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For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Corvette 🢒 Body and Accessories 🢒 Lighting Systems 🢒 Headlamp Aiming

Headlamp Aiming Mechanical Method


Object Number: 64688 Size: SH

If a headlamp testing machine is used, it should give results equivalent to those obtained using the screen method. It should be in good repair and adjustment, and should be used in accordance with the manufacturer's instructions. The machine using a photoelectric cell or cells to determine aim should also have a visual screen upon which the beam pattern is projected proportional to its appearance and aim on a screen at 7.62 m (25 ft). Such a visual screen should be plainly visible to the operator and should have horizontal and vertical reference lines to permit visual appraisal of the lamp beam.

Horizontal and vertical aiming of each of the composite headlamps is done by turning adjusting screws which move the headlamp capsule in relation to the headlamp frame. The horizontal adjustment screw (1) is located on the inboard side of each of the headlamp assemblies, covered by a plug (2) on the headlamp bezel. The vertical adjustment screw (3) is located on the inboard side of each of the headlamp assemblies, below the lower edge of the headlamp bezel.

Vehicle Preparation

Prepare the vehicle for checking the headlamp beam aim as follows:

    • Make sure that all the components are in place on the vehicle, if other service has been performed on the vehicle.
    • Make sure the fuel level is 1/2 full or less.
    • Be sure tires are inflated to the proper pressures.
    • Stop all other operations of work on the vehicle.
    • Close the doors.
    • Rock the vehicle sideways to stabilize the suspension.

Adjustment Procedure

Tools Required

J 25300-D Headlamp Aimer


    Object Number: 64616 Size: SH
  1. Raise the hood.
  2. Raise the headlamps.
  3. Remove the headlamp adjustment screw plug from the headlamp bezel.

    4. Reach under the headlamp bezel and push out the plug from behind.


    Object Number: 194431 Size: SH

    Important: Select aim-adjusting tools carefully since one full turn of an adjusting screw will move the aim approximately 89 mm (3.5 in) when measured at 7.62 m (25 ft).

  4. Install J 25300-D , using the small pad pattern adapter J 25300-203 included with J25300-E, to the headlamp capsule lens.
  5. Calibrate the mechanical aimers (conforming to SAE J1602) as follows:
    6. 5.1. Set the master fixture to 0 up/down and 0 right/left.
    5.2. Calibrate the aimers on the master fixture to read 0 up/down and 0 right/left.
  6. Inspect the horizontal and vertical aim and adjust as necessary.

    7. Object Number: 64616 Size: SH
  7. Install the headlamp adjustment screw plug.

    8. Push to secure.

  8. Turn OFF the headlamps.
  9. Lower the hood.

Headlamp Aiming Screen Method


Object Number: 64688 Size: SH

Horizontal and vertical aiming of each of the composite headlamps is done by turning adjusting screws which move the headlamp capsule in relation to the headlamp frame. The horizontal adjustment screw (1) is located on the inboard side of each of the headlamp assemblies, covered by a plug (2) on the headlamp bezel. The vertical adjustment screw (3) is located on the inboard side of each of the headlamp assemblies, below the lower edge of the headlamp bezel.

Some state and local authorities have specific requirements for aiming the headlamps. These requirements must be followed.

Aiming Area Preparation

Choose an appropriate aiming area, then prepare the aiming screen as described in the following.

   • 
Object Number: 171874 Size: SH
  • The aiming area should be darkened and large enough to accommodate the vehicle and an additional 7.62 m (25 ft) measured from the face of the headlamp capsules to the front of the screen.
    •    • 
  • The floor on which the vehicle rests must be flat with the bottom of the screen. If the floor is not level, compensate as necessary.
    •    • 
  • The aiming screen should be at least 1.52 m (5 ft) high by 3.66 m (12 ft) wide with a matte white surface well shaded from extraneous light, and properly adjusted to the floor on which the vehicle stands. The screen should be provided with a vertical centerline (3), 2 laterally adjustable vertical tapes (2), and 1 vertically adjustable horizontal tape (1).
    •    • 

    Important: For each vehicle checked, the horizontal line or tape (1) on the screen must be adjusted. Vehicles of the same model and year may have different standing height for the headlamp capsules.

  • Make provisions to allow the screen to be movable, so that it can be aligned parallel with the rear axle of the vehicle. This will allow for a horizontal line drawn perpendicular to the centerline of the screen to pass through the center point between the 2 headlamp capsules (4).
    •    • 
  • After the aiming screen has been set up in a permanent location, paint or tape a reference line on the floor 7.62 m (25 ft) from the screen, to identify the proper location of the headlamp capsules when they are being aimed (5).

    • If a regular commercial aiming screen is not available, the screen may consist of a vertical wall having a clear uninterrupted area at least 1.83 m (6 ft) high by 3.66 m (12 ft) wide, finished with a washable non-gloss white paint.

