GM Corsica/Beretta 1988-1996 Repair Guide

Headlights

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REMOVAL & INSTALLATION



See Figure 1

On the vehicles covered by this information, composite style headlamps, which contain replacement bulbs, are used (instead of the sealed beam type headlights). The bulb located inside the headlamp assembly, can be removed from under the hood.



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Fig. Fig. 1: You can find information regarding bulb replacement in your owners manual


CAUTION
Halogen bulbs contain gas under pressure. Handling the bulbs incorrectly could cause it to shatter into flying glass fragments. Do NOT leave the light switch ON. Always allow the bulb to cool before removal. Handle the bulb only by the base; avoid touching the glass itself. Whenever handling a halogen bulb, ALWAYS follow these precautions:



Turn the headlight switch OFF and allow the bulb to cool before changing it. Leave the switch OFF until the change is complete.
 
ALWAYS wear eye protection when changing a halogen bulb.
 
Handle the bulb only by its base. Avoid touching the glass.
 
DO NOT drop or scratch the bulb.
 
Keep dirt and moisture off of the bulb.
 
Carefully place the old bulb in the new bulb's carton and dispose of properly.
 
Keep halogen bulbs out of reach of children.
 

Beretta

See Figure 2

  1. Open the hood, then disconnect the negative battery cable.
  2.  
  3. Remove the two retainers holding the filler panel over the headlight assembly.
  4.  
  5. If you are replacing just the bulb, perform the following:
    1. Remove the bulb socket.
    2.  
    3. Detach the electrical connector by carefully opening the tabs.
    4.  
    5. Remove the bulb assembly.
    6.  

  6.  
  7. If removing the headlight assembly, perform the following:
    1. Remove the retainer located near the radiator by carefully prying it off.
    2.  
    3. Remove the bolt from the front of the filler panel
    4.  
    5. Remove the two bolts from the top of the headlight assembly.
    6.  
    7. Remove the headlight assembly by lifting it up and out, then pulling forward. Lift the filler panel slightly for clearance to remove the light assembly.
    8.  

  8.  
  9. Remove the sockets from the headlight.
  10.  



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Fig. Fig. 2: Exploded view of the headlight assembly - Beretta

To install:
  1. For installation of the headlight assembly, perform the following:
    1. Fasten the sockets securely in the headlight assembly.
    2.  
    3. Position the headlight assembly, making sure the inner side is behind the grille.
    4.  
    5. Install the retaining bolt located at the rear of the assembly.
    6.  
    7. Install the two top headlight assembly retaining bolts.
    8.  
    9. Fold the filler panel over to its original position.
    10.  
    11. Install the bolt to the front of the filler panel.
    12.  
    13. Fasten the retainer near the radiator by pressing it into place.
    14.  

  2.  
  3. If installing a new bulb only, perform the following:
    1. Install a new bulb in the socket.
    2.  
    3. Attach the electrical connector.
    4.  
    5. Install the socket into the headlight assembly.
    6.  

  4.  
  5. Install the two retainers on the filler panel.
  6.  
  7. Close the hood.
  8.  
  9. Connect the negative battery cable and check the headlight operation. Take the vehicle to a reputable repair shop to have the headlight aim check and adjusted, if necessary.
  10.  

Corsica

See Figure 3, 4, 5, 6 and 7

  1. Open the hood, then disconnect the negative battery cable.
  2.  
  3. Remove the two retainers holding the filler panel over the headlight assembly.
  4.  
  5. Fold the filler panel back for access to the headlight assembly.
  6.  
  7. Remove the two retainers securing the top of the headlight assembly.
  8.  
  9. Remove the headlight assembly by lifting it up to clear the guide pin at the right, then pulling it forward.
  10.  
  11. Remove the socket(s) from the headlight assembly.
  12.  
  13. Carefully remove the bulb(s) from the socket(s).
  14.  



