GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 L300/LW300 🢒 Body 🢒 Lighting Systems 🢒 Headlamp Assembly or Headlamp Bulb Replacement

Removal Procedure

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

   • Turn off the headlamp switch and allow the bulb to cool before changing bulbs. Leave the headlamp 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.
   • Do not drop or scratch the bulb. Keep moisture away.
   • Place the used bulb in the new bulb's carton and dispose of it properly. Keep halogen bulbs out of the reach of children.

  1. Remove the upper grille. Refer to Front Bumper Upper Fascia Grille Replacement in Bumpers.

    2. Object Number: 946024 Size: SH
  2. Remove the bolts from the headlamp.

    3. Object Number: 946048 Size: SH
  3. Rotate the locking lever to release the ball and socket retainers (1).
  4. Remove the headlamp from the headlamp pocket.
  5. Disconnect the electrical connectors from the headlamp.
  6. Remove the headlamp from the vehicle.
  7. Remove the headlamp bulbs , if required.

Installation Procedure

    Object Number: 946048 Size: SH
  1. Install the headlamp bulbs , if required.
  2. Connect the electrical connectors to the headlamp.
  3. Position the headlamp to the ball and sockets (1) in the headlamp pocket.
  4. Rotate the locking lever to capture the ball and socket retainers.

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


    Object Number: 946024 Size: SH
  5. Install the bolts to the headlamp.

    6. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  6. Install the upper grille. Refer to Front Bumper Upper Fascia Grille Replacement in Bumpers.
  7. Inspect the headlamps adjustment, adjust if required. Refer to Headlamp Aiming .