GM Service Manual Online
For 1990-2009 cars only

Horn Replacement Coupe

Removal Procedure


    Object Number: 866509  Size: MH
  1. Remove the left headlamp assembly.
  2. Remove the 2 headlamp attachment bolts.
  3. Disconnect the headlamp bulbs and the turning signal sockets from the headlamp housing.
  4. Lift the headlamp housing to remove.
  5. Disconnect the horn connector.
  6. Remove the horn bolt.

  7. Object Number: 863271  Size: SH
  8. Remove the horn assembly.
  9. • Horn connector (1)
    • Horn (2)
    • Horn bolt (3)
    • Left front motor compartment rail (4)
    • Forward lamp harness - horn lead (5)

Installation Procedure

  1. Install the horn assembly, lining up the horn bracket to rail.
  2. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the horn bolt.
  4. Tighten
    Tighten the horn bracket-to frame rail bolt to 10 N·m (89 lb in).

  5. Connect the horn connector.
  6. Align the headlamp attachment bolts over the J-clips and push the lamp down until it is seated.
  7. Install the headlamp bulb sockets and the turn signal socket into the headlamp housing. Rotate the sockets to lock in place.
  8. Install the attaching bolts.
  9. Tighten
    Tighten the headlamp attachment bolts to 6 N·m (53 lb in).

    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.

  10. Check the headlamp aim. Adjust if required. Refer to Headlamp Aiming procedure in Lighting Systems.

Horn Replacement Sedan/Wagon


    Object Number: 864939  Size: SH
  1. Remove the left headlamp assembly.
  2. Remove the headlamp attachment bolts, 1 upper and 1 lower, connecting to the headlamp mounting bracket.
  3. Disconnect the headlamp bulb and the turn signal sockets from the headlamp housing.
  4. Pull the center edge of housing forward, then slide the headlamp housing toward the center of the vehicle to remove.
  5. Disconnect the horn connector.
  6. Remove the horn bolt.

  7. Object Number: 863271  Size: SH
  8. Remove the horn assembly
  9. • Horn connector (1)
    • Horn (2)
    •  Horn bolt (3)
    • Left front motor compartment rail (4)
    • Forward lamp harness - horn lead (5)

Installation Procedure

  1. Install the horn assembly, lining up the horn bracket to rail.
  2. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the horn bolt.
  4. Tighten
    Tighten the horn bracket-to-frame rail bolt to 10 N·m (89 lb in).

  5. Connect the horn connector.

  6. Object Number: 864928  Size: SH
  7. Install the headlamp bulb sockets and the turn signal socket into the headlamp housing. Rotate the sockets to lock in place.
  8. Slide the headlamp housing into place on the vehicle.
  9. Align the housing and install the attaching bolts.
  10. Tighten
    Tighten the headlamp housing-to-front clip fasteners to 6 N·m (53 lb in).

    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.

  11. Check the headlamp aim. Adjust if required. Refer to Headlamp Aiming in Lighting Systems.