GM Service Manual Online
For 1990-2009 cars only

Headlamp Replacement Chevrolet

Removal Procedure


    Object Number: 208241  Size: SH
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .

  2. Object Number: 294727  Size: SH
  3. Remove the headlamp housing bracket bolt attaching the headlamp to the headlamp bracket.
  4. Slide the headlamp outboard to disengage the headlamp tabs from the headlamp brackets slots.

  5. Object Number: 294726  Size: SH
  6. Pull the headlamp forward to access electrical connectors.
  7. Disconnect the electrical connectors from the headlamp.
  8. Remove the headlamp.

Installation Procedure


    Object Number: 294726  Size: SH
  1. Perform the following to install the headlamp:
  2. 1.1. Connect the electrical connector to the headlamp.
    1.2. Engage tabs on back of headlamp into the slots in the headlamp bracket.

    Object Number: 294727  Size: SH
  3. Install the headlamp housing bracket bolt attaching the headlamp to the headlamp bracket.
  4. Tighten
    Tighten the headlamp housing bracket bolt to 7 N·m (62 lb in).


    Object Number: 208241  Size: SH
  5. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection

Headlamp Replacement Pontiac

Removal Procedure


    Object Number: 341078  Size: SH
  1. Turn the ignition key to the RUN position (4).
  2. Turn the headlamps ON, then turn the switch back to park lamps.
  3. This will leave the headlamps in the up position with the lamps off.

  4. Turn the ignition key to the OFF position (1).

  5. Object Number: 402675  Size: SH
  6. Open the hood.
  7. Remove the headlamp bezel screws.
  8. Remove the headlamp bezel.

  9. Object Number: 402683  Size: SH
  10. Remove the headlamp screws that attach the mounting ring to the headlamp housing.
  11. Remove the headlamp mounting ring.
  12. Disconnect the electrical connector from the headlamp.

  13. Object Number: 402693  Size: SH
  14. Remove the headlamp.

Installation Procedure


    Object Number: 402693  Size: SH
  1. Connect the electrical connector to the headlamp.
  2. Install the headlamp.

  3. Object Number: 402683  Size: SH
  4. Install the headlamp mounting ring.
  5. Install the headlamp screws that attach the mounting ring to the headlamp housing.

  6. Object Number: 402675  Size: SH
  7. Install the headlamp bezel.
  8. Install the headlamp bezel screws.
  9. Tighten
    Tighten the headlamp bezel screws to 1.7 N·m (15 lb in).

  10. Close the hood.
  11. Turn the headlamp switch off.