GM Astro/Safari 1985-1996 Repair Guide

Headlights

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REMOVAL & INSTALLATION



The following procedures may require the use of the GM Safety Aimer tool No. J687801 or equivalent.

Sealed Beam

See Figures 1, 2, 3, 4 and 5

  1. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the headlight bezel-to-fender screws and the bezel; allow the bezel to hang by the parking/side marker light wires.
  4.  
  5. Remove the headlight retaining-to-fender spring.
  6.  
  7. Remove the headlight retaining ring-to-fender screws and the retaining ring.
  8.  
  9. Disconnect the electrical connector from the headlight and remove the headlight from the vehicle.
  10.  

To install:
  1. Connect the electrical connector to the headlight and install the headlight into the vehicle.
  2.  
  3. Install the headlight retaining ring and the retaining ring-to-fender screws.
  4.  
  5. Install the headlight retaining ring-to-fender spring.
  6.  
  7. Install the headlight bezel and the bezel-to-fender screws.
  8.  
  9. Connect the negative battery cable to the battery.
  10.  
  11. Check the headlight operation. Although, adjustment procedures may not be necessary, DO check the aim of the headlight.
  12.  

If necessary to adjust the headlight aim, use the GM Safety Aimer tool No. J687801 or equivalent.

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Fig. Fig. 1: Sealed beam headlight mounting



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Fig. Fig. 2: The headlight bezel needs to be removed to access the mounting screws for the bulb itself



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Fig. Fig. 3: Be careful with the headlight retaining ring screws. They can strip out easily



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Fig. Fig. 4: If the ring becomes damaged, it can be replaced with parts from most auto supply stores



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Fig. Fig. 5: Check the terminals for signs of burning. A bad connection here can cause all sorts of light problems

Composite Headlamp

See Figures 6, 7, 8, 9, 10, 11, 12, 13, 14 and 15

  1. Open the hood. Disconnect the negative battery cable from the battery.
  2.  
  3. Remove the composite headlamp side lens.
  4.  
  5. Remove the 3 bolts holding the composite headlight assembly to the body.
  6.  
  7. Unplug the bulb connector and remove the assembly from the vehicle.
  8.  
  9. Installation is the reverse of removal.
  10.  

HEADLIGHT AIMING



See Figures 16, 17 and 18

Horizontal and vertical aiming of each headlight is done by 2 adjusting screws which move the mounting ring against the tension of the coil spring.

Some state and local authorities have specific requirements for aiming headlights and these requirements should be followed.



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Fig. Fig. 6: Composite headlamp assembly



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Fig. Fig. 7: Composite headlamp side lens



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Fig. Fig. 8: Remove this screw to release the side lens



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Fig. Fig. 9: Pull the side lens out to expose the main headlight mounting points



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Fig. Fig. 10: Headlight side mounting bolt



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Fig. Fig. 11: Headlight bracket mounting bolt



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Fig. Fig. 12: Pull the entire headlight unit out from the body



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Fig. Fig. 13: The composite headlights use sperate bulbs that mount to the headlight assembly



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Fig. Fig. 14: Do not touch the surface of the bulb or it will burn out prematurely



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Fig. Fig. 15: With the headlight removed, you can get to the parking light bulbs



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Fig. Fig. 16: Headlight adjusting screws



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Fig. Fig. 17: Headlight aiming preparation



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Fig. Fig. 18: Headlight aiming limits

 
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