Chevrolet Cobalt Service & Repair Manual: Headlamp Alignment, Adjust

Visual Aim

Headlamp aim should be inspected when a new headlamp capsule is installed, or if service or repairs to the front end area have, or may have, disturbed the headlamps or their mounting.
The area should consist of a level surface large enough to allow for a vehicle and an additional 25 feet, as measured from face of headlamps to aiming screen.
The screen should be a wall or other flat surface at least 5 feet high by 12 feet wide, with a matte white surface well shaded from extraneous light, and properly adjusted to the floor on which vehicle stands. Provisions should be made to align the aiming screen parallel with the vehicle.
The screen should be provided with a fixed vertical centerline, two laterally adjustable vertical tapes, and one vertically adjustable horizontal tape.
If a regular commercial aiming screen is not available, the screen may consist of a vertical wall having a clear uninterrupted area approximately 6 feet high and 12 feet wide. The surface should be finished with a washable non-gloss white paint.

Aiming Preparation

Do not place a cover directly on the headlamp assembly while the headlamp is ON.
1. Remove any snow, ice or mud from vehicle.
2. Vehicle must have a full tank of gas.
3. Stop all other work on vehicle.
4. If any service has been performed on vehicle, ensure that all components are back in their original place.
5. Vehicle must be on a level surface.
6. Lefthand vehicle tires must be aligned with reference line extending from screen, with headlamps aligned with reference line as illustrated in Fig. 1.
7. Do not load any cargo in vehicle.
8. Vehicle must contain approximately 165 lbs. on driver seat.
9. Inflate tires to proper pressure.
10. Simulate vehicle loads if intended use of vehicle is for hauling heavy loads or towing a trailer.
11. Rock vehicle to stabilize suspension.
12. Turn ON headlamps to low beam and observe lefthand and top edges of high intensity zone on screen. Edges of high intensity zone should fall within specifications.

Aiming

Do not cover headlamp. This may cause excessive heat build up.
The headlamps cannot be adjusted horizontally.
Refer to Fig. 2 for headlamp aiming chart.
1. Raise hood.
2. Measure from floor to center of headlamp bulb. Some headlamps have an aim dot marked on headlamp lens.
3. At screen, measure from floor and place horizontal tape at measured distance.
4. Measure from reference line on floor to lefthand headlamp bulb centerline.
5. At screen, measure from reference line and place vertical tape at measured distance.
6. Measure from reference line on floor to righthand headlamp bulb centerline.
7. At screen, measure from reference line and place vertical tape at measured distance.
8. Turn ON low beam headlamps. Block light from projecting onto screen from passenger side headlamp, Fig. 3.
9. Adjust headlamps to specifications required by state and local authorities or as indicated in step 8, Fig. 4.
10. Repeat aiming procedure for passenger side headlamp while blocking light from projecting onto screen from driver side headlamp.
11. Turn headlamps OFF.
12. Close hood.

Fig. 1 Vehicle alignment to headlamp aiming screen

Fig. 2 Headlamp aiming chart

Fig. 3 Headlamp aiming beam pattern

Fig. 4 Headlamp vertical aim screw location

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