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Adjustments

Lighting and Horns › Headlamp
Unified entry — merged from multiple cross-listed pages in the original manual.
Procedures
Fog/Driving Lamp: Adjustments19 steps
ℹ NOTE
Due to the linear nature of the headlamp cutoff, a properly aimed low beam headlamp will project the top edge of the high intensity pattern on the alignment screen from the horizontal line to 50 millimeters (2 inches) below the horizontal line for domestic market vehicles, or to 125 millimeters (5 inches) below the horizontal line for export market vehicles. No horizontal (right/left) adjustment is required for this headlamp beam pattern in domestic market vehicles. Export market vehicles have a second horizontal (right/left) adjustment screw provided. The high beam pattern will be correct when the low beams are properly aimed.
ℹ NOTE
Each front fog lamp shares a common reflector with the headlamp for that side of the vehicle and is automatically adjusted correctly when the headlamp is properly adjusted.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
  1. Check for and correct any burnt out bulbs.
  2. If the vehicle is equipped with headlamp leveling, be certain that the headlamp leveling switch is in the 0 position.
  3. Repair or replace any ineffective, worn or damaged body or suspension components that could hinder proper lamp alignment.
  4. Verify proper tire inflation pressures.
  5. Remove any accumulations of mud, snow or ice from the vehicle underbody and clean the front lamp lenses.
  6. Verify that there is no load in the vehicle (cargo or passengers), except for the driver.
  7. The fuel tank should be FULL. Add 2.94 kilograms (6.5 pounds) of weight over the fuel tank for each estimated gallon of missing fuel.
  8. Verify correct vehicle suspension height. LAMP ALIGNMENT SCREEN PREPARATION The procedure that follows will prepare a suitable front lamp alignment screen.
  9. Tape a line on a level floor 7.62 meters (25 feet) away from and parallel to the flat wall that will be used as the lamp alignment screen. The level floor will be used as the horizontal zero reference.
  10. An adjacent wall or floor member that is perpendicular to the alignment screen can be used as the vertical zero reference. If there is no adjacent wall or floor member that is perpendicular to the screen, tape a second line on the floor perpendicular to both the alignment screen and the first line, and outboard of either side of where the vehicle will be positioned. This will be used as the vertical zero reference.
  11. Position the vehicle so that the side of the vehicle is parallel to the vertical zero reference, and so that the front of the lamp lenses are in the vertical plane of the parallel line taped on the floor 7.62 meters (25 feet) away from the screen.
  12. Rock the vehicle side-to-side three times to allow the suspension to stabilize.
  13. Jounce the front suspension three times by pushing downward on the front bumper and releasing.
  14. Measure the distance between the optical center of one of the lamps being aimed (head or fog) and the floor (horizontal zero reference). Transfer this measurement to the alignment screen with a piece of tape placed horizontally to the floor. This line will be used as the lamp horizontal reference.
  15. Measure the distance between the vertical zero reference and the optical center of the nearest lamp being aimed (head or fog). Transfer this measurement to the alignment screen with a piece of tape placed vertically across the appropriate (head or fog) lamp horizontal reference. This is the centerline reference for the first lamp.
  16. Measure the distance on center between the first and the second lamp being aimed. Transfer this measurement to the alignment screen with a second piece of tape placed vertically across the appropriate (head or fog) lamp horizontal reference. This is the centerline reference for the second lamp. HEADLAMP ALIGNMENT
  17. Turn the headlamps ON and select the LOW beams for vehicles in all markets.
  18. On all vehicles except those with headlamp leveling, use a screwdriver to rotate the headlamp vertical adjustment screw (2) on the back of the front lamp unit just inboard of the fender and forward of the upper radiator crossmember (1) to adjust the beam height as required.
  19. For export markets only, use a screwdriver to rotate the headlamp horizontal adjustment screw on each headlamp to adjust the beam right or left as required. FOG LAMP ALIGNMENT
Headlamp: Adjustments19 steps
ℹ NOTE
Due to the linear nature of the headlamp cutoff, a properly aimed low beam headlamp will project the top edge of the high intensity pattern on the alignment screen from the horizontal line to 50 millimeters (2 inches) below the horizontal line for domestic market vehicles, or to 125 millimeters (5 inches) below the horizontal line for export market vehicles. No horizontal (right/left) adjustment is required for this headlamp beam pattern in domestic market vehicles. Export market vehicles have a second horizontal (right/left) adjustment screw provided. The high beam pattern will be correct when the low beams are properly aimed.
ℹ NOTE
Each front fog lamp shares a common reflector with the headlamp for that side of the vehicle and is automatically adjusted correctly when the headlamp is properly adjusted.
Fig. 1
Fig. 1
Fig. 2
Fig. 2
  1. Check for and correct any burnt out bulbs.
  2. If the vehicle is equipped with headlamp leveling, be certain that the headlamp leveling switch is in the 0 position.
  3. Repair or replace any ineffective, worn or damaged body or suspension components that could hinder proper lamp alignment.
  4. Verify proper tire inflation pressures.
  5. Remove any accumulations of mud, snow or ice from the vehicle underbody and clean the front lamp lenses.
  6. Verify that there is no load in the vehicle (cargo or passengers), except for the driver.
  7. The fuel tank should be FULL. Add 2.94 kilograms (6.5 pounds) of weight over the fuel tank for each estimated gallon of missing fuel.
  8. Verify correct vehicle suspension height. LAMP ALIGNMENT SCREEN PREPARATION The procedure that follows will prepare a suitable front lamp alignment screen.
  9. Tape a line on a level floor 7.62 meters (25 feet) away from and parallel to the flat wall that will be used as the lamp alignment screen. The level floor will be used as the horizontal zero reference.
