Chevrolet Full-size Cars 1968-1978 Repair Guide

Headlights

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REMOVAL & INSTALLATION





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Fig. Fig. 1 Exploded view of the headlight assembly on 1968-76 vehicles



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Fig. Fig. 2 Headlight aiming screw locations for 1968-76 vehicles



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Fig. Fig. 3 Exploded view of the headlight assembly on 1977-78 vehicles



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Fig. Fig. 4 Headlight aiming screw locations for 1977-78 vehicles



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Fig. Fig. 5 Remove the headlight trim screws ...



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Fig. Fig. 6 ... then remove the plastic trim from around the headlight(s)



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Fig. Fig. 7 Loosen the four headlight retaining ring screws ...



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Fig. Fig. 8 ... then remove the headlight retaining ring



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Fig. Fig. 9 Pull out gently on the headlight and disconnect the electrical plug. Remove the headlight

  1. Unscrew the four retaining screws and remove the headlight bezel.
  2.  
  3. On the 1968-75 vehicles, remove the headlight bulb retaining screws. These are the screws which hold the retaining ring for the bulb in the front of the vehicle. Do not touch the two headlight aiming screws, at the top and the side of the retaining ring (these screws will have different heads), or the headlight aim will have to be re-adjusted.
  4.  
  5. On the 1977-78 vehicles, disengage the spring from the retaining ring, using a cotter pin removal tool, then remove the retaining ring screws.
  6.  
  7. Pull the bulb and ring forward and then separate them. Unplug the electrical connector from the rear of the bulb.
  8.  
  9. Plug the new bulb into the electrical connector. Install the bulb into the retaining ring and then install the ring and the bulb. Install the headlight bezel.
  10.  

HEADLIGHT AIMING



The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim, and adjusted if necessary, after installing a new sealed beam unit if the front end sheet metal has been replaced. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made.

The fuel tank should be about half full when adjusting the headlights. Tires should be properly inflated, and if a heavy load is carried in the trunk or in the cargo area of station wagons, it should remain there.

Horizontal and vertical aiming of each sealed beam unit is provided by two adjusting screws, which move the mounting ring in the body against the body of the coil spring. There is no adjustment for focus; this is done during headlight manufacturing.

 
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