Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 2060 (LIGHTING SYSTEM)REPAIR INSTRUCTIONSHEADLAMP REPLACEMENT (HD DIESEL)

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Headlamp Replacement (HD Diesel)

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Headlamp Replacement (HD Diesel)

WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Headlamp (HD Diesel)

Courtesy of GENERAL MOTORS CORP.

Callout	Component Name
Preliminary Procedure Lower the front bumper impact bar. Refer to Front Bumper Impact Bar Replacement (Chevrolet) or Front Bumper Impact Bar Replacement (GMC) . Loosen only, do not remove, the lower outside hidden headlamp bolt (2). Depress the housing support tab with a flat-bladed tool downward in order to release the headlamp assembly from the support. Pull the lamp assembly slightly forward to access the electrical connection. Disconnect the forward lamp harness main electrical connector from the headlamp harness.
1	Headlamp Screw (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 6 N.m (53 lb in)
2	Headlamp Screw (Hidden) Tighten: 6 N.m (53 lb in)
3	Headlamp Housing Support

RENDER: 1.0x

NO RELATED

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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.