GM Service Manual Online
For 1990-2009 cars only

Headlamp Replacement Chevrolet

Removal Procedure

  1. Remove the upper air intake splash shield. Refer to Hood Close Out Filler Replacement in Body Front End.

  2. Object Number: 591193  Size: SH
  3. Remove the headlamp assembly bolts.
  4. Pull the headlamp assembly upward and outward to remove.
  5. Caution: Refer to Halogen Bulb Caution in the Preface section.

  6. Remove the socket/bulb (2).
  7. Remove the housing/lens assembly from the bracket.
  8. Remove the screws and the adjusters if necessary.

Installation Procedure


    Object Number: 591193  Size: SH
  1. Install the headlamp housing/lens to the bracket assembly.
  2. Install the socket/bulb (4).
  3. Align the slots and twist the bulb.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the headlamp assembly bolts (5).
  5. Tighten
    Tighten the bolts to 8 N·m (71 lb in).

  6. Install the upper air intake splash shield. Refer to Hood Close Out Filler Replacement in Body Front End.
  7. Inspect the headlamp for proper operation.
  8. Aim the headlamps according to the to the manufacturer's instructions. Refer to the following procedures:
  9. Headlamp Aiming

Headlamp Replacement Pontiac

Removal Procedure

  1. Remove the upper air intake splash shield. Refer to Hood Close Out Filler Replacement in Body Front End.

  2. Object Number: 280073  Size: SH
  3. Remove the headlamp assembly bolts (6).
  4. Caution: Refer to Halogen Bulb Caution in the Preface section.

  5. Remove the socket/bulb.
  6. Remove the housing/lens (5) assembly from the bracket.
  7. Remove the screws and the adjusters if necessary.

Installation Procedure


    Object Number: 280073  Size: SH
  1. Install the headlamp housing/lens (5) to the bracket assembly.
  2. Install the socket/bulb.
  3. Align the slots and twist the bulb.

  4. Install the headlamp assembly bolts (6).
  5. Install the upper air intake splash shield. Refer to Hood Close Out Filler Replacement in Body Front End.
  6. Inspect the headlamp for proper operation.
  7. Aim the headlamps according to the to the manufacturer's instructions. Refer to the following procedures:
  8. Headlamp Aiming