I changed my headlamp assemblies last summer, not very hard. As I recall, you'll have to pull the grill and also the cover plates below each headlight. There are 2 semi-hidden screws in the middle of the grill, about halfway down to look for, that have to come out. For the plates under the headlamps, there is one screw on top, and one below that screw into the fenders. The end of the plate at the grill just has a slip out stud, no fasteners. While the passenger side is apart, it's a good time to inspect the vacuum reservoir and hoses that are behind all of that.

 

I went with the TYC as the headlights look to mount just like the stock units so there is no need to use the brackets that come with them. It's supposed to warm up the next couple of days and I plan on seeing about how well they go in place.

 

Good news on the headlight front. The TYC headlight units go right in and lock in like the stock headlights. No more cloudiness and more light on the road. Makes a huge difference in how the front of the van looks too.

 

The install of the PS pulley was more involved than it should have been. I had noticed that the original pulley wan't on all the way and thought that a little odd and then while trying to get the pulley off it wasn't going to be straight forward as it was very tight. I also noticed there were no threads to use to put the new pulley on. I though it was just a mud robbers nest and got a pick to clean it out. What was in there was alot harder than a mud nest so I took the whole pump off and found they had broke the bolt off while installing the pulley which happened to have a made in china notification and they evidently didn't get the ID right. Luckily the bolt just spun right out. Getting the pulley off was time consuming and a strain. Every time it moved it was with a pop and it took alot of pressure to get it to move, but it finally relented and came off. Install of the aluminum pulley was easy and nothing broke. Took this time to flush the entire power steering system with Amsoil synthetic fluid using the steering box as the pump moving the steering wheel side to side. Worked very slick.
The misalignment of the original pulley may have been causing some squealing as things are quiet now, but that's just here in the driveway. Need to get out on the road, but still working on the parasitic draw. Unplugged alot of things with no change. Got a thermal imaging camera that I am hoping will help pinpoint a hotspot.

 

This is latest project on the van. Saw a bunch of things that could be improved on the air cleaner housing and then really went over the top. Intake temps should be cooler now. Kind of ugly, but no one will see it, except now all you get to see it. Also took a couple of pics of the power steering pulley.
Found out the 98 and newer vans have an aluminum driveshaft in them and found a 99 being parted out sort of close to me and the price was very reasonable so I rode the bike out and paid for it today. It's going to need to be shortened which i checked out prices for that before I bit the bullet on it. They wouldn't pull it unless it was paid for and I didn't want to put it on a card. Looked like an excuse to go for a good ride.

 

@jeffersonracing

Hi!
I have an issue with intake temps too...here in South Florida is was HOT yesterday....I was using an Bluetooth monitor and found my intake temps at idle were almost 150...then running down the interstate it only dropped to about 130-135....that really hot and I can see the van is pulling timing with the app too...I also have found when it get over150 it will backfire.

I would really like to see if you have any data on the intake temps before and after...THANKS!

 

I have a scan gauge 2 that I keep track of things on, but never really kept track of intake air temps. I know it was pretty high as for one thing the sensor is in the intake manifold rather than outboard of it. I can post what temps I see and try and keep track of outside temps as well.

 

Once the engine is fully up to temp, the sensor is telling you manifold temp, not the air passing thru it. Sensor gets heat soaked, and that's the end of accurate readings.

 

Got out in the van today and saw 107F on a 60 degree day on the hwy. Sat for 10 or 15 minutes and on leaving was registering 154 degrees. Went down to 114 by the time I got home.

 

wow...I get at 85degs+humidity 125 at idle and 145 flowing...
sometimes 150 but not often....