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MODULE 4–HEADLAMPS
Topic A. Exterior And Interior Lamps
Turn Signal Lamp
And Hazard Lamp
Headlamps
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Cornering Lamp
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Underhood Lamp
Side Marker Lamps
And Parking Lamps
Fog Lamp
Side Marker Lamp
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A-2 There are many different types of exterior lamps found on the front
of the vehicle.
Exterior lamps in the front of the vehicle include:
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headlamps. Headlamps are white lights that are on
when the headlamp switch is turned ON or they
may use a sensor to automatically turn ON.
fog lamps. Fog lamps are white or amber lights
that are on when the fog lamp switch is turned
ON.
driving lamps. Driving lamps are white lights that
are on when the driving lamp switch is turned
ON.
turn signal lamps. Turn signal lamps are amber
lights that are on when the turn signal switch is
turned ON. Additional turn signal lamps may be
located in the side mirrors or along the fenders.
The turn signal lamp may be the same lamp as the
parking lamp. Multiple turn signal lamps located
on the same side of the vehicle may alternately
flash.
cornering lamps. Cornering lamps are white lights
that are on when the corresponding turn signal
is turned ON.
parking lamps. Parking lamps are amber lights that
are on when the headlamp switch is in the PARK
position and when the headlamps are ON.
side marker lamps. Side marker lamps are amber
lights that are on when the parking lamps or
headlamps are ON. Side marker lamps may be
separate from the parking lamps.
additional marker lamps. Additional marker lamps
include the lights above the windshield in exterior
visors or on the roof of a truck. Additional marker
lamps are on when the standard parking lamps
are ON.
hazard lamps. Hazard lamps are amber lights
that are on when the hazard lamp switch is ON.
Hazard lamps may use the same bulb as turn
signal lamps, therefore the hazards may also
alternately flash.
underhood lamps. The underhood lamp is a white
light that is on when the hood is open. Underhood
lamps may use a mercury switch or a button to
turn them OFF when the hood is closed. Many
mercury switches in vehicles are being replaced
with different types of switches for environmental
reasons.
High-Mount
Stop Lamps
Stop Lamps
Additional Turn
Signal Lamp
License
Plate Lamps
Side Marker
Lamps And
Parking Lamps
Back-Up Lamp
Turn Signal
Lamp And
Hazard Lamp
Additional
Marker Lamps
Cargo Lamp
A-3 There are many different types of exterior lamps found on the rear
of the vehicle.
Exterior lamps located in the rear of the vehicle
include:
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
© 2003 Inter-Industry Conference On Auto Collision Repair
stop lamps. The stop lamps are red lights that
are on when the brakes are applied. The stop
lamps may use the same bulb as parking lamps,
but brighter. Switches for the stop lamps are
located on the brake pedal arm or on the master
cylinder.
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high-mount stop lamps. High-mount stop lamps
are red lights that are on when the brakes are
applied. High-mount stop lamps may be mounted
in the rear closure panel, in a spoiler, above the
backlite, at the top of the backlite, or on the
interior rear shelf.
parking lamps. Parking lamps are red lights that
are on when the parking lamps or headlamps are
ON.
side marker lamps. The side marker lamps are
red lights that are on when the parking lamps or
headlamps are ON.
additional marker lamps. Additional marker
lamps include the lamps in the rear fenders of
six-wheel trucks, along the tailgate of some heavyduty trucks, along the running boards, and along
the sides of conversion vans. Additional marker
lamps are on when the standard parking lamps
are ON.
license plate lamps. The license plate lamps are
white lights that are on when the parking lamps
or headlamps are ON.
turn signal lamps. Turn signal lamps may be red
or amber lights that are on when the turn signal
switch is ON. Turn signal lamps may be the same
bulb as the stop or parking lamp except that they
flash. Multiple turn signal lamps may alternately
flash.
hazard lamps. Hazard lamps are red or amber
lights that are on when the hazard lamp switch
is ON. Hazard lamps typically use the same bulb
as signal lamps, therefore the hazards may also
alternately flash.
back-up lamps. Back-up lamps are white lights that
are on when the transmission is in REVERSE.
trunk lamps. The trunk lamp is a white light that
is on when the trunk is open.
cargo lamps. The cargo lamp is a white light that
is on when the cargo lamp switch is ON. The
cargo lamp lights the bed of the truck.
