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HOMESERVICE MANUALSCHEVROLET2001CHEVY EXPRESS G3500, VAN PASSENGER EXTENDED, 6.5 FREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 704 (LIGHTING SYSTEMS)REPAIR INSTRUCTIONSHEADLAMP CAPSULE REPLACEMENTINSTALLATION PROCEDURE
2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 F

Installation Procedure

2001 Chevrolet Chevy Express G3500, Van Passenger Extended, 6.5 FSECTION Installation 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: Headlamp Bulb/Socket Electrical Connectors
    GM64682Courtesy of GENERAL MOTORS CORP.
  1. Install the headlamp bulb/sockets to the headlamp capsule.
  2. Connect the headlamp bulb/socket electrical connectors.
  3. Position the headlamp capsule to the headlamp pivot and adjustment bracket.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the headlamp capsule retaining screws.

    Tighten:  Tighten the headlamp capsule retaining screws to 4 N.m (35 lb in).

  5. Install the headlamp bezel. Refer to Headlamp Bezel Replacement .
    6. Fig 2: RH Headlamp Wiring Harness Electrical Connector To Forward Lamp Wiring Harness
    GM64644Courtesy of GENERAL MOTORS CORP.
  6. Connect the headlamp wiring harness electrical connector to the forward lamp wiring harness.
  7. Remove any protective tape applied during the removal procedure.
    8. Fig 3: Headlamp Actuator Knob Cover
    GM777768Courtesy of GENERAL MOTORS CORP.
  8. Rotate the headlamp motor/actuator manual control knob clockwise to lower the headlamp.
  9. Install the headlamp motor/actuator knob cover.
  10. Check and adjust the headlamp aim as necessary. Refer to Headlamp Aiming (Visual Method)  or Headlamp Aiming (Export, LH Rule of the Road)  or Headlamp Aiming (Export, RH Rule of the Road) .
  11. Close the hood.
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.