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I recently had some body work done to my 2008 Caliber SXT that involved pulling the front fascia, and passenger side headlight. Despite all my effort the headlight enclosure doesn't seem to fit in as well as before it was removed. Its only off by about 3/16ths of a inch so I figure I'll just re-aim the headlight to make the beams even again. Question is...how do you aim the headlights while in place?
 

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FRONT LAMP AIMING
VEHICLE PREPARATION FOR LAMP ALIGNMENT
1. Check for and correct any burnt out bulbs.
2. Repair or replace any ineffective, worn or damaged body or suspension components that could hinder proper
lamp alignment.
3. Verify proper tire inflation pressures.
4. Remove any accumulations of mud, snow or ice from the vehicle underbody and clean the front lamp lenses.
5. Verify that there is no load in the vehicle (cargo or passengers), except for the driver.
6. 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.
7. Verify correct vehicle suspension height.
PM LAMPS/LIGHTING - EXTERIOR - SERVICE INFORMATION 8L - 77
ALIGNMENT SCREEN PREPARATION
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.
8L - 78 LAMPS/LIGHTING - EXTERIOR - SERVICE INFORMATION PM
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.
HEADLAMP ALIGNMENT
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.
No horizontal (right/left) adjustment is required for
this headlamp beam pattern. The high beam pattern
will be correct when the low beams are properly
aimed.
1. Turn the headlamps ON and select the LOW
beams.
2. Rotate the headlamp vertical adjustment screw
which is located just inboard of the headlamp bulb
(1) to adjust each lamp beam height as required.
 
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