GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 Preface 🢒 Cautions and Notices 🢒 Headlamp Replacement

Headlamp Replacement Four Door/Wagon

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1308850 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the headlamp mounting bolts.

    3. Object Number: 1541298 Size: SH
  3. Remove the headlamp mounting nut.

    4. Object Number: 1541300 Size: SH
  4. Disconnect the turn signal electrical connector.
  5. Remove the turn signal bulb, if necessary.

    6. Object Number: 1541301 Size: SH
  6. Disconnect the headlamp electrical connector.

    7. Object Number: 1541302 Size: SH
  7. Remove the headlamp assembly.
  8. Turn left and remove the headlamp bulb cap, if necessary.

    9. Object Number: 1541305 Size: SH
  9. Dry off the headlamp bulb clip.
  10. Disconnect the headlamp bulb connector.

    11. Object Number: 1541307 Size: SH
  11. Remove the headlamp bulb, if necessary.

Installation Procedure

    Object Number: 1541307 Size: SH
  1. Install the headlamp bulb, if removed.

    2. Object Number: 1541305 Size: SH
  2. Connect the headlamp bulb connector.
  3. Install the headlamp bulb clip.

    4. Object Number: 1541302 Size: SH
  4. Turn to the right and install the headlamp bulb cap.
  5. Install the headlamp assembly.

    6. Object Number: 1541301 Size: SH
  6. Connect the headlamp electrical connector.

    7. Object Number: 1541300 Size: SH
  7. Install the turn signal bulb, if removed.
  8. Connect the turn signal connector.

    9. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1541298 Size: SH
  9. Install the headlamp mounting nut.

    10. Tighten
    Tighten the headlamp mounting nut to 4 N·m (35 lb in).


    Object Number: 1308850 Size: SH
  10. Install the headlamp mounting bolts.

    11. Tighten
    Tighten the headlamp mounting bolts to 4 N·m (35 lb in).

  11. Connect the negative battery cable.

Headlamp Replacement Five Door

Removal Procedure

    Caution: Refer to Battery Disconnect Caution in the Preface section.


    Object Number: 1541384 Size: SH
  1. Disconnect the negative battery cable.
  2. Remove the radiator grille screws.

    3. Object Number: 1541385 Size: SH
  3. Insert a flat-bladed tool, into the radiator service hole and then push the radiator grille clips.
  4. Remove the radiator grille.

    5. Object Number: 1541386 Size: SH
  5. Remove the headlamp mounting bolts.

    6. Object Number: 1541387 Size: SH
  6. Disconnect the parklamp electrical connector.
  7. Disconnect the headlamp electrical connector.
  8. Remove the headlamp assembly.

    9. Object Number: 1541388 Size: SH
  9. Turn left and remove the headlamp bulb cap, if necessary.

    10. Object Number: 1541392 Size: SH
  10. Pry off the headlamp bulb clip, if necessary.
  11. Disconnect the headlamp bulb connector, if necessary.
  12. Remove the headlamp bulb, if necessary.

Installation Procedure

    Object Number: 1541392 Size: SH
  1. Install the headlamp bulb, if removed.
  2. Install the headlamp bulb clip, if removed.
  3. Connect the headlamp bulb electrical connector, if removed.

    4. Object Number: 1541388 Size: SH
  4. Install the cap concealing the headlamp bulb, if removed.

    5. Object Number: 1541387 Size: SH
  5. Install the headlamp assembly.
  6. Connect the headlamp electrical connector.
  7. Connect the park lamp electrical connector.

    8. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1541386 Size: SH
  8. Install the headlamp mounting bolts.

    9. Tighten
    Tighten the headlamp mounting bolts to 4 N·m (35 lb in).


    Object Number: 1541384 Size: SH
  9. Install the radiator grille.
  10. Install the radiator grille screws.
  11. Connect the negative battery cable.