern
on the alignment screen, disable the headlamps by
disengaging the wire connectors from the headlamp
bulbs.
The Town and Country fog lamp adjustment screw
is located through the lens (Fig. 7).
Fig. 6 Fog Lamp Alignment
Fig. 5 Magnifying Window and Bubble Level
Calibration
Fig. 7 Fog Lamp Adjustment Screw
8L - 8 LAMPSNS
ADJUSTMENTS (Continued)

EXTERIOR LAMP BULB SERVICE
INDEX
page page
REMOVAL AND INSTALLATION
CENTER HIGH MOUNTED STOP LAMP
(CHMSL) BULB........................ 13
FOG LAMP BULB ± TOWN and COUNTRY..... 11
FOG LAMP BULB........................ 10
FRONT PARKING AND TURN SIGNAL LAMP
BULB ± TOWN and COUNTRY............ 12
FRONT SIDE MARKER LAMP BULB TOWN and
COUNTRY............................ 11HEADLAMP BULB ± TOWN & COUNTRY....... 9
HEADLAMP BULB........................ 9
LICENSE PLATE LAMP BULB.............. 13
PARKING AND TURN SIGNAL BULB......... 11
TAIL, STOP, TURN SIGNAL AND BACK-UP
LAMP BULB.......................... 12
REMOVAL AND INSTALLATION
HEADLAMP BULB
REMOVAL
(1) Release hood latch and open hood.
(2) From behind radiator closure panel, disconnect
wire connector from back of headlamp bulb base.
(3) Rotate headlamp bulb retaining ring counter-
clockwise.
(4) Remove retaining ring from headlamp (Fig. 1).
(5) Pull headlamp bulb from back of headlamp.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) From behind radiator closure panel, insert
headlamp bulb into back of headlamp.
(2) Engage retaining ring onto headlamp (Fig. 1).(3) Rotate headlamp bulb retaining ring clockwise.
(4) Connect wire connector into headlamp bulb
base.
(5) Verify headlamp alignment.
HEADLAMP BULB ± TOWN & COUNTRY
HEADLAMP HIGH BEAM
REMOVAL
(1) Release hood latch and open hood.
(2) From behind radiator closure panel, disconnect
wire connector from back of high headlamp bulb
base.
(3) Rotate headlamp bulb counterclockwise and
pull bulb from back of headlamp module (Fig. 2).
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.
(1) Insert bulb into the back of the headlamp mod-
ule.
(2) Rotate headlamp bulb clockwise to engage
bulb.
(3) Connect wire connector to the low beam head-
lamp. Verify headlamp bulb operation
(4) Verify headlamp alignment.
HEADLAMP LOW BEAM
REMOVAL
(1) Release hood latch and open hood.
(2) Remove the three headlamp mounting nuts.
(3) Remove one attaching screw on top of the
crossmember.
(4) Disconnect wire connector from the back of the
low beam headlamp bulb base (Fig. 4).
Fig. 1 Headlamp Bulb
NSLAMPS 8L - 9