Tool Required Chevrolet Chevy Express H2500

Tool Required

Composite Headlight Aimer Adapter

Instructions for use accompany the tool.

This procedure may only be used on headlamps equipped with aiming pads. Adjustment settings are embossed on the headlamp lens. They are typically located near the aiming pads. In some cases, the adjustment settings are located in other areas of the lens. They will be represented by a number followed by the letter V or the letter H.

1. Remove any snow, ice or mud from the vehicle.
2. The vehicle should be fully assembled and all other work stopped while the headlamp aiming is being done.
3. The vehicle should contain cargo or be loaded to represent normal vehicle use.
4. Tires should be properly inflated.
5. Rock the vehicle to stabilize the suspension.
6. Using, adjust the headlamps to the specifications required by state and local authorities.

Scheme 159

Scheme 160

1. Disconnect the electrical connector from the lamp assembly.
2. Remove the nut retaining the lamp assembly to the bracket.
3. Remove the lamp assembly from the bumper.

Scheme 161

Scheme 162

1. Install the lamp assembly to the bumper. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
2. Install the nut to retain the lamp assembly to the bracket. Tighten Tighten the nut to 2 N.m (18 in lb).
3. Install the electrical connector to the lamp assembly.

Scheme 163

1. Remove the screws retaining the lens to the lamp.
2. Remove the lens from the lamp.
3. Gently push in on the bulb and turn the bulb 1/4 turn counterclockwise.
4. Remove the bulb from the socket.

Scheme 164

1. Install the bulb to the socket.
2. Gently push in on the bulb and turn the bulb 1/4 turn clockwise.
3. Install the lens to the lamp assembly. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the screws to retain the lens to the lamp assembly. Tighten Tighten the screws to 1.5 N.m (13 lb in).

Scheme 165

1. Remove the screws holding the retaining ring to the headlamp housing assembly.
2. Remove the retaining ring from the position lamp.
3. Remove the headlamp capsule (1) from the position lamp.
4. Remove the bulb (4) and socket from the rubber grommet in the lamp capsule.
5. Push in on the side of the bulb (4) and turn the bulb 1/4 turn counterclockwise.
6. Remove the bulb (4) from the socket.

Scheme 166

1. Install the bulb (4) to the socket.
2. Push in on the bulb (4) and turn 1/4 turn clockwise.
3. Install the bulb (4) and socket into the rubber grommet in the headlamp capsule (1).
4. Install the headlamp capsule (1) to the headlamp housing.
5. Install the retaining ring to the headlamp housing assembly. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
6. Install the screws to the retaining ring to the headlamp housing assembly. Tighten Tighten the screws to 1.5 N.m (13 lb in).

Scheme 167

1. Push the light assembly (2) towards the front of the vehicle while gently prying the rear edge of the light assembly away from the fender with a small flat-bladed tool in order to remove the light assembly.
2. Remove the bulb and socket from the light assembly (3) by turning the socket 1/4 turn counterclockwise.
3. Remove the bulb (1) from the socket.

Scheme 168

1. Install the bulb (1) into the socket.
2. Turn the socket (3) 1/4 turn clockwise in order to install the socket into the light assembly.
3. Hook the front tab on the lens into the fender and press the light assembly (2) retaining clip into the fender until fully seated.

Scheme 169

1. Remove the screw (4) that retains the front side marker lamp to the radiator grille.
2. Lift the side marker lamp (3) up and out in order to disengage the tab.
3. Disconnect the bulb socket (1) from the side marker lamp.
4. Remove the bulb (1) from the socket.

Scheme 170

1. Connect the bulb (1) into the socket.
2. Connect the bulb socket (1) into the side marker lamp.
3. Install the side marker lamp (3) to the radiator grille (5). CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the side marker lamp retaining screw (4). Tighten Tighten the screws to 1.5 N.m (13 lb in).

Scheme 171

1. Remove the screw (4) that retains the side marker or the reflector to the grille.
2. Remove the side marker lamp (3) or the reflector (5) from the grille.
3. Disconnect the bulb socket (2) from the side marker lamp.
4. Remove the bulb (2) from the socket by turning the bulb in a counter clockwise direction.

Scheme 172

1. Install the bulb (2) into the socket by turning the bulb in a clockwise direction.
2. Connect the bulb socket (2) into the side marker lamp.
3. Install the side marker lamp (3) or the reflector (5) to the radiator grille (1). CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the side marker lamp or reflector retaining screw (4) to the grille. Tighten Tighten the screws to 1.5 N.m (13 lb in).

Scheme 173

1. Remove the screws (4) from the park/turn signal lamp to the grille.
2. Remove the park/turn signal lamp (3) from the grille.
3. Disconnect the bulb socket(s) (1) from the park/turn signal lamp by turning the bulb sockets in a counterclockwise direction.
4. Remove the bulb(s) (1) from the socket.

