GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2001 🢒 PJJ 🢒 Body and Accessories 🢒 Lighting Systems 🢒 Headlamp Replacement

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

    2. Object Number: 591190 Size: SH
  2. Remove the headlamp assembly bolts (1).

    3. Caution: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury:

       • Turn off the lamp switch and allow the bulb to cool before changing the bulb.
       • Leave the lamp switch OFF until the bulb change is complete.
       • Always wear eye protection when changing a halogen bulb.
       • Handle the bulb only by its base. Avoid touching the glass.
       • Keep dirt and moisture off the bulb.
       • Properly dispose of the used bulb.
       • Keep halogen bulbs out of the reach of children.

  3. Remove the socket/bulb (2).
  4. Remove the housing/lens assembly from the bracket.
  5. Remove the screws and the adjusters if necessary.

Installation Procedure

    Object Number: 591190 Size: SH
  1. Install the headlamp housing/lens to the bracket assembly.
  2. Install the socket/bulb (2).

    3. Align the slots and twist the bulb.

  3. Install the headlamp assembly bolts (2).

    4. Tighten
    Tighten the bolts to 8 N·m (71 lb in).

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