[Starship]

Front Wheelhouse Panel Splash Shield

1. Remove 4 screws (1).
2. Remove 9 plastic retainers (2).
3. Remove the front wheelhouse panel splash shield (3).

Tighten screw (1) to 2 N·m (18 lb in).

 

[Starship]

Re: Headlamp Replacement

Front Compartment Sight Shield

1. Remove 10 bolts (1).
2. Remove 4 plastic retainers (2).
3. Remove the front compartment sight shield (3)

Tighten bolt (1) to 2 N·m (18 lb in).

 

[Starship]

Re: Headlamp Replacement

Engine Splash Shields (is this necessary?)

1. Remove the retainers.
2. Remove the engine splash shield (passenger side and driver side shown).

 

[Starship]

Re: Headlamp Replacement

Front Bumper Fascia

1. Remove bolt (1), accessible from underneath the wheelhouse.
2. Loosen bolt (2).
3. Pull the front fascia (3) to disconnect from the fender side.
4. Pull up on the front fascia (4) to disconnect from the upper fender.
5. Disconnect any electrical connectors.

Tighten bolt (1) and bolt (2) to 6 N·m (53 lb in).

 

[Starship]

Re: Headlamp Replacement

Front Bumper Fascia Bracket

1. Remove 2 bolts (1).
2. Remove the front bumper fascia bracket (2).

Tighten bolt (1) to 6 N·m (53 lb in).

 

[Starship]

Re: Headlamp Replacement

Headlamp

1. Remove 2 screws (1).
2. Pull forward on the outside edge of the headlamp in order to release the up and down locator tabs on the backside of the headlamp.
3. Pull forward on the top inside edge of the headlamp to release the inboard up/down locator.
4. Pull the headlamp assembly down.
5. Pull the headlamp assembly forward far enough to access the electrical connection.
6. Disconnect the headlamp electrical connector from the forward lamp harness connector.
7. Remove the headlamp assembly (2).

Tighten screw (1) to 3 N·m (27 lb in).

 

[Starship]

Re: Headlamp Replacement

I thought it'd be good to have our own procedure so we can refine it as we go along. Please post your own tricks and shortcuts.

 

[Silver LTZ]

Re: Headlamp Replacement

This should help alot of members out, good job.

Looking at all that needs to be done to change a bulb makes me sick. Not looking forward to doing it on the wife's Malibu when one goes.

I turned off the DRL's, which should extend the life of the bulbs.

 

[Axiom]

Re: Headlamp Replacement

so this is what it takes to change the bulbs as well if so that is the most thing overly annoying. great write up and all looks like it cam right out the repair book form gm. but im going to be pissed if this is going to be what it takes!!!!

 

[DrivenDaily]

Re: Headlamp Replacement

You may want to be pissed now and get it over with, then. To change the headlights you have to remove the headlight housing. To do that you have to remove the bumper cover.

 

[mrblanche]

Re: Headlamp Replacement

And, had I known that before I bought the Malibu, I probably wouldn't have bought it.

But I have replace no headlight bulbs in the Cobalt, and it's five years old, so maybe it' won't be an issue.

 

[busguy847]

Re: Headlamp Replacement

Holy Crap! If anyone wonders why GM got into such a financial mess, then look no further.

Question: Is the person who approved this design nightmare willing to step forward, admit responsibility, and apologize to Chevrolet's customers?

 

[DrivenDaily]

Re: Headlamp Replacement

Concessions to design in the engineering department.

 

[Oncewasarental]

Re: Headlamp Replacement

This should help alot of members out, good job.

Looking at all that needs to be done to change a bulb makes me sick. Not looking forward to doing it on the wife's Malibu when one goes.

I turned off the DRL's, which should extend the life of the bulbs.

How did you turn them off?

 

[chevyguy8893]

Re: Headlamp Replacement

How did you turn them off?

It is easy, all that needs to be done is pull the fuse for the DRLs from the underhood fuse block.

 

[Oncewasarental]

Re: Headlamp Replacement

Sweet, thank you, Ill pull that fuse this weekend. I think when one of them burns out Ill put LEDs in for the turn/signal marker lights while I have it all apart.

 

[armoredsaint]

Re: Headlamp Replacement

It is easy, all that needs to be done is pull the fuse for the DRLs from the underhood fuse block.

good tip!!!

 

[bullitt4204]

Re: Headlamp Replacement

Would there be any way to make openings in the panels that could be sealed from the weather for future bulb changes? Like maybe through the fender wells or something?

 

[chevyguy8893]

Re: Headlamp Replacement

Would there be any way to make openings in the panels that could be sealed from the weather for future bulb changes? Like maybe through the fender wells or something?

The only way to gain easy access would be to cut the metal from the body behind the housing, and I don't even know if that would help or be a good idea.

 

[Everglades]

Re: Headlamp Replacement

I pulled fuse 46 (DRL) yesterday.