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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 512 (LIGHTING SYSTEMS)REPAIR INSTRUCTIONSHEADLAMP AIMING (VISUAL METHOD)ADJUSTMENT PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Adjustment Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION Adjustment Procedure
WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise the hood.
  2. Raise the headlamps.
  3. Remove the headlamp adjustment screw plug from the headlamp bezel.

    Reach under the headlamp bezel and push out the plug from behind.

    Fig 1: Removing Headlamp Adjustment Screw Plug From Headlamp Bezel
    G01453330Courtesy of GENERAL MOTORS CORP.

    Important:  DO NOT cover the headlamp, this may cause excessive heat build up.

  4. Turn on the low beam headlamps and block the light from projecting onto the screen from the passenger side headlamp.
  5. Inspect the horizontal aim.
  6. Adjust the aim using the horizontal adjusting screw, to align the left edge of the high intensity zone with the headlamp vertical centerline (1), within the range of 102 mm (4 in) to the left (4) of the lamp vertical centerline (1), to 102 mm (4 in) to the right (3) of the lamp vertical centerline (1) on the aiming screen.
  7. Inspect the vertical aim.
    Fig 2: Inspecting Horizontal & Vertical Aiming
    G01453331Courtesy of GENERAL MOTORS CORP.
  8. Adjust the aim using the vertical adjusting screw, to align the top edge of the high intensity zone to the headlamp horizontal centerline (2), within the range of 51 mm (2 in) above (6) the lamp horizontal centerline (2), to 64 mm (2.5 in) below (5) the lamp horizontal centerline (2) on the aiming screen.
  9. Install the headlamp adjustment screw plug.

    Push to secure.

  10. Repeat the aiming procedure for the passenger side headlamp while blocking the light from projecting onto the screen from the driver side headlamp.
  11. Turn OFF the headlamps.
  12. Close the hood.
    Fig 3: Headlamp Adjustment Screw Plug
    G01453332Courtesy 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.