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Fig. Fig. 3: Remove filler panel retainers in order to access the headlight assembly



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Fig. Fig. 4: Loosen the and remove the retainers securing the top of the headlight assembly



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Fig. Fig. 5: If necessary, you can unplug the electrical connector from the headlight bulb socket



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Fig. Fig. 6: Carefully twist, then remove the headlight bulb from the socket



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Fig. Fig. 7: Exploded view of the headlight assembly mounting - Corsica

To install:
  1. Install a new bulb into the socket.
  2.  
  3. Install the socket into the headlight assembly.
  4.  
  5. Position the headlight assembly, making sure the guide pins on the back of the assembly are inserted properly in the holes in the headlight housing panel.
  6.  
  7. Fasten the two retainers into the headlight assembly.
  8.  
  9. Install the filler panel and secure with the two retainers.
  10.  
  11. Close the hood.
  12.  
  13. Connect the negative battery cable and check the headlight operation. Take the vehicle to a reputable repair shop to have the headlight aim check and adjusted, if necessary.
  14.  

HEADLIGHT AIMING



See Figures 8, 9, 10, 11 and 12

The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made.


CAUTION
About once a year, when the headlights are replaced or any time front end work is performed on your vehicle, the headlight should be accurately aimed by a reputable repair shop using the proper equipment. Headlights not properly aimed can make it virtually impossible to see and may blind other drivers on the road, possibly causing an accident. Note that the following procedure is a temporary fix, until you can take your vehicle to a repair shop for a proper adjustment.

Headlight adjustment may be temporarily made using a wall, as described below, or on the rear of another vehicle. When adjusted, the lights should not glare in oncoming car or truck windshields, nor should they illuminate the passenger compartment of vehicles driving in front of you. These adjustments are rough and should always be fine-tuned by a repair shop which is equipped with headlight aiming tools. Improper adjustments may be both dangerous and illegal.

For most of the vehicles covered by this guide, horizontal and vertical aiming of each sealed beam unit is provided by two adjusting screws which move the retaining ring and adjusting plate against the tension of a coil spring. There is no adjustment for focus; this is done during headlight manufacturing.

Because the composite headlight assembly is bolted into position, no adjustment should be necessary or possible. Some applications, however, may be bolted to an adjuster plate or may be retained by adjusting screws. If so, follow this procedure when adjusting the lights, BUT always have the adjustment checked by a reputable shop.

Before removing the headlight bulb or disturbing the headlamp in any way, note the current settings in order to ease headlight adjustment upon reassembly. If the high or low beam setting of the old lamp still works, this can be done using the wall of a garage or a building:

  1. Park the vehicle on a level surface, with the fuel tank about 1 / 2 full and with the vehicle empty of all extra cargo (unless normally carried). The vehicle should be facing a wall which is no less than 6 feet (1.8m) high and 12 feet (3.7m) wide. The front of the vehicle should be about 25 feet from the wall.
  2.  



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Fig. Fig. 8: Location of the aiming screws on most vehicles with sealed beam headlights



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Fig. Fig. 9: Dual headlight adjustment screw locations - one side shown here (other side should be mirror image)



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Fig. Fig. 10: Example of headlight adjustment screw location for composite headlamps

  1. If aiming is to be performed outdoors, it is advisable to wait until dusk in order to properly see the headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible by closing shades or hanging cloth over the windows.
  2.  
  3. Turn the headlights ON and mark the wall at the center of each light's low beam, then switch on the brights and mark the center of each light's high beam. A short length of masking tape which is visible from the front of the vehicle may be used. Although marking all four positions is advisable, marking one position from each light should be sufficient.
  4.  



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Fig. Fig. 11: Low-beam headlight pattern alignment



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Fig. Fig. 12: High-beam headlight pattern alignment

  1. If neither beam on one side is working, and if another like-sized vehicle is available, park the second one in the exact spot where the vehicle was and mark the beams using the same-side light. Then switch the vehicles so the one to be aimed is back in the original spot. It must be parked no closer to or farther away from the wall than the second vehicle.
  2.  
  3. Perform any necessary repairs, but make sure the vehicle is not moved, or is returned to the exact spot from which the lights were marked. Turn the headlights ON and adjust the beams to match the marks on the wall.
  4.  
  5. Have the headlight adjustment checked as soon as possible by a reputable repair shop.
  6.  

 
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