Vanity Mirror Lamps
Dome Lamp
Courtesy Lamps
Map Lamps
Instrument Panel Lamps
A-4 There are many different types of interior lamps.
Interior lamps are white lights including:
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
© 2003 Inter-Industry Conference On Auto Collision Repair
the dome lamp.
courtesy lamps.
vanity mirror lamps.
map lamps.
instrument panel lamps.
accessory lamps.
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Topic B. Headlamps
B-2 Standard sealed beam headlamps are typically found on older
vehicles.
B-1 High-intensity discharge and projector headlamps are two different
types of headlamps.
Standard sealed beam headlamps:
Headlamp types include:
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standard sealed beam.
halogen sealed beam.
composite.
high-intensity discharge (HID).
projector.
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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may be the two-headlamp style.
may be the four-headlamp style. The high beam
and the low beam are separate lamps.
must stay sealed for the bulb to light and stay
lit.
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Vented Headlamp
B-3 Sealed beam halogen headlamps are typically a rectangular shape.
Sealed beam halogen headlamps:
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light and remain lit even if the housing is broken
or cracked. A damaged housing does not prevent the bulb from lighting, but may cause poor
light quality depending on the location of the
damage.
require the bulb and the housing to be replaced
if the bulb is burned out.
B-4 Vented composite headlamps may have a filter that is covered by
a drain tube.
Composite headlamps:
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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use a replaceable halogen bulb. Therefore if the
bulb is burned out, only the bulb requires replacement, not the entire assembly.
may be vented. Condensation in a vented composite headlamp does not damage the bulb initially,
but excessive moisture may cause the socket to
corrode.
may be nonvented. Condensation in a nonvented
composite headlamp requires replacement of the
assembly. Condensation may cause damage to
the bulb or distort the light.
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HID Bulb
B-5 An HID headlamp bulb may be replaced separately or as part of the
headlamp assembly.
B-6 A projector headlamp is easy to distinguish from the other types of
headlamps.
Projector headlamps:
High-intensity discharge headlamps or HID headlamps:
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may have a bluer hue compared to traditional
headlamps.
may also be called xenon headlamps.
use an electronic control unit (ECU) or HID ballast unit that changes DC volts to AC volts and
provides 25,000 volts and 20 amps to light the
HID capsule.
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create a focused beam of light.
are typically used for the low beam headlamps.
may also be used for fog lamps.
Use caution when working with these types
of headlamps. High amounts of electricity
are used to light this type of headlamp, so
serious injury may occur when working on a
malfunctioning system.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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Topic C. Headlamp Removal And
Replacement
C-2 The code on the bulb should match the code on the base of the
lamp assembly.
When selecting a replacement lamp:
C-1 The bumper cover and grille may require removal to access the
headlamp assembly fasteners.
When removing and replacing headlamps:
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identify if the bulb has to be replaced, or if the
entire assembly requires replacement. If the
assembly requires replacement, determine if
the bulbs are supplied with the assembly.
parts such as the bumper require removal to gain
access.
a variety of different hardware is available depending on the vehicle make and model. Damaged
adjusters also require replacement.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
© 2003 Inter-Industry Conference On Auto Collision Repair
use the standard trade number located on the
lamp housing for identification.
choose the same type and style.
HEADLAMP REMOVAL
Refer to screen C-3v of your CD-ROM for a
video on different types of headlamp hardware
and attachment methods.
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Topic D. Aiming Headlamps
C-4 Minor damage to a lamp such as a chip may be repairable using a
product designed to fix lenses.
Types of headlamp lens damage that may be repaired
includes small:
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chips that can be repaired using special plastic
repair product. Check local and provincial laws
for lamp repairability standards. Red and yellow
products are also available for colored lenses.
scuffs that can be polished using special
products.
D-1 There are several equipment makers that specialize in headlamp
aiming equipment.
Types of headlamp aiming equipment includes:
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LENS REPAIR PRODUCTS
Select the Demonstration Icon found on
screen C-4 of your CD-ROM for examples of
lens repair products.
manual using a screen or chart.
the type that is already built into the headlamp
assembly.
the suction cup type.
the computerized type.
the light-sensitive type.
MANUAL HEADLAMP AIMING
Select the Demonstration Icon found on screen
D-1 of your CD-ROM for an example of manual
headlamp aiming instructions.
LENS REPAIR
Refer to screen C-5v of your CD-ROM for a
video on repairing a chip in a tail lamp lens
and polishing a hazy headlamp lens.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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D-2 A bubble level may be built into the headlamp for aiming purposes.
D-3 Only headlamps that have protruding pegs can be aimed using suction cup type aiming equipment.
Built-in headlamp aimers may:
The suction cup type aiming equipment:
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be a dual bubble level.
automatically adjust.
be controlled from inside the vehicle.
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
© 2003 Inter-Industry Conference On Auto Collision Repair
uses protruding pegs built into the headlamp lens.
Headlamps without these pegs cannot be aimed
using this type of equipment.
requires the lens to be smooth. The suction cup
will not attach to a lens with raised letters.
physically levels the headlamp assembly. This type
of headlamp aiming equipment is for the type
of headlamp that adjusts the assembly, not just
the beam of light. Some headlamp assemblies
adjust the beam of light inside the headlamp,
the exterior part of the assembly does not move
with the adjustment.
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D-4 Computerized aiming equipment can be used to aim any type of
headlamp.
D-5 This headlamp aiming equipment uses heat intensity to determine
where the headlamps are aimed.
Computerized headlamp aiming equipment:
Light-sensitive aiming equipment:
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may use a mark on the headlamp lens. This mark
indicates the center of the beam of light.
uses the beam of light to aim the headlamp
assembly. This type of equipment may be used
on any type of headlamp.
uses the hottest spot of the light beam for
adjustment.
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uses the beam of light to aim the headlamp. The
headlamps are coded for the shape of light that
is projected.
uses a color-changing method to indicate heat
intensity.
Deflated Tire
D-6 A deflated tire may cause the vehicle to be unlevel.
Before aiming headlamps:
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
© 2003 Inter-Industry Conference On Auto Collision Repair
install parts that affect ride height such as the
hood.
remove materials that affect ride heights such as
excessive snow or mud.
verify that tires are properly inflated.
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Low Beam
Left And Right
High Beam
Up And Down
High Beam
Left And Right
Low Beam
Up And Down
D-7 Several adjusters may be located on the headlamp assembly.
Headlamp aiming hardware:
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may use a screw or a knob to adjust the position
of the headlamp beam of light.
includes vertical or up-and-down adjustments.
All headlamps have vertical adjustments.
may include horizontal or left-and-right adjustments. Some headlamps have vertical and horizontal adjustments.
D-8 An instruction manual is typically provided with the aiming
equipment.
When aiming headlamps, follow all federal, state,
provincial, and local laws and the headlamp aiming
equipment maker’s instructions.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
© 2003 Inter-Industry Conference On Auto Collision Repair
HEADLAMP AIMING
Refer to screen D-9v of your CD-ROM for a
video on different product makers’ headlamp
aiming equipment.
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Topic E. Lighting Circuit
E-2 Start the troubleshooting process by defining the problem and
verifying that the switch is operational.
E-1 All lamps should be checked to verify that they are operational.
When problem-solving lighting failures with no vehiclespecific troubleshooting flowchart, follow the I-CAR
Five Step Troubleshooting Flowchart. The steps in
this flowchart require:
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defining the problem.
knowing the system.
finding the cause.
making the repair.
testing the system.
