Dodge Sprinter. Manual - part 62

(3) Remove the cover panel from the top of the

driver side seat riser.

(4) Remove the fog lamp relay by grasping it

firmly and pulling it straight out of the relay connec-
tor.

INSTALLATION

Fog lamps are optional equipment on this model.

On vehicles equipped with fog lamps, a fog lamp
relay is located in a dedicated connector of the vehi-
cle wire harness. This connector is snapped into an
opening in a stamped sheet metal bracket which is
secured with screws within the driver side front seat
riser just beneath the seat riser cover panel.

WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental

restraint

system

before

attempting

any

steering wheel, steering column, airbag, seat belt
tensioner, or instrument panel component diagno-
sis or service. Disconnect and isolate the battery
negative (ground) cable, then wait two minutes for
the system capacitor to discharge before perform-
ing further diagnosis or service. This is the only
sure way to disable the supplemental restraint sys-
tem. Failure to take the proper precautions could
result in accidental airbag deployment.

(1) Position the fog lamp relay to the relay connec-

tor.

(2) Align the fog lamp relay terminals with the

terminal cavities in the relay connector.

(3) Using hand pressure, push firmly and evenly

on the top of the fog lamp relay until the terminals
are fully seated in the relay connector.

(4) Position the cover panel onto the top of the

driver side seat riser (Fig. 15).

(5) Install and tighten the two screws that secure

the cover panel to the top of the seat riser under the
driver side front seat.

(6) Move the driver side front seat back to its driv-

ing position.

(7) Reconnect the battery negative cable.

FOG LAMP SWITCH

REMOVAL

WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental

restraint

system

before

attempting

any

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the cluster bezel from the instrument

panel (Fig. 16). (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER BEZEL - REMOVAL).

(3) From the back of the cluster bezel, squeeze the

two latches on the fog lamp switch body and push
the switch out through the face of the bezel (Fig.
17).

Fig. 15 Seat Riser Cover

1 - DRIVER SEAT BACK
2 - COVER PANEL
3 - SCREW (2)
4 - SEAT RISER

Fig. 16 Fog Lamp Switch

1 - FOG LAMP SWITCH
2 - SCREW (2)
3 - CLUSTER BEZEL
4 - TO REAR WINDOW DEFOGGER SWITCH (OPTION AL)
5 - TO HEADLAMP LEVELING SWITCH
6 - TO FOG LAMP SWITCH (OPTIONAL)

8L - 12

LAMPS/LIGHTING - EXTERIOR

(4) Remove the fog lamp switch from the face of

the cluster bezel.

INSTALLATION

WARNING: To avoid personal injury or death, on
vehicles equipped with airbags, disable the supple-
mental

restraint

system

before

attempting

any

(1) Position the fog lamp switch to the proper

mounting hole on the face of the cluster bezel (Fig.
16).

(2) Using hand pressure, push the fog lamp switch

firmly and evenly into the switch mounting hole of
the cluster bezel until both of the latches on the
switch body are fully engaged.

(3) Reinstall the cluster bezel onto the instrument

panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
CLUSTER BEZEL - INSTALLATION).

(4) Reconnect the battery negative cable.

FRONT LAMP UNIT

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the front grille from the vehicle. (Refer

to 23 - BODY/EXTERIOR/GRILLE - REMOVAL).

(3) Remove the two screws that secure the cover at

the inboard side of the front lamp unit (Fig. 18).

(4) Remove the cover from the front lamp unit.
(5) From the engine compartment, disconnect the

vehicle wire harness connector from the connector
receptacle for the front lamp unit.

(6) Remove the four screws that secure the front

lamp unit to the front of the vehicle.

(7) Remove the front lamp unit from the front of

the vehicle.

INSTALLATION

(1) Position the front lamp unit to the front of the

vehicle (Fig. 18).

(2) Install and tighten the four screws that secure

the front lamp unit to the front of the vehicle.

(3) From the engine compartment, reconnect the

vehicle wire harness connector to the connector
receptacle for the front lamp unit.

(4) Position the cover to the front lamp unit.
(5) Install and tighten the two screws that secure

the cover at the inboard side of the front lamp unit.

(6) Reinstall the front grille onto the vehicle.

(Refer to 23 - BODY/EXTERIOR/GRILLE - INSTAL-
LATION).