    Vehicle Preparation

    Prepare the vehicle for checking the headlamp beam aim as follows:


      Object Number: 194506 Size: SH
    1. Make sure that all the components are in place on the vehicle, if other service has been performed on the vehicle.
    2. Make sure the fuel level is 1/2 full or less.
    3. Make sure the tires are inflated to the proper pressures.
    4. Stop all other operations of work on the vehicle.
    5. Position the vehicle so it is square with the aiming screen, and with the headlamp capsules directly over the reference line which has been painted or taped on the floor.
    6. Locate the vertical center line on the aiming screen (3) so that it is in line with the center of the vehicle (4). This can be accomplished by sighting through the center of the rear window and over the hood.

      7. Mark the vertical center of the front and rear windows with narrow tape. Use these marks as sights to locate the centerline of the vehicle. Move the vehicle or the screen until the center line of the screen comes into alignment with the 2 points.

    7. Close the doors.
    8. Rock the vehicle sideways to stabilize the suspension.
    9. Measure the height from the floor to the horizontal center of a headlamp capsule lens (6). Adjust the horizontal tape on the aiming screen (1) to match this dimension.
    10. Measure the distance between the centerline of the right headlamp capsule lens and the center of the left headlamp capsule lens (5). Position the vertical tapes on the aiming screen (2) this distance to the right and left of the screen centerline.

    Adjustment Procedure

      Object Number: 64616 Size: SH
    1. Raise the hood.
    2. Raise the headlamps.
    3. Remove the headlamp adjustment screw plug from the headlamp bezel.

      4. Reach under the headlamp bezel and push out the plug from behind.


      Object Number: 64619 Size: SH
    4. Turn ON the low beam lamps.
    5. Inspect the horizontal aim.
    6. Adjust the aim using the horizontal adjusting screw, to align the left edge of the high intensity zone with the headlamp vertical centerline (1), within the range of 102 mm (4 in) to the left (4) of the lamp vertical centerline (1), to 102 mm (4 in) to the right (3) of the lamp vertical centerline (1) on the aiming screen.
    7. Inspect the vertical aim.
    8. Adjust the aim using the vertical adjusting screw, to align the top edge of the high intensity zone to the headlamp horizontal centerline (2), within the range of 51 mm (2 in) above (6) the lamp horizontal centerline (2), to 64 mm (2.5 in) below (5) the lamp horizontal centerline (2) on the aiming screen.

      9. Object Number: 64616 Size: SH
    9. Install the headlamp adjustment screw plug.

      10. Push to secure.

    10. Turn OFF the headlamps.
    11. Lower the hood.

    Headlamp Aiming Export, LH Rule of the Road


      Object Number: 64616 Size: SH
    1. Prepare the aiming screen and the vehicle for headlamp aiming. Refer to Headlamp Aiming .
    2. Raise the hood.
    3. Raise the headlamps.
    4. Remove the headlamp adjustment screw plug from the headlamp bezel.

      5. Reach under the headlamp bezel and push out the plug from behind.


      Object Number: 203472 Size: SH
    5. Turn ON the low beam lamps.
    6. Inspect the horizontal aim.
    7. Adjust the aim using the horizontal adjusting screw, to align the break point (3) of the high intensity zone to the headlamp vertical centerline (1), within the range of 38 mm (1.5 in) to the left (4) of the lamp vertical centerline (1), to 38 mm (1.5 in) to the right (5) of the lamp vertical centerline (1) on the aiming screen.
    8. Inspect the vertical aim.
    9. Adjust the aim using the vertical adjusting screw, to align the upper edge of the beam horizontal cut off line 114 mm (4.5 in) below (7) the headlamp horizontal centerline (2), within the range of 76 mm (3 in) below (8) the lamp horizontal centerline (2), to 191 mm (7.5 in) below (6) the lamp horizontal centerline (2) on the aiming screen.

      10. Object Number: 64616 Size: SH
    10. Install the headlamp adjustment screw plug.

      11. Push to secure.

    11. Turn OFF the headlamps.
    12. Lower the hood.

    Headlamp Aiming Export, RH Rule of the Road


      Object Number: 64616 Size: SH
    1. Prepare the aiming screen and the vehicle for headlamp aiming. Refer to Headlamp Aiming .
    2. Raise the hood.
    3. Raise the headlamps.
    4. Remove the headlamp adjustment screw plug from the headlamp bezel.

      5. Reach under the headlamp bezel and push out the plug from behind.


      Object Number: 171870 Size: SH
    5. Turn ON the low beam lamps.
    6. Inspect the horizontal aim.
    7. Adjust the aim using the horizontal adjusting screw, to align the break point (3) of the high intensity zone to the headlamp vertical centerline (1), within the range of 38 mm (1.5 in) to the left (5) of the lamp vertical centerline (1), to 38 mm (1.5 in) to the right (4) of the lamp vertical centerline (1) on the aiming screen.
    8. Inspect the vertical aim.
    9. Adjust the aim using the vertical adjusting screw, to align the upper edge of the beam horizontal cut off line 114 mm (4.5 in) below (7) the headlamp horizontal centerline (2), within the range of 76 mm (3 in) below (8) the lamp horizontal centerline (2), to 191 mm (7.5 in) below (6) the lamp horizontal centerline (2) on the aiming screen.

      10. Object Number: 64616 Size: SH
    10. Install the headlamp adjustment screw plug.

      11. Push to secure.

    11. Turn OFF the headlamps.
    12. Lower the hood.