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Home >> Pontiac >> 2004 >> Aztek Base, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 331 (Lighting Systems) >> Repair Instructions >> Headlamp Replacement >> Installation Procedure
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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.
  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. Fig 1: Headlamp Bracket To Headlamp Stud Plate Nuts
    GM64650Courtesy of GENERAL MOTORS CORP.
  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.
    6. Fig 2: Headlamp Bracket To Frame Rail Bolts
    GM64649Courtesy of GENERAL MOTORS CORP.
  6. Install the headlamp bracket to the frame rail bolts.
    7. 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).

    9. Fig 3: Electrical Connectors To Headlamp Control Module
    GM64648Courtesy 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 .
    13. Fig 4: RH Headlamp Wiring Harness Electrical Connector To Forward Lamp Wiring Harness
    GM64644Courtesy 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.
    15. Fig 5: Headlamp Actuator Knob Cover
    GM777768Courtesy 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.
    18. Fig 6: HDLP Maxi Circuit Breaker #54 To IP Electrical Center
    GM777765Courtesy of GENERAL MOTORS CORP.
  18. Install the HDLP Maxi circuit breaker #54 into the IP electrical center.
    19. Fig 7: Cover To IP Electrical Center
    GM777763Courtesy of GENERAL MOTORS CORP.
  19. Install the cover to the IP electrical center.
    20. Fig 8: Passenger Side Front Floor Kick Up Panel To IP Electrical Center
    GM71195Courtesy 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) .
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