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HOMESERVICE MANUALSCHEVROLET2006SUBURBAN K2500, 6.0 UREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 512 (LIGHTING SYSTEMS)REPAIR INSTRUCTIONSHEADLAMP REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Suburban K2500, 6.0 U

Installation Procedure

2006 Chevrolet Suburban K2500, 6.0 USECTION Installation 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. Install the headlamp capsule to the headlamp. Refer to HEADLAMP CAPSULE REPLACEMENT .
  2. Install the headlamp motor/actuator to the headlamp. Refer to HEADLAMP MOTOR/ACTUATOR REPLACEMENT .
  3. Install the headlamp intermediate bracket to the headlamp. Refer to HEADLAMP INTERMEDIATE BRACKET REPLACEMENT .
  4. Position the headlamp assembly onto the studs extending from the headlamp stud plate.
  5. Loosely install the headlamp bracket to the headlamp stud plate nuts.
    Fig 1: Loosely Installing Headlamp Bracket To Headlamp Stud Plate Nuts
    G01453289Courtesy of GENERAL MOTORS CORP.
  6. Install the headlamp bracket to the frame rail bolts.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  7. Beginning with the upper location, tighten the headlamp bracket to the frame rail bolts.

    Tighten 

    Tighten the headlamp mounting bolts to 20 N.m (15 lb ft).

  8. Beginning with the upper inner location, tighten the headlamp to stud plate nuts.

    Tighten 

    Tighten the headlamp mounting nuts to 10 N.m (89 lb in).

    Fig 2: Installing Headlamp Bracket To Frame Rail Bolts
    G01453290Courtesy of GENERAL MOTORS CORP.
  9. Connect the electrical connectors to the headlamp automatic control module, RH side.
  10. Install the brake caliper cooling duct. Refer to BRAKE CALIPER COOLING DUCT REPLACEMENT - FRONT in Bumpers.
  11. Install the front fascia lower closeout panel. Refer to CLOSE OUT PANEL - FRONT BUMPER FASCIA LOWER in Bumpers.
  12. Install the headlamp bezel. Refer to HEADLAMP BEZEL REPLACEMENT .
    Fig 3: Connecting Electrical Connectors To Headlamp Automatic Control Module
    G01453291Courtesy of GENERAL MOTORS CORP.
  13. Connect the headlamp wiring harness electrical connector to the forward lamp wiring harness.
  14. Rotate the headlamp motor/actuator manual control knob clockwise to lower the headlamp.
    Fig 4: Connecting Headlamp Wiring Harness Electrical Connector
    G01453292Courtesy of GENERAL MOTORS CORP.
  15. Install the headlamp motor/actuator knob cover.
  16. Remove the protective tape installed during removal of the headlamp.
  17. Close the hood.
    Fig 5: Headlamp Motor/Actuator Knob Cover
    G01453293Courtesy of GENERAL MOTORS CORP.
  18. Install the HDLP Maxi circuit breaker #54 into the IP electrical center.
    Fig 6: Installing HDLP Maxi Circuit Breaker #54 Into IP Electrical Center
    G01453294Courtesy of GENERAL MOTORS CORP.
  19. Install the cover to the IP electrical center.
    Fig 7: Installing Cover To IP Electrical Center
    G01453295Courtesy of GENERAL MOTORS CORP.
  20. Install the floor kick up panel.
  21. Check the alignment of the headlamp opening door. Refer to HEADLAMP OPENING DOOR ADJUSTMENT .
  22. Check and adjust 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) .
    Fig 8: Floor Kick Up Panel
    G01453296Courtesy 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.