GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 General Information 🢒 General Information 🢒 Headlamp Assembly or Headlamp Bulb Replacement

Removal Procedure
  1. Open the hood.

    2. Object Number: 864086 Size: SH

    Important: Hold the headlamp to prevent damage to the headlamp or fascia.

  2. Pull up on the headlamp retaining pins. Remove the pins.

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

  3. Position the headlamp assembly away from the vehicle to access the electrical connectors.
  4. Disconnect the electrical connectors from the headlamp bulb/socket and the park/turn bulb, if necessary.
  5. Remove the headlamp from the vehicle.

    6. Object Number: 864087 Size: SH
  6. Remove the headlamp bulb retaining nut by rotating the nut counterclockwise.
  7. Remove the headlamp bulb from the housing.

Installation Procedure

    Object Number: 864088 Size: SH
  1. Install the headlamp bulb into the housing.
  2. Install the headlamp bulb retaining nut by rotating the nut clockwise.

    3. Object Number: 864086 Size: SH
  3. Position the headlamp to the vehicle.
  4. Connect the headlamp bulb and the park/turn bulb electrical connectors.

    5. Important: Ensure that the retaining pins are properly seated in the headlamp bracket.

  5. Install the headlamp retaining pins by pushing the pins downward.
  6. Close the hood.