Headlight Aiming and Adjustment Procedure Checklist

This headlight aiming and adjustment checklist ensures headlights are aimed correctly for maximum road visibility without blinding oncoming drivers. Misaimed headlights reduce nighttime visibility by 50% or more and cause glare for oncoming traffic creating dangerous driving conditions. Headlights must be re-aimed after front-end collision repair, suspension work, or headlight replacement. Aligned with SAE J599 headlight aiming standards and FMVSS 108 lighting equipment regulations.

Industry: Automotive Service
Frequency: After Headlight Replacement / Suspension Repair / Per State Inspection
Estimated Time: 20-30 minutes
Role: Service Technician / Inspection Technician
Total Items: 28
Compliance: SAE J599 Headlamp Aiming Standards, FMVSS 108 (Lighting Equipment), State Vehicle Inspection Headlight Requirements, DOT Headlight Aiming Regulations, AAMVA Vehicle Inspection Standards

Pre-Aiming Vehicle Preparation

Prepare vehicle for accurate headlight aiming measurements.

All four tires inflated to placard specification pressure?
Fuel tank at approximately half full (or weight added to simulate fuel load)?
Vehicle positioned on level floor surface with suspension settled?
Trunk and cargo area empty of heavy items (or driver weight added to driver seat if required by spec)?
Headlight lenses clean and clear with no oxidation or yellowing?

Aiming Equipment Setup

Set up headlight aimer or alignment screen for measurement.

Optical headlight aimer calibrated and bubble level centered?
Alignment screen positioned 25 feet from headlights (standard SAE distance)?
Alignment screen perpendicular to vehicle centerline?
Distance from floor to headlight center measured and marked on screen?
Headlight vertical and horizontal aim adjusters accessible and not stripped?

Low Beam Aiming Adjustment

Adjust low beam vertical and horizontal aim to specification.

Only low beam activated during aiming (high beam and fog lights off)?
One headlight covered while aiming opposite headlight?
Vertical aim adjusted so top edge of beam pattern is at or below headlight center line (2-4 inches below at 25 feet)?
Horizontal aim adjusted so beam pattern centered on headlight axis (cutoff breakpoint slightly right of center)?
Both low beam headlights aimed identically with symmetric beam patterns?

High Beam Pattern Verification

Verify high beam operation and pattern after low beam aiming.

High beams activate correctly and provide bright wide illumination pattern?
High beam indicator illuminates on instrument cluster when high beams are on?
Automatic high beam system functional if equipped (switches to low beam when oncoming traffic detected)?
Daytime running lights functional if equipped?

Service Completion and Documentation

Document headlight aim adjustment service and verify compliance.

Road test at night confirms improved visibility and proper aim?
Headlights not causing excessive glare for oncoming traffic (no complaints during test)?
Headlight aim meets state vehicle inspection requirements if applicable?
Headlight aim service documented with before/after measurements?
Customer advised that headlight aim should be rechecked if front-end work or suspension service is performed?
Headlight bulb replacement offered if bulbs are dim or mismatched colors?
Headlight lens restoration recommended if lenses are cloudy or oxidized?
Final headlight aim verified to meet DOT and state inspection standards?
Service reminder sticker applied noting headlight aim service date?

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Why Use This Headlight Aiming and Adjustment Procedure Checklist?

This headlight aiming and adjustment procedure checklist helps automotive service teams maintain compliance and operational excellence. Designed for service technician / inspection technician professionals, this checklist covers 28 critical inspection points across 5 sections. Recommended frequency: after headlight replacement / suspension repair / per state inspection.

Ensures compliance with SAE J599 Headlamp Aiming Standards, FMVSS 108 (Lighting Equipment), State Vehicle Inspection Headlight Requirements, DOT Headlight Aiming Regulations, AAMVA Vehicle Inspection Standards, UK MOT Headlight Aim Requirements, India CMVR AIS-008 Headlight Standards. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Headlight Aiming and Adjustment Procedure Checklist cover?

This checklist covers 28 inspection items across 5 sections: Pre-Aiming Vehicle Preparation, Aiming Equipment Setup, Low Beam Aiming Adjustment, High Beam Pattern Verification, Service Completion and Documentation. It is designed for automotive service operations and compliance.

How often should this checklist be completed?

This checklist should be completed after headlight replacement / suspension repair / per state inspection. Each completion takes approximately 20-30 minutes.

Who should use this Headlight Aiming and Adjustment Procedure Checklist?

This checklist is designed for Service Technician / Inspection Technician professionals in the automotive service industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.