This procedure covers the removal and installation of both left and right headlight assemblies on the 2023 Chevrolet Bolt EUV, including disconnection of electrical connectors and proper alignment.

Warnings

Tools required

Parts

• Left headlight assembly × 1 — Use OEM specification
• Right headlight assembly × 1 — Use OEM specification
• Headlight mounting bolts (if corroded) × 6 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn off all electrical systems and remove key fob from vehicle interior
3. Open hood and secure with prop rod
4. Disconnect 12V battery negative terminal and wait 2 minutes for system discharge
5. Protect front bumper and fenders with towels or fender covers to prevent scratches

Procedure

1. 1

   Access Driver Side Headlight
   Remove the front wheelwell liner partially if additional access is needed. Remove the two upper mounting bolts accessible from the top of the headlight assembly using 10mm socket. These bolts secure the headlight to the radiator support.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
2. 2

   Remove Driver Side Lower Fastener
   Locate and remove the lower mounting bolt accessed from below the headlight assembly near the bumper interface. Use 10mm socket. This may require turning the steering wheel fully right for better access.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
3. 3

   Disconnect Driver Side Electrical Connectors
   Reach behind the headlight assembly and locate the main headlight connector. Press the release tab and pull connector straight back. If equipped with adaptive lighting, disconnect the second smaller connector for the leveling motor. Mark connectors with tape if needed to identify during reinstallation.
   ⚠Do not pull on wires; always grasp the connector body to avoid damaging the harness.
4. 4

   Remove Driver Side Headlight Assembly
   Carefully pull the headlight assembly forward and outward from the vehicle. It may require gentle rocking to disengage the alignment pins at the rear of the housing. Guide the assembly out without contacting painted surfaces.
   ⚠The headlight assembly weighs approximately 8-10 lbs and has protruding alignment tabs that can scratch the fender if not carefully removed.
5. 5

   Access Passenger Side Headlight
   Repeat the process on the passenger side. Remove the two upper mounting bolts accessible from the top of the headlight assembly using 10mm socket. Note that access may be slightly different due to underhood component placement.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
6. 6

   Remove Passenger Side Lower Fastener
   Locate and remove the lower mounting bolt from below the passenger headlight assembly. Turn steering wheel fully left for improved access. Use 10mm socket.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
7. 7

   Disconnect Passenger Side Electrical Connectors
   Disconnect the main headlight connector and any secondary connectors (adaptive lighting module if equipped) from the passenger headlight assembly. Press release tabs and pull connectors straight back from the headlight housing.
   ⚠Connectors may be stiff on new vehicles; avoid excessive force that could break the connector tabs.
8. 8

   Remove Passenger Side Headlight Assembly
   Pull the headlight assembly forward and outward from the vehicle, disengaging the rear alignment pins. Support the assembly weight and guide it out carefully to avoid contact with adjacent components.
9. 9

   Prepare New Headlight Assemblies
   Inspect new headlight assemblies for shipping damage. Remove any protective film or packaging. Verify that alignment pins on the rear of the housing are intact and mounting points are clean. Transfer any necessary components from old assemblies if performing partial replacement.
10. 10

    Install Passenger Side Headlight
    Guide the new passenger headlight assembly into position, aligning the rear pins with their corresponding holes in the body structure. Apply gentle pressure to seat the assembly fully. Ensure even gaps around the headlight perimeter before installing fasteners.
11. 11

    Secure Passenger Side Headlight
    Install the lower mounting bolt finger-tight first. Then install both upper mounting bolts finger-tight. Once all three bolts are started, torque them in sequence (lower, then upper bolts) to specification using a torque wrench.
    ⚠Do not fully tighten one bolt before starting others, as this can cause misalignment and uneven panel gaps.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
12. 12

    Connect Passenger Side Electrical
    Reconnect the main headlight connector by aligning the connector and pressing firmly until you hear/feel a click. Connect any secondary connectors (adaptive lighting module). Gently tug on each connector to verify it is locked in place.
13. 13

    Install Driver Side Headlight
    Position the driver side headlight assembly, aligning rear pins with body mounting points. Seat the assembly fully and check for even gaps. Install the lower bolt finger-tight, followed by both upper mounting bolts finger-tight.
14. 14

    Secure Driver Side Headlight
    Torque all three mounting bolts to specification in sequence (lower first, then upper bolts) using a torque wrench. Verify headlight assembly is seated flush with adjacent body panels and gaps are even.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
15. 15

    Connect Driver Side Electrical and Reconnect Battery
    Reconnect all electrical connectors on the driver side headlight assembly, ensuring each clicks into place. Reconnect the 12V battery negative terminal and torque to specification. Clear any protective coverings from the work area.
    ℹ️Battery terminal must be torqued to exact specification; overtightening can damage the terminal post.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Check headlight alignment and panel gaps before final testing
3. Reinstall any wheelwell liner clips or fasteners that were removed for access
4. Clean headlight lenses with appropriate cleaner to remove fingerprints

Verification

• Turn ignition to ON position and verify both headlights illuminate on low beam
• Test high beam function on both sides
• Verify daytime running lights (DRLs) operate correctly
• Test turn signals integrated into headlight assemblies
• If equipped, verify adaptive headlight function by turning steering wheel lock-to-lock
• Check for any warning lights on instrument cluster related to exterior lighting
• Inspect headlight alignment visually; if beams appear to point incorrectly, headlight aim adjustment may be required
• Verