GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 Astra 🢒 Body Systems 🢒 Lighting 🢒 Headlamp Replacement

Headlamp Replacement without Dipped Beam

Removal Procedure

Caution: The high intensity discharge system produces high voltage and current. In order to reduce the risk of severe shocks and burns, the battery negative cable must be disconnected any time service work is being performed on or around the high intensity discharge system.

Caution: The high intensity discharge system produces high voltage and current. To reduce the risk of severe shocks and burns:

   • Never open the high intensity discharge system ballast or the arc tube assembly starter.
   • Never probe between the high intensity discharge system ballast output connector and the arc tube assembly.

Caution: Refer to Halogen Bulb Caution in the Preface section.

  1. Remove front bumper fascia. Refer to Front Bumper Fascia Replacement .

    2. Object Number: 1941064 Size: LF
  2. Remove the headlamp.
    3. • Remove the 3 screws (1, 2)
    • Release the wiring harness plug (3) and disconnect.
    • Remove the headlamps.
  3. Remove the lights.
    4. • Open the 2 covers.
    • Remove the 3 bulbs.
    • Remove the indicator light.
    • Remove the bulb from the holder.

Installation Procedure
  1. Install the lights.
    2. • Install the 3 bulbs.
    • Install the indicator light.
    • Install the bulb in the holder.
    • Close the 2 covers.

    Notice: Refer to Fastener Notice in the Preface section.

  2. Install the headlamp.

    3. Connect the wiring harness plug.

    Tighten
    Tighten the 3 bolts to 2.5 N·m (22 lb in).

  3. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  4. Adjust the headlamp. Refer to Headlamp Aiming .

Headlamp Replacement with Dipped Beam

Removal Procedure

Caution: The high intensity discharge system produces high voltage and current. In order to reduce the risk of severe shocks and burns, the battery negative cable must be disconnected any time service work is being performed on or around the high intensity discharge system.

Caution: The high intensity discharge system produces high voltage and current. To reduce the risk of severe shocks and burns:

   • Never open the high intensity discharge system ballast or the arc tube assembly starter.
   • Never probe between the high intensity discharge system ballast output connector and the arc tube assembly.

Caution: Refer to Halogen Bulb Caution in the Preface section.

Important: Warning, high voltage. Do not touch components in the xenon dipped beam when the dipped beam is switched on. Ignition and light switch OFF.

  1. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  2. Remove the fuse.

    3. Object Number: 1938385 Size: LH
  3. Release the headlamp.

    4. Remove the 3 screws (1, 2).

  4. Remove the headlamps.
    5. • Remove the connector.
    • Remove the headlamps.
    • Disconnect the wiring harness plug (3).
  5. Remove the lights and the control units.

Installation Procedure
  1. Install the lights and control units.
  2. Insert the headlamp.
    3. • Connect the wiring harness plug.
    • Install the connector.

    Notice: Refer to Fastener Notice in the Preface section.

  3. Install the headlamp.

    4. Install the connector.

    Tighten
    Tighten the 3 bolts to 2.5 N·m (22 lb in).

  4. Insert the fuse.
  5. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement .
  6. Adjust the headlamp.