If a lamp does not work, begin the troubleshooting
process by asking questions such as:
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
© 2003 Inter-Industry Conference On Auto Collision Repair
what else does not work? Try other switches that
control the same load. Try switches and loads that
might be related. Isolate the problem or group
of problems as much as possible.
is the circuit trying to work, but cannot? Listen
for a motor humming or relay clicking. These can
be signs of too much resistance. Try jiggling the
switch lightly or positioning it between settings
to see if it makes a difference.
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When using a service manual to troubleshoot a
problem, determine if it has a diagnostic chart for
the problem. However, when using service manuals to diagnose electrical problems, note that most
are NOT written from a collision repair standpoint.
This may require some modification of the flowchart
steps. General circuit information may be found in an
owner’s manual. It may be referenced in a general
sense if a service manual is not available.
Use the collision advantage to troubleshoot a damaged system. The collision advantage is the concept
of inspecting the:
E-3 Know the system by referencing manuals for specific vehicle
electrical systems.
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Learn how the circuit works by reading the system
description and using a wiring diagram. The system
description is used to verify if the part is working correctly or incorrectly. A wiring diagram is necessary
unless the circuit is very simple and its operation
obvious. A wiring diagram is used:
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area of direct impact for damaged parts before
inspecting all parts of the vehicle.
parts of the vehicle that were replaced or removed
during the repair.
to find the ground and power distribution. If there
are several different loads not working, a common
ground or circuit protector should be inspected
for damage.
if one load, or set of closely related loads are not
working properly, start where the power comes
into the circuit protector.
to determine if the key must be in RUN or ACC
for the circuit to work or if the circuit is normally
closed.
to determine the type of circuit protector and its
amperage rating.
to determine the current flow through the switch,
load, and to ground.
to determine the current flow when the switch
is moved to different positions.
to determine where current is flowing when the
switches are in the normal, or at rest, position.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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E-4 A loose ground may be the cause of an improperly operating
lighting circuit.
E-5 A pinched wiring harness may be the cause of an improperly operating lighting circuit.
Start with the simplest solutions. There may be some
obvious signs of faults that allow the problem to be
solved quickly. These fault “quick checks” include:
If none of these are obvious, closer inspection is
required. Check for:
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tracing the circuit back to the fuse, doing voltage
checks until voltage is present. This process is
typically performed when voltage is not getting
to the load because of an open in the hot side
of the circuit.
checking for an open ground. This is indicated
by the load not working, full supply voltage getting to the load, and power on both sides of the
load.
checking the load itself for proper operation.
replacing a fuse and having it blow immediately
after replacement or after a period of time. This
can be caused by a short to ground between the
fuse and the load.
checking if the load is not connected to the circuit, dropping out the main source of resistance
in the circuit.
making sure that the fuse is the proper size.
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loose or damaged connectors.
bare spots in the insulation, especially where a
wire passes through a body panel or metal clip.
This could cause a wire to rub against a metal
surface, cut the insulation, and cause a short.
signs of pinched wires.
signs of stretched wires.
signs of discoloration in connectors or harnesses.
signs of spilled battery acid or corrosion.
any harness clips or brackets not fastened
correctly.
Check wiring under brackets or clips by performing
a voltage-drop check. To perform a voltage-drop
check:
1. Connect the DVOM from the load to the nearest
ground.
2. Wiggle the wire.
3. If the DVOM changes readings, there is likely a
hidden short.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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E-6 Follow the vehicle maker’s guidelines when repairing damaged
wires.
E-8 Splice locations should be staggered, which typically requires cutting
the new replacement wires.
Once the problem has been identified:
Connector replacement kits:
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repair or replace damaged wiring harnesses.
replace damaged parts.
test the circuit before reassembling or reinstalling
parts.
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are partial wiring harnesses with the connector.
These kits are available from the vehicle maker
for some vehicles and applications.
replace the damaged connectors and the wiring
near the connector.
