GM Service Manual Online
For 1990-2009 cars only
Makes šŸ¢’ Saturn šŸ¢’ 2002 šŸ¢’ SL šŸ¢’ Body and Accessories šŸ¢’ Lighting Systems šŸ¢’ Headlamp Bulb Replacement

Headlamp Bulb Replacement All Models

Removal Procedure
Object Number: 865212 Size: SH

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:

   ā€¢ 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.
   ā€¢ Always wear eye protection when changing a halogen bulb.
   ā€¢ Handle the bulb only by its base. Avoid touching the glass.
   ā€¢ Do not drop or scratch the bulb. Keep moisture away.
   ā€¢ 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. The key must be in the lock position.
  2. Disconnect the headlamp bulb sockets from the headlamp lens by rotating the socket a 1/4 turn. Pull the socket rearward until the bulb clears the housing and lift up for access to the bulb assembly.
  3. Remove the headlamp bulb from the headlamp harness.

Installation Procedure
  1. Without touching the glass, connect the headlamp bulb to the harness.
  2. Insert the bulb into the headlamp housing and rotate a 1/4 turn to lock. Assembly must be correctly positioned to insert and lock.

Headlamp Bulb Replacement 2001 Coupe

Removal Procedure
Object Number: 866500 Size: MH

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:

   ā€¢ 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.
   ā€¢ Always wear eye protection when changing a halogen bulb.
   ā€¢ Handle the bulb only by its base. Avoid touching the glass.
   ā€¢ Do not drop or scratch the bulb. Keep moisture away.
   ā€¢ 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 2 headlamp attachment bolts.
  2. Disconnect the headlamp bulbs and turn the signal sockets from the headlamp housing.
  3. Lift the headlamp housing to remove.

Installation Procedure
  1. Align the headlamp attachment bolts over the J-clips and push the lamp down until seated.
  2. Install the headlamp bulb sockets and turn the signal socket into the headlamp housing. Rotate the sockets to lock into place.

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

  3. Install the attaching bolts.

    4. Tighten
    Tighten the attaching bolts to the headlamp housing to 7 NĀ·m (61 lb in).

  4. Check the headlamp aim. Adjust if required.