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HOMESERVICE MANUALSCHEVROLET2006CHEVY EXPRESS G2500, VAN CARGO, 6.6 2REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 543 (LIGHTING SYSTEMS)REPAIR INSTRUCTIONSHEADLAMP CONTROL MODULE REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2

Removal Procedure

2006 Chevrolet Chevy Express G2500, Van Cargo, 6.6 2SECTION 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 cover to access the instrument panel (IP) electrical center.
    2. Fig 2: Headlamp Circuit Breaker To IP Electrical Center
    GM214811Courtesy of GENERAL MOTORS CORP.
  2. Remove the headlamp circuit breaker from the IP electrical center.
  3. Open the hood.
    4. Fig 3: RH Headlamp Wiring Harness Electrical Connector To Forward Lamp Wiring Harness
    GM64644Courtesy of GENERAL MOTORS CORP.
  4. Raise the RH headlamp manually.
  5. Turn the headlamp motor/actuator manual control knob counterclockwise to raise the headlamp.
  6. Disconnect the RH headlamp wiring harness electrical connector from the forward lamp wiring harness.
    7. Fig 4: Brake Caliper Cooling Duct To Front Fascia
    GM171878Courtesy of GENERAL MOTORS CORP.
  7. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Remove the front fascia lower closeout panel. Refer to Close Out Panel - Front Bumper Fascia Lower in Bumpers.
  9. Release the brake caliper cooling duct from the front fascia and reposition the duct.
    10. Fig 5: Electrical Connectors To Headlamp Control Module
    GM64648Courtesy of GENERAL MOTORS CORP.
  10. Disconnect the electrical connectors from the headlamp control module.
    11. Fig 6: Nuts Mounting The Module To Headlamp Bracket
    GM64652Courtesy of GENERAL MOTORS CORP.
  11. Remove the nuts mounting the module to the headlamp bracket.
  12. Remove the module from the vehicle.
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.