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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 450 (LIGHTING SYSTEMS)REPAIR INSTRUCTIONSHEADLAMP ASSEMBLY OR HEADLAMP BULB REPLACEMENT (AZTEK)INSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8

Installation Procedure

2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the headlamp bulb into the socket, if required.

    Press into place until fully seated.

    Fig 1: Headlamp Assembly or Headlamp Bulb Installation - Aztek (1 Of 8)
    G01515460Courtesy of GENERAL MOTORS CORP.
  2. Install the headlamp bulb to the socket, turning clockwise.
    Fig 2: Headlamp Assembly or Headlamp Bulb Installation - Aztek (2 Of 8)
    G01515461Courtesy of GENERAL MOTORS CORP.
  3. Install the rubber access cover to the headlamp for the bulb you are replacing, if required.
    Fig 3: Headlamp Assembly or Headlamp Bulb Installation - Aztek (3 Of 8)
    G01515462Courtesy of GENERAL MOTORS CORP.
  4. Connect the electrical connector to the headlamp.
    Fig 4: Headlamp Assembly or Headlamp Bulb Installation - Aztek (4 Of 8)
    G01515463Courtesy of GENERAL MOTORS CORP.

    Important:  The headlamp electrical connector must be positioned into the upper fascia support panel for proper seating of the headlamp.

    Fig 5: Headlamp Assembly or Headlamp Bulb Installation - Aztek (5 Of 8)
    G01515464Courtesy of GENERAL MOTORS CORP.
  5. Position the headlamp electrical connector into the access hole in the upper fascia support.
  6. Position the headlamp vertical retainer into the slot.
  7. Position the headlamp retainer through hole in the upper fascia support.
    Fig 6: Headlamp Assembly or Headlamp Bulb Installation - Aztek (6 Of 8)
    G01515465Courtesy of GENERAL MOTORS CORP.
  8. Position the headlamp ball studs into the grommet retainers.
  9. Position the headlamp rubber outer seal to properly fit into the front bumper fascia.
  10. Press the headlamp into place until fully seated.
  11. Inspect the headlamp for proper fit.
    Fig 7: Headlamp Assembly or Headlamp Bulb Installation - Aztek (7 Of 8)
    G01515466Courtesy of GENERAL MOTORS CORP.
  12. Install the headlamp vertical retainer, by sliding downward until fully seated.
  13. Check the headlamp aim, if a new headlamp was installed, or if service or repairs in the front end area were made. Refer to HEADLAMP AIMING (AZTEK)  or HEADLAMP AIMING (RENDEZVOUS)  .
  14. Close the hood.
    Fig 8: Headlamp Assembly or Headlamp Bulb Installation - Aztek (8 Of 8)
    G01515467Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.