Headlamp - Pattern Improvements
NO: 08-38-94 Rev. AGROUP: Electrical
DATE: Oct. 21, 1994
SUBJECT:
Headlamp Pattern Improvement
THIS TECHNICAL SERVICE BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-38-94 DATED AUG. 5, 1994 WHICH SHOULD BE REMOVED FROM YOUR FILES ADDITIONAL MODELS, PARTS AND PROCEDURES HAVE BEEN ADDED. CHANGES ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1993 - 1994 (LH) Intrepid/LHS/New Yorker**
DISCUSSION:
A new headlamp with an improved beam pattern has been developed.
PARTS REQUIRED:
1 4778256 Right Headlamp, Intrepid
1 4778257 Left Headlamp, Intrepid
1 4778254 Right Side Marker, Park, and Turn Signal Lamp, Intrepid
1 4778255 Left Side Marker, Park, and Turn Signal Lamp, Intrepid
**1 4778258 Right Headlamp, New Yorker**
**1 4778259 Left Headlamp, New Yorker**
**1 4778260 Right Headlamp, LHS**
**1 4778261 Left Headlamp, LHS**
**4 152953 # 8 x 1/2" Pan Head Tapping Screw, LHS**
**2 152959 # 8 x 1" Pan Head Tapping Screw, LHS**
NOTE:
THE INTREPID SIDE MARKER, PARK AND TURN SIGNAL LAMPS ARE BEING REPLACED FOR COSMETIC REASONS ONLY. THE ONLY CHANGE IS TO THE LENS TO MATCH THE NEW HEADLAMPS.
REPAIR PROCEDURE:
This bulletin involves replacing both headlamps and side marker, and park/turn lamps on Intrepid models.
INTREPID MODELS
1. Release hood latch and open hood.
2. Remove screws (2) holding headlamp to lamp module.
3. Separate headlamp from lamp module.
4. Disengage wire connector from headlamp bulb.
NOTE:
DO NOT TOUCH BULB WITH YOUR FINGERS. OIL CONTAMINATION WILL SEVERELY SHORTEN BULB LIFE. IF THE BULB COMES IN CONTACT WITH ANY OILY SURFACE, CLEAN THE BULB WITH RUBBING ALCOHOL.
5. Separate headlamp from vehicle.
6. Disengage clips holding side marker, park/turn signal lamp to lamp module.
7. Pull lamp body away from lamp module.
8. Remove bulb socket from lamp.
9. Separate lamp from vehicle.
10. Place new side marker, park/turn signal lamp in position on vehicle.
11. Install bulb socket in lamp.
12. Insert lamp into lamp module.
13. Place headlamp in position on vehicle.
14. Engage wire connector to headlamp bulb.
15. Place headlamp in position in module.
16. Install screws (2) to hold headlamp to lamp module. Late build 1994 headlamp and adjuster brackets may have a place for a third screw. This screw is not necessary. Do not replace the bracket.
17. Repeat procedure on other side of vehicle.
18. Verify headlamp and side marker, park/turn signal lamp operation.
**LHS/NEW YORKER MODELS
1. Release hood latch and open hood.
2. Remove radiator closure panel sight shield as necessary to gain access to headlamp fasteners.
3. Remove screws (2) holding headlamp module to mount adapter.
4. Separate headlamp module from mount adaptor.
5. Disengage wire connectors from headlamp and fog lamp (if equipped).
NOTE:
DO NOT TOUCH BULB WITH YOUR FINGERS. OIL CONTAMINATION WILL SEVERELY SHORTEN BULB LIFE. IF THE BULB COMES IN CONTACT WITH ANY OILY SURFACE, CLEAN THE BULB WITH RUBBING ALCOHOL.
6. Separate headlamp from vehicle.
7. Transfer fog lamp to revised headlamp (if equipped).
NOTE:
THE REVISED HEADLAMP MAY REQUIRE LARGER FOG LAMP MOUNTING SCREWS. INSTALL THE TWO SHORTER SCREWS, P/N 152953, IN THE UPPER FOG LAMP MOUNTING HOLES. INSTALL THE LONGER SCREW, P/N 152959, IN THE LOWER FOG LAMP MOUNTING HOLE. TIGHTEN THE LONGER SCREW UNTIL THERE IS A 9.6 mm GAP BETWEEN THE FOG LAMP LOWER SCREW MOUNTING BOSS AND THE HEADLAMP ASSEMBLY AS SHOWN. THIS GAP SETS THE FOG LAMP AIM. VERIFY FOG LAMP AIM AFTER VEHICLE IS ASSEMBLED.
8. Engage wire connectors to revised headlamp and fog lamp (if equipped).
9. Place headlamp module in position on mount adaptor.
10. Install screws to hold headlamp module to mount adaptor.
11. Repeat procedure on other side of vehicle.
12. Install radiator closure panel sight shield.
13. Verify headlamp and fog lamp operation (if equipped)**.
HEADLAMP ALIGNMENT:
1. Align vehicle to the headlamp aiming screen as shown.
2. Turn on the headlamps, making sure they are on HIGH BEAM, NOT low beam.
3. Headlamp Alignment: The high intensity area (hot spot) of the high beam should be centered about the horizontal line on the screen which represents the height of the headlamp at its center. For a normal vehicle without any occupants and a full tank of gas, this height will be 25.34 in. (643.72 mm.) Intrepid, and 24.45 in. (621.0 mm) LHS/New Yorker.
The high intensity area of the high beam will be shifted to the right of the vertical centerline of each lamp approximately 4 in. as measured from the vehicle centerline. The location of the vertical centerline of each lamp as measured from the vehicle centerline is 23.32 in. (592 mm.).
Make the vertical and horizontal adjustment for each lamp. The beams should look like the illustration. Check the low beam to ensure no part of the low beam high intensity area is above the horizontal.
4. Rotate the bubble level calibration screw in or out until bubble is centered in the vial.
5. Center arrow sticker, P/N 4630294, to gauge sticker for left/right reference.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-50-31-95 0.6 Hrs.
FAILURE CODE: P8 - New Part