(7) Reconnect the battery negative cable.
(8) Check and adjust the front lamp alignment as

required. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT-
ING - EXTERIOR/FRONT LAMP UNIT - ADJUST-
MENTS).

Fig. 17 Fog Lamp Switch Remove/Install

1 - FOG LAMP SWITCH
2 - LATCH (2)
3 - CLUSTER BEZEL

Fig. 18 Front Lamp Unit Remove/Install

1 - SCREW (2)
2 - COVER
3 - SCREW (4)
4 - LAMP UNIT
5 - WIRE HARNESS CONNECTOR

LAMPS/LIGHTING - EXTERIOR

8L - 13

ADJUSTMENTS

ADJUSTMENT - FRONT LAMP UNIT

VEHICLE PREPARATION FOR FRONT LAMP UNIT
ALIGNMENT

(1) Verify

headlamp

dimmer

(multi-function)

switch, fog lamp switch (if equipped), and high beam
indicator operation.

(2) Verify that the headlamp leveling switch is in

the “0” position.

(3) Repair or replace any faulty or damaged com-

ponents that could interfere with proper lamp align-
ment.

(4) Verify proper tire inflation.
(5) Clean front lamp unit lenses.
(6) Verify that the cargo compartment is not

heavily loaded. Vehicle should be at or near curb
weight.

(7) The fuel tank should be “Full.” Add 2.94 kilo-

grams (6.5 pounds) of weight over the fuel tank for
each estimated gallon of missing fuel.

(8) Load the driver’s seat with 75 kilograms (165

pounds) of weight.

FRONT LAMP UNIT ALIGNMENT

(1) Position the vehicle on a level surface.
(2) Turn On the headlamp low beams or the fog

lamps (if equipped).

(3) Open the hood.
(4) Set up the headlamp adjuster according to the

instructions provided by the manufacturer of the
unit.

(5) Adjust the front lamp unit reflector as required

by turning the adjustment screws in or out (Fig.
19).

(6) When properly aligned, the low beam head-

lamps and, if equipped, fog lamps should provide a

cut-off pattern as shown in (Fig. 20) and (Fig. 21).
Repeat the adjustment procedure as necessary to
obtain the recommended cut-off patterns.

FRONT POSITION LAMP BULB

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Disengage and swing the retainers that secure

the front lamp unit rear cover to each side of the
lamp housing and remove the cover (Fig. 22).

Fig. 19 Front Lamp Unit Adjusting Screws

1 - HORIZONTAL ADJUSTMENT
2 - VERTICAL ADJUSTMENT

Fig. 20 Low Beam Headlamp Cut-Off Pattern

Fig. 21 Fog Lamp Cut-Off Pattern

8L - 14

LAMPS/LIGHTING - EXTERIOR

(3) Pull the position lamp bulb holder straight out

to remove it from the front lamp unit reflector (Fig.
23).

(4) Remove the position lamp bulb from the bulb

holder.

INSTALLATION

(1) Install the position lamp bulb into the bulb

holder (Fig. 23).

(2) Push the position lamp bulb holder straight

into the mounting hole in the front lamp unit reflec-
tor.

(3) Position the front lamp unit rear cover onto the

lamp housing and engage the retainers over each
side of the cover to secure it (Fig. 22).

(4) Reconnect the battery negative cable.

FRONT TURN / PARK / SIDE
MARKER LAMP BULB

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Locate the turn/park/side marker bulb holder

on the rear outboard side of the front lamp unit
housing (Fig. 24).

(3) Rotate the bulb holder counterclockwise about

30 degrees and pull it straight out from the lamp
housing (Fig. 25).

Fig. 22 Front Lamp Unit Bulbs Remove/Install

1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT

Fig. 23 Position Lamp Bulb Remove/Install

1 - BULB HOLDER
2 - LAMP REFLECTOR

Fig. 24 Front Lamp Unit Bulbs Remove/Install

1 - COVER RETAINER (2)
2 - BULB RETAINER (3)
3 - FOG LAMP BULB (OPTIONAL)
4 - COVER
5 - LOW BEAM BULB
6 - POSITION BULB
7 - HIGH BEAM BULB
8 - TURN/PARK/SIDE MARKER BULB
9 - FRONT LAMP UNIT

LAMPS/LIGHTING - EXTERIOR

8L - 15

Content .. 60 61 62 63 ..