Headlight & Lighting System Inspection Checklist
This headlight and lighting system inspection checklist ensures all vehicle lighting meets FMVSS 108 (lamps, reflective devices, and associated equipment) and state safety inspection requirements. Covers headlight aim, lens clarity, all exterior lighting circuits, and LED/HID/ADAS lighting systems. Perform this inspection at every seasonal service, state inspection preparation, or when lighting concerns are reported.
- Industry: Automotive Service
- Frequency: Annually / Per Safety Inspection
- Estimated Time: 15-20 minutes
- Role: Service Technician / State Safety Inspector
- Total Items: 28
- Compliance: FMVSS 108 (Lamps, Reflective Devices & Equipment), SAE J1383 Headlamp Performance Standards, State Vehicle Safety Inspection Requirements, NHTSA Headlamp Aiming Standards, SAE J565 Sealed Beam Headlamps
Headlight Lens & Output Condition
Inspect headlight lens clarity and light output. Oxidized headlight lenses reduce output by up to 80%, creating a significant safety hazard.
- Headlight lenses clear - no significant yellowing, hazing, or UV oxidation?
- Headlight lenses free of cracks or chips that allow moisture intrusion?
- No significant condensation inside headlight housing?
- Both low beam headlights functional and matched intensity?
- Both high beam headlights functional?
- Daytime Running Lights (DRL) functional (if equipped)?
Headlight Aim Verification
Verify headlight aim is within acceptable range. Misaimed headlights reduce road illumination and blind oncoming drivers.
- Headlight aim verified - low beams not aimed too high (blinding oncoming) or too low (inadequate range)?
- Headlight aimer or targeting screen used to verify/adjust aim (not estimated)?
- Adaptive/pivoting headlights (if equipped) functioning correctly - aim follows steering?
- Automatic headlight leveling system (HID/LED) functioning with no fault codes?
Full Exterior Lighting Circuit Check
Systematically verify all required exterior lighting circuits per FMVSS 108.
- Both front turn signals (amber) functional at correct flash rate (60-120 flashes/min)?
- Both rear turn signals functional?
- Both rear brake lights functional (apply brake and verify from outside)?
- Center high-mount stop lamp (CHMSL) functional?
- Both tail lights illuminate with parking lights/headlights on?
- Reverse/backup lights functional when transmission in reverse?
- All four corner hazard lights flash simultaneously when activated?
Specialty & Safety Lighting
Inspect license plate lighting, side markers, and any specialized safety lighting systems.
- License plate illumination light(s) functional?
- Front (amber) and rear (red) side marker lights functional?
- Front parking lights functional when headlights are on?
- Front and rear fog lights functional (if equipped)?
- Interior dome/courtesy lights functional?
- Any non-functional lights documented on repair order with replacement recommendation?
Lighting Service Documentation & State Inspection Readiness
Complete documentation and verify state safety inspection readiness.
- All lighting systems pass state safety inspection standards?
- Any burned-out bulbs replaced with customer approval?
- OEM-specified bulb types used (correct wattage, base, and type)?
- Headlight lens restoration service offered if lenses were oxidized?
- Complete lighting inspection results documented on repair order?
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Why Use This Headlight & Lighting System Inspection Checklist?
This headlight & lighting system inspection checklist helps automotive service teams maintain compliance and operational excellence. Designed for service technician / state safety inspector professionals, this checklist covers 28 critical inspection points across 5 sections. Recommended frequency: annually / per safety inspection.
Ensures compliance with FMVSS 108 (Lamps, Reflective Devices & Equipment), SAE J1383 Headlamp Performance Standards, State Vehicle Safety Inspection Requirements, NHTSA Headlamp Aiming Standards, SAE J565 Sealed Beam Headlamps, UK MOT Lighting Inspection Standards, India CMVR Rule 104 Lighting Regulations. Regulatory-aligned for audit readiness and inspection documentation.
Frequently Asked Questions
What does the Headlight & Lighting System Inspection Checklist cover?
This checklist covers 28 inspection items across 5 sections: Headlight Lens & Output Condition, Headlight Aim Verification, Full Exterior Lighting Circuit Check, Specialty & Safety Lighting, Lighting Service Documentation & State Inspection Readiness. It is designed for automotive service operations and compliance.
How often should this checklist be completed?
This checklist should be completed annually / per safety inspection. Each completion takes approximately 15-20 minutes.
Who should use this Headlight & Lighting System Inspection Checklist?
This checklist is designed for Service Technician / State Safety Inspector 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.