GM Malibu/Cutlass 1997-2000

Headlights

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REMOVAL & INSTALLATION




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

  1. Remove the air intake splash shield from the vehicle.
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Fig. Pry the air intake splash shield retainers up . . .



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Fig. . . . remove the clips from the air intake splash shield . . .



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Fig. . . . then remove the air intake shield from the vehicle

  1. Pull the two sliding release tabs upward to release the aim adjuster ball from socket.
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Fig. Pull the two sliding release tabs upward to release aim adjuster ball from socket

  1. Remove the lamp assembly from the front of the vehicle.
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  3. Detach the bulb headlamp connector.
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WARNING
Do not touch the glass bulb with your fingers. Oil from your fingers can severely shorten the life of the bulb. If necessary, wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation.

  1. Remove the socket by depressing the locking tab and rotating the socket 1 / 4 turn counterclockwise.
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  3. Remove the headlamp bulb from the headlamp.
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Fig. Carefully remove the headlamp bulb from the headlamp, being sure to hold the assembly by the base, NOT the bulb

To install:

  1. Install a new bulb into the socket and wipe it clean with a dry lint-free cloth.
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  3. Install the bulb and socket assembly by the depressing locking tab and rotating the socket 1 / 4 turn clockwise.
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  5. Attach the headlamp connector.
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  7. Place the headlamp assembly into place, being careful to line up the aim adjuster balls to the sockets.
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Fig. Place the headlamp assembly into place being careful to line up the aim adjuster balls to the sockets

  1. Gently press down on the locking tabs until the aim adjuster balls are locked into place.
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Fig. Gently press down on the locking tabs until the aim adjuster balls are locked into place

  1. Install the air intake splash shield.
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  3. Connect the negative battery cable.
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AIMING



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.


NOTE
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.
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  3. 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.
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  5. 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.
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Fig. Low-beam headlight pattern alignment



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Fig. 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.
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  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.
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  5. Have the headlight adjustment checked as soon as possible by a reputable repair shop.
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