  10. An adjacent wall or floor member that is perpendicular to the alignment screen can be used as the vertical zero reference. If there is no adjacent wall or floor member that is perpendicular to the screen, tape a second line on the floor perpendicular to both the alignment screen and the first line, and outboard of either side of where the vehicle will be positioned. This will be used as the vertical zero reference.
  11. Position the vehicle so that the side of the vehicle is parallel to the vertical zero reference, and so that the front of the lamp lenses are in the vertical plane of the parallel line taped on the floor 7.62 meters (25 feet) away from the screen.
  12. Rock the vehicle side-to-side three times to allow the suspension to stabilize.
  13. Jounce the front suspension three times by pushing downward on the front bumper and releasing.
  14. Measure the distance between the optical center of one of the lamps being aimed (head or fog) and the floor (horizontal zero reference). Transfer this measurement to the alignment screen with a piece of tape placed horizontally to the floor. This line will be used as the lamp horizontal reference.
  15. Measure the distance between the vertical zero reference and the optical center of the nearest lamp being aimed (head or fog). Transfer this measurement to the alignment screen with a piece of tape placed vertically across the appropriate (head or fog) lamp horizontal reference. This is the centerline reference for the first lamp.
  16. Measure the distance on center between the first and the second lamp being aimed. Transfer this measurement to the alignment screen with a second piece of tape placed vertically across the appropriate (head or fog) lamp horizontal reference. This is the centerline reference for the second lamp. HEADLAMP ALIGNMENT
  17. Turn the headlamps ON and select the LOW beams for vehicles in all markets.
  18. On all vehicles except those with headlamp leveling, use a screwdriver to rotate the headlamp vertical adjustment screw (2) on the back of the front lamp unit just inboard of the fender and forward of the upper radiator crossmember (1) to adjust the beam height as required.
  19. For export markets only, use a screwdriver to rotate the headlamp horizontal adjustment screw on each headlamp to adjust the beam right or left as required. FOG LAMP ALIGNMENT
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
VEHICLE PREPARATION FOR LAMP ALIGNMENT
1. Check for and correct any burnt out bulbs. 2. If the vehicle is equipped with headlamp leveling, be certain that the headlamp leveling switch is in the 0 position. 3. Repair or replace any ineffective, worn or damaged body or suspension components that could hinder proper lamp alignment. 4. Verify proper tire inflation pressures. 5. Remove any accumulations of mud, snow or ice from the vehicle underbody and clean the front lamp lenses. 6. Verify that there is no load in the vehicle (cargo or passengers), except for the driver. 7. The fuel tank should be FULL. Add 2.94 kilograms (6.5 pounds) of weight over the fuel tank for each estimated gallon of missing fuel. 8. Verify correct vehicle suspension height.
LAMP ALIGNMENT SCREEN PREPARATION📷 1
The procedure that follows will prepare a suitable front lamp alignment screen.
1. Tape a line on a level floor 7.62 meters (25 feet) away from and parallel to the flat wall that will be used as the lamp alignment screen. The level floor will be used as the horizontal zero reference. 2. An adjacent wall or floor member that is perpendicular to the alignment screen can be used as the vertical zero reference. If there is no adjacent wall or floor member that is perpendicular to the screen, tape a second line on the floor perpendicular to both the alignment screen and the first line, and outboard of either side of where the vehicle will be positioned. This will be used as the vertical zero reference. 3. Position the vehicle so that the side of the vehicle is parallel to the vertical zero reference, and so that the front of the lamp lenses are in the vertical plane of the parallel line taped on the floor 7.62 meters (25 feet) away from the screen. 4. Rock the vehicle side-to-side three times to allow the suspension to stabilize. 5. Jounce the front suspension three times by pushing downward on the front bumper and releasing. 6. Measure the distance between the optical center of one of the lamps being aimed (head or fog) and the floor (horizontal zero reference). Transfer this measurement to the alignment screen with a piece of tape placed horizontally to the floor. This line will be used as the lamp horizontal reference. 7. Measure the distance between the vertical zero reference and the optical center of the nearest lamp being
aimed (head or fog). Transfer this measurement to the alignment screen with a piece of tape placed vertically across the appropriate (head or fog) lamp horizontal reference. This is the centerline reference for the first lamp. 8. Measure the distance on center between the first and the second lamp being aimed. Transfer this measurement to the alignment screen with a second piece of tape placed vertically across the appropriate (head or fog) lamp horizontal reference. This is the centerline reference for the second lamp.
figure
HEADLAMP ALIGNMENT📷 1
NOTE: Due to the linear nature of the headlamp cutoff, a properly aimed low beam headlamp will project the top edge of the high intensity pattern on the alignment screen from the horizontal line to 50 millimeters (2 inches) below the horizontal line for domestic market vehicles, or to 125 millimeters (5 inches) below the horizontal line for export market vehicles. No horizontal (right/left) adjustment is required for this headlamp beam pattern in domestic market vehicles. Export market vehicles have a second horizontal (right/left) adjustment screw provided. The high beam pattern will be correct when the low beams are properly aimed.
1. Turn the headlamps ON and select the LOW beams for vehicles in all markets. 2. On all vehicles except those with headlamp leveling, use a screwdriver to rotate the headlamp vertical adjustment screw (2) on the back of the front lamp unit just inboard of the fender and forward of the upper radiator crossmember (1) to adjust the beam height as required. 3. For export markets only, use a screwdriver to rotate the headlamp horizontal adjustment screw on each headlamp to adjust the beam right or left as required.
figure
FOG LAMP ALIGNMENT📷 1
NOTE: Each front fog lamp shares a common reflector with the headlamp for that side
of the vehicle and is automatically adjusted correctly when the headlamp is properly adjusted.

Specifications

CENTER HIGH MOUNTED STOP

Assembly

FRONT FOG 9145 (H10) 3157AK - DOMESTIC
FRONT PARK/TURN SIGNAL 3757AK (PY27W/7W) - EXPORT
FRONT SIDE MARKER (DOMESTIC ONLY) 168 9008 (H13) - DOMESTIC
HEADLAMP 9003 (H4 60/55W) - EXPORT
figure
HEADLAMP LEVELING MOTOR
The headlamp leveling motor (6) is located on the rear outboard side of each front lamp unit housing (1) on vehicles equipped with the headlamp leveling system, which is available only in certain markets where it is required equipment. The motor is encased within a molded plastic housing and is secured by an integral wedge- type mounting boss to a keyed flange on the back of the front lamp unit housing. A rubber seal around the circumference of the mounting boss seals the motor to the lamp housing.
The outside of the motor housing features an integral molded connector on its rearward surface and a plastic pushrod with a ball formation on its free end extends from the motor mounting boss. Within the motor housing is a 12-volt Direct Current (DC) servo motor, an electronic controller board that includes the motor logic circuits, and an integral screw-drive transmission. The headlamp leveling motor is connected to the vehicle electrical system through a dedicated take out and connector of the front end module wire harness.
The headlamp leveling motor is serviced as a unit with the front lamp unit. The motor cannot be repaired and, if ineffective or damaged, the entire front lamp unit must be replaced.
HEADLAMP LEVELING MOTOR📷 1
The controller board and logic circuitry of the headlamp leveling motor controls motor operation based upon a voltage signal input received from the Totally Integrated Power Module (TIPM). The TIPM uses electronic messages received over the Controller Area Network (CAN) data bus from the ElectroMechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) to determine the correct voltage signal to provide the leveling motor, while the EMIC uses electronic messages received over the Local Interface Network (LIN) data bus from the instrument panel switch pod to monitor the headlamp leveling switch selection.
The headlamp leveling motors have a path to ground at all times. The motors operate on battery voltage received through the headlamp low beam feed circuits so that the system will only operate when the headlamp low beams are turned ON. When the motor is energized it will extend or retract the motor pushrod through an integral screw-drive transmission. The ball on the end of the pushrod is snapped into a socket on the back of the reflector within the front lamp unit housing, which will cause the reflector to move as the pushrod is extended
or retracted, changing the angle at which the light is projected from the headlamp low beam bulb filaments.
The hard wired circuits for the headlamp leveling motors may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the active electronic elements within the headlamp leveling motors or the electronic controls and communication between other modules and devices that provide some features of the headlamp leveling system. The most reliable, efficient, and accurate means to diagnose the headlamp leveling motor or the electronic controls and communication related to headlamp leveling system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information.
SWITCH-HEADLAMP LEVELING
figure