CONNECTOR REPLACEMENT
Refer to screen E-9v of your CD-ROM for a
video on replacing a headlamp connector
using one vehicle maker’s repair kit.
E-7 A scan tool can be used to retrieve some electrical circuit information.
Some lighting circuit problems may be identified using
a scan tool. Do NOT use a test light to test lighting
circuits unless recommended by the vehicle maker.
Some circuits include computers that may be damaged by a test light. Use a DVOM unless a test light
is recommended by the vehicle maker.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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Topic F. Switches
F-2 License plate lamps should light with the rest of the parking lamps.
F-1 There are several different types of headlamp switches.
The PARK position of the headlamp switch supplies
power to the:
The headlamp switch is typically powered all of the
time. The headlamp switch may be:
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mounted on the instrument panel.
part of the multifunctional switch on the steering
column.
a rotary switch.
a push-button switch.
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side marker lamps in the front and the rear of the
vehicle.
license plate lamps.
instrument panel lamps.
HEADLAMP
PARK
OFF
F-3 Symbols are typically used instead of words to identify the positions
on the switch.
The HEADLAMP position of the headlamp switch
supplies power to the headlamps and the lamps lit
by the PARK circuit. Each headlamp may be fused
separately. This allows each headlamp to operate
separately if a lamp is burned out.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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Dimmer Switch
F-4 Late model vehicles use the multifunctional switch to dim the
headlamps.
F-6 An automatic lighting system sensor may be located on the instrument panel.
The headlamp dimmer switch:
An automatic lighting system:
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switches the headlamps from high beam to low
beam and vise versa.
is controlled by either pushing or pulling the
multifunctional switch on the steering column.
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uses a light-sensitive photocell sensor or amplifier
to turn the headlamps ON and OFF. This sensor
is in the upper part of the instrument panel near
the windshield.
is overridden by the headlamp switch. The headlamps may be manually turned ON and OFF or
the AUTO setting may be used.
F-5 The multifunctional switch typically controls the flash-to-pass function.
Flash-to-pass:
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switches on the high beam headlamps with the
headlamp switch in ON, OFF, or PARK. The high
beams are only on for as long as the switch is
held.
is controlled by the headlamp dimmer switch.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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F-7 The automatic headlamp dimmer sensor may be attached to the
base of the rearview mirror.
An automatic headlamp dimmer switch:
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switches the headlamps from high beam to low
beam.
uses a photocell or image-sensing technology. A
photocell is activated by the light from the environment, approaching headlamps, or tail lamps.
Image-sensing technology uses a camera-on-achip.
may have a switch used to control the sensitivity
of the photocell.
F-8 Headlamps may stay on for a specified length of time.
Headlamps may be delayed:
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
© 2003 Inter-Industry Conference On Auto Collision Repair
to stay on for a specific period of time after the
ignition switch is turned off.
for a length of time that is controlled by a switch.
Some delay timers are built-in and cannot be
adjusted.
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F-9 Daytime running lamps may use an amber bulb.
F-10 Daytime running lamps may use a headlamp bulb.
Daytime running lamps are:
Daytime running lamps may:
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on when the vehicle is running or in gear depending on the make and model vehicle.
deactivated by the parking brake and headlamp
switch. Daytime running lamps automatically turn
OFF when the headlamps are ON or when the
parking brake is applied.
required by Canadian law for safety.
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Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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be a separate light.
use the high beam headlamps at a reduced voltage.
use the turn signal lamps.
use the low beam headlamps.
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Topic G. Retractable Headlamps
Topic H. Review
REVIEW
Refer to screens H-1 and H-2 of your CD-ROM
for review questions on headlamps.
G-1 Retractable headlamps are found on a limited number of late-model
vehicles.
Retractable headlamps:
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are controlled by electric or vacuum motors.
may also be referred to as concealed or pop-up
headlamps.
Lighting, Starting, And Charging Systems Program 1 v.5.1–Module 4
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