Chrysler PT Cruiser. Manual — part 501

HEADLAMP

DIAGNOSIS AND TESTING - HEADLAMPS

Always begin any diagnosis by testing all of the

fuses and circuit breakers in the system. Refer to
Wiring Diagrams.

HEADLAMP DIAGNOSIS

CONDITION

POSSIBLE CAUSES

CORRECTION

HEADLAMPS ARE
DIM WITH ENGINE
IDLING OR
IGNITION TURNED
OFF.

1. Loose or corroded battery
cables.

1. Clean and secure battery cable clamps and posts.

2. Loose or worn generator drive
belt.

2. Adjust or replace generator drive belt.

3. Charging system output too
low.

3. Test and repair charging system. Refer to Charging
System.

4. Battery has insufficient
charge.

4. Test battery state - of - charge. Refer to Battery.

5. Battery is sulfated or shorted.

5. Load test battery. Refer to Battery.

6. Poor lighting circuit Z1 -
ground.

6. Test for voltage drop across Z1 - ground locations.
Refer to Wiring Diagrams.

7. Both headlamp bulbs
defective.

7. Replace both headlamp bulbs.

HEADLAMP BULBS
BURN OUT
FREQUENTLY.

1. Charging system output too
high.

1. Test and repair charging system. Refer to Charging
System.

2. Loose or corroded terminals
or splices in circuit.

2. Inspect and repair all connectors and splices. Refer
to Wiring Diagrams.

HEADLAMPS ARE
DIM WITH ENGINE
RUNNING EVEN
ABOVE IDLE.*

1. Charging system output too
low.

1. Test and repair charging system. Refer to Charging
Systems.

2. Poor lighting circuit Z1 -
ground.

2. Test for voltage drop across Z1 - ground locations.
Refer to Wiring Diagrams.

3. High resistance in headlamp
circuit.

3. Test amperage draw of headlamp circuit.

4. Both headlamp bulbs
defective.

4. Replace both headlamp bulbs.

HEADLAMPS FLASH
RANDOMLY.

1. Poor lighting circuit Z1 -
ground.

1. Test for voltage drop across Z1 - ground locations.
Refer to Wiring Diagrams.

2. High resistance in headlamp
circuit.

2. Test amperage draw of headlamp circuit. Should
not exceed 30 amps.

3. Faulty headlamps switch
circuit breaker.

3. Replace headlamp switch.

4. Loose or corroded terminals
or splices in circuit.

4. Inspect and repair all connectors and splices. Refer
to Wiring Diagrams.

8L - 10

LAMPS/LIGHTING - EXTERIOR

PT

CONDITION

POSSIBLE CAUSES

CORRECTION

HEADLAMPS DO
NOT ILLUMINATE.

1. No voltage to headlamps.

1. Repair open headlamp circuit. Refer to Wiring
Diagrams.

2. No Z1 - ground at headlamps.

2. Repair circuit ground. Refer to Wiring Diagrams.

3. Faulty headlamp switch.

3. Replace headlamp switch.

4. Faulty headlamp dimmer
(multi-function) switch.

4. Replace multi-function switch.

5. Broken connector terminal or
wire splice in headlamp circuit.

5. Repair connector terminal or wire splice.

(DRL EQUIPPED
VEHICLES)
HEADLAMPS STAY
ON WITH KEY
REMOVED.

Failed DRL module.

Replace DRL module.

*Canada vehicles must have lamps ON.

REMOVAL

(1) Remove headlamp access cover in splash shield

(Fig. 14).

(2) Rotate socket counterclockwise one quarter

turn.

(3) Remove bulb and socket from headlamp hous-

ing.

(4) Disconnect wire connector from back of head-

lamp high or low beam bulb.

INSTALLATION

CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.

(1) Connect wire connector to the back of head-

lamp high or low beam bulb.

(2) Install bulb into headlamp housing (Fig. 14)
(3) Rotate socket clockwise one quarter turn.
(4) Test operation of lamps.
(5) Install headlamp access cover into splash

shield.

HEADLAMP UNIT

STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT

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.

(2) If necessary, tape a line on the floor 7.62

meters (25 ft.) away from and parallel to the wall
(Fig. 15).

Fig. 14 HEADLAMP BULB ACCESS

1 - HIGH BEAM LAMP
2 - LOW BEAM LAMP
3 - PARK/TURN SIGNAL LAMP

PT

LAMPS/LIGHTING - EXTERIOR

8L - 11

HEADLAMP (Continued)

(3) From the floor up 65.8 Centimeters (26 in.),

tape a vertical 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 to allow

suspension to stabilize.

(5) Jounce front suspension three times by pushing

downward on front bumper and releasing.

(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.
15). 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.

Fig. 15 HEADLAMP UNIT ALIGNMENT SCREEN

1 - CENTER OF VEHICLE

4 - FRONT OF HEADLAMP

2 - CENTER OF HEADLAMPS

5 - 7.62 METERS (25 FT.)

3 - 65.8cm (26 IN.) OR HEIGHT OF LOW BEAM DOT ON FOG
LAMP UNIT LENS

8L - 12

LAMPS/LIGHTING - EXTERIOR

PT

HEADLAMP UNIT (Continued)

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. 16) and (Fig. 17).

(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. 18).

(9) Remove headlamp housing by lowering the fas-

cia as necessary (Fig. 19) and (Fig. 20).

(10) Disconnect wire connector.

INSTALLATION

CAUTION: Do not touch the glass of halogen bulbs
with fingers or other possibly oily surface, reduced
bulb life will result.

(1) Connect wire connectors to the back of head-

lamp housing.

(2) Place headlamp housing in to position, lower

fascia as necessary to install headlamp housing in to
position (Fig. 20) and (Fig. 19). Tilt headlamp unit to
opening as necessary.

Fig. 16 FASCIA CENTER ATTACHING POINT

1 - ATTACHING POINTS
2 - FRONT FASCIA

Fig. 17 LOOSENING THE FASCIA

1 - HEADLAMP HOUSING
2 - ATTACHING POINT
3 - FRONT FASCIA

Fig. 18 HEADLAMP UNIT HOUSING

1 - ATTACHING STUDS
2 - ATTACHING STUDS
3 - FRONT SIDE MARKER/TURN SIGNAL/PARK LAMP BULB
4 - LOW BEAM LAMP
5 - HIGH BEAM LAMP

PT

LAMPS/LIGHTING - EXTERIOR

8L - 13

HEADLAMP UNIT (Continued)