Scheme 174

1. Install the bulb(s) (1) into the socket by turning the bulb sockets in a clockwise direction.
2. Connect the bulb socket(s) (1) into the park/turn ' signal lamp.
3. Install the park/turn signal lamp (3) to the grille (5). CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the park/turn signal lamp retaining screws (4) to the grille. Tighten Tighten the screws to 1.5 N.m (13 lb in).

Scheme 175

1. Remove the screws (3) from the park/turn signal lamp to the grille.
2. Remove the park/turn signal lamp (2) from the grille.
3. Disconnect the bulb socket (1) from the park/turn signal lamp by turning the bulb sockets in a counterclockwise direction.
4. Remove the bulb (1) from the socket.

Scheme 176

1. Install the bulb (1) into the socket by turning the bulb sockets in a clockwise direction.
2. Connect the bulb socket (1) into the park/turn signal lamp.
3. Install the park/turn signal lamp (2) to the grille (5). CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the park/turn signal lamp retaining screws (3) to the grille. Tighten Tighten the screws to 1.5 N.m (13 lb in).

Scheme 177

1. Remove the screws (3) that retain the center high mounted stop lamp lens.
2. Remove the center high mounted stop lamp lens (2).
3. Disconnect the bulb socket (1) from the center high mounted stop lamp.
4. Remove the bulb (1) from the socket.

Scheme 178

1. Install the bulb (1) into the socket.
2. Connect the bulb socket (1) into the center high mounted stop lamp lens.
3. Install the center high mounted stop lamp lens (2). CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the center high mounted stop lamp lens retaining screws (3). Tighten Tighten the center high mounted stop lamp lens screws to 1.5 N.m (13 lb in).

Scheme 179

1. Disconnect the electrical connector.
2. Using a plastic flat bladed tool, release the double sided tape that retains the light assembly to the vehicle.

Scheme 180

1. Install the light assembly into the vehicle with double sided tape. Important: In order to insure a good replacement of new adhesive or of old adhesive, verify that the surface meets the following conditions: The temperature of the surface is approximately 24-41 °C (80-105°F). The surface is clean. The surface is free of wax or of oily film.
2. Connect the electrical connector.

Scheme 181

Scheme 182

1. Disconnect the electrical connector from the lamp assembly.
2. Remove the nut retaining the lamp assembly to the bracket.
3. Remove the lamp assembly from the bumper.

Scheme 183

Scheme 184

1. Install the lamp assembly to the bumper. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
2. Install the nut to the lamp. Tighten Tighten the nut to 2 N.m (18 in lb).
3. Connect the electrical connector to the lamp assembly.

Scheme 185

1. Remove the screws the lens to the lamp assembly.
2. Remove the lens from the lamp assembly.
3. Gently push in on the bulb and turn the bulb 1/4 turn counterclockwise.
4. Remove the bulb from the socket.

Scheme 186

1. Install the bulb to the socket.
2. Gently push in on the bulb and turn the bulb 1/4 turn clockwise.
3. Install the lens to the lamp assembly. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the screws in order to retain the lens to the lamp assembly. Tighten Tighten the screws to 1.5 N.m (13 lb in).

Scheme 187

1. Remove the screws (4) that retain the license plate lamp to the license pocket.
2. Remove the license plate lamp (3) from the license pocket.
3. Disconnect the bulb socket (2) from the license plate lamp.
4. Remove the bulb (2) from the socket.

Scheme 188

1. Connect the bulb (2) into the socket.
2. Connect the bulb socket (2) into the license plate lamp.
3. Install the license plate lamp (3) to the license pocket. CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
4. Install the license plate lamp retaining screws (4) to the license pocket. Tighten Tighten the screws to 2.5 N.m (22 lb in).

Scheme 189

1. Remove the upper quarter panel applique. Refer to «TAIL LAMP, BACK BODY OPENING APPLIQUE REPLACEMENT - SIDE»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#body-rear-end) .
2. Remove the nuts (2) that retain the tail lamp to, the upper quarter panel.
3. Remove the center high mounted stop lamp lens (2) from the center high mounted stop lamp applique (1).
4. Disconnect the bulb sockets from the tail lamp (3).
5. Remove the bulbs from the sockets by turning the bulbs in a counterclockwise direction.

Scheme 190

1. Install the bulbs into the sockets by turning the bulbs in a clockwise direction.
2. Connect the bulb sockets into the tail lamp (3). CAUTION: Refer to «FASTENER NOTICE»(/chevrolet/chevy-express-h2500/2003-2003/remont/oem-general-information/#gm-vehicles-cautions-notices__fastener-notice) .
3. Install the tail lamp retaining nuts (2) to the upper quarter panel. Tighten Tighten the nuts to 5 N.m (44 lb in).
4. Install the upper quarter panel applique. Refer to «TAIL LAMP, BACK BODY OPENING APPLIQUE REPLACEMENT - SIDE»(/chevrolet/chevy-express-h2500/2003-2003/remont/exterior-body-panels/#body-rear-end) .