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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G2500, VAN CARGO EXTENDED, 5.7 R, L31/KL8REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 704 (LIGHTING SYSTEMS)REPAIR INSTRUCTIONSHEADLAMP REPLACEMENTREMOVAL PROCEDURE
2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8

Removal Procedure

2001 Chevrolet Chevy Express G2500, Van Cargo Extended, 5.7 R, L31/KL8SECTION Removal Procedure
WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Passenger Side Front Floor Kick Up Panel To IP Electrical Center
    GM71195Courtesy of GENERAL MOTORS CORP.
  1. Remove the passenger side front floor kick up panel to access the IP electrical center.
    2. Fig 2: Cover To IP Electrical Center
    GM777763Courtesy of GENERAL MOTORS CORP.
  2. Remove the cover from the IP electrical center.
    3. Fig 3: HDLP Maxi Circuit Breaker #54 To IP Electrical Center
    GM777765Courtesy of GENERAL MOTORS CORP.
  3. Remove the HDLP Maxi circuit breaker #54, from the IP electrical center.
  4. Raise the hood.
    5. Fig 4: RH Headlamp Wiring Harness Electrical Connector To Forward Lamp Wiring Harness
    GM64644Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the headlamp wiring harness electrical connector from the forward lamp wiring harness.
    6. Fig 5: Headlamp Actuator Knob Cover
    GM777768Courtesy of GENERAL MOTORS CORP.
  6. Remove the headlamp actuator knob cover.
  7. Raise the headlamp by turning the headlamp motor/actuator manual control knob counterclockwise.
    8. Fig 6: Electrical Connectors To Headlamp Control Module
    GM64648Courtesy of GENERAL MOTORS CORP.
  8. Remove the headlamp bezel. Refer to Headlamp Bezel Replacement .
    9. NOTE: Refer to Notice - Apply Tape When Removing Body Panels in Cautions and Notices.
  9. Apply tape to the fender and hood edge to protect the paint.
  10. Remove the front fascia lower closeout panel. Refer to Close Out Panel - Front Bumper Fascia Lower in Bumpers.
  11. Remove the brake caliper cooling duct. Refer to Brake Caliper Cooling Duct Replacement - Front in Bumpers.
  12. Disconnect the electrical connectors from the headlamp automatic control module, RH side only.
    13. Fig 7: Headlamp Bracket To Frame Rail Bolts
    GM64649Courtesy 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.