GM S-Series Pick-ups and SUV's 1994-1999 Repair Guide

Headlight Switch

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See Figure 1



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Fig. Fig. 1: Headlight switch location (arrow)-1994 model

REMOVAL & INSTALLATION



1994 Pick-Up Models And All 1995-96 Models

See Figure 2



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Fig. Fig. 2: Exploded view of the headlight switch-to-bezel mounting

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the instrument cluster trim bezel.
  4.  
  5. Unplug the electrical connector.
  6.  
  7. Remove the switch-to-bezel retaining screws.
  8.  
  9. Remove the switch from the bezel.
  10.  

To install:
  1. Engage the switch to the bezel and tighten the switch-to-bezel retaining screws.
  2.  
  3. Engage the electrical connector.
  4.  
  5. Install the instrument cluster trim panel.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Check the switch for proper operation.
  10.  

1994 Utility Models
  1. Disconnect the negative battery cable.
  2.  
  3. Unfasten the trim plate screws.
  4.  
  5. Remove the trim plate by pivoting it out at the bottom, then pull the plate down.
  6.  
  7. Unplug any electrical connections that will facilitate switch removal.
  8.  
  9. Unfasten the screws from the switch trim plate, the remove the switch from the bracket.
  10.  

To install:
  1. Place the switch onto the bracket, then install and tighten the switch trim plate screws.
  2.  
  3. Attach any electrical connections that were unplugged.
  4.  
  5. Install the switch trim plate by pivoting it outward at the bottom and pulling the plate downward until it is aligned.
  6.  
  7. Install the trim plate screws.
  8.  
  9. Connect the negative battery cable and check for proper switch operation.
  10.  

1997-99 Models
  1. Disconnect the negative battery cable.
  2.  
  3. Make sure the headlight switch is OFF and the ignition switch is in the LOCK position.
  4.  
  5. Remove the instrument panel accessory trim plate as follows:
    1. Remove the left instrument panel insulator by unfastening the screws that attach the Data Link Connector (DLC) to the insulator, then feed the DLC through the hole in the insulator. Unfasten the screws that attach the insulator to the knee bolster and the cowl panel and the nut that attaches the insulator to the accelerator pedal bracket. Unplug the remote control lock module electrical connector and remove the module from the insulator.
    2.  
    3. Remove the knee bolster by setting the parking brake and blocking the wheels. Release the parking brake release cable from the parking brake lever. Remove the center sound insulator, by unfastening the screws that attach it to the knee bolster, instrument panel, heater assembly and floor duct. Unfasten the screw that attaches the courtesy lamp to the knee bolster and the knee bolster-to-instrument panel screws. Disconnect the lap cooler duct and lighter outlet electrical connector. Remove the knee bolster.
    4.  
    5. Disable the air bag system. Refer to the procedure in this section.
    6.  
    7. Unfasten the steering column-to-instrument panel nuts and lower the column for clearance.
    8.  
    9. Unfasten the accessory trim plate-to-instrument panel screws, unplug all necessary electrical connections and remove the trim plate.
    10.  

  6.  
  7. Unplug the electrical connection and unfasten the switch-to-accessory trim plate screws.
  8.  
  9. Disconnect the switch panel from the accessory trim plate.
  10.  
  11. Remove the switch from the switch panel.
  12.  

To install:
  1. Connect the switch to the switch panel.
  2.  
  3. Attach the switch panel to the accessory trim plate.
  4.  
  5. Install the switch-to-accessory trim plate screws and attach the electrical connection.
  6.  
  7. Install the instrument panel accessory trim plate as follows:
    1. Attach all necessary electrical connections to the trim plate, place the trim plate into position and install the plate-to-instrument panel screws. Tighten the screws to 17 inch lbs. (1.9 Nm).
    2.  
    3. Place the steering column into position and install the column retaining nuts. Tighten the nuts to 22 ft. lbs. (30 Nm).
    4.  
    5. Enable the air bag system. Refer to the procedure in this section.
    6.  
    7. Attach the lighter outlet and cooler duct to the knee bolster, place the knee bolster in position and tighten the Torx head screws to 80 inch lbs. (9 Nm) and the hex head screws to 17 inch lbs. (1.9 Nm). Place the courtesy light in position and tighten its retaining screw to 17 inch lbs. (1.9 Nm). Install the center sound insulator and tighten the screws that attach it to the knee bolster, instrument panel, heater assembly and floor duct to 17 inch lbs. (1.9 Nm). Attach the parking brake release cable to the brake lever.
    8.  
    9. Attach the remote control door lock module to the left instrument panel sound insulator and attach the module electrical connection. Install the nut that attaches the insulator panel to the accelerator pedal bracket. Tighten the nut to 35 inch lbs. (4 Nm). Install the screws that attach the insulator panel to the cowl panel and the knee bolster. Tighten the screws to 17 inch lbs. (1.9 Nm). Feed the DLC through the hole in the insulator panel and install its retaining screws. Tighten the screws to 21 inch lbs. (2.4 Nm).
    10.  

  8.  
  9. Connect the negative battery cable and check for proper switch operation.
  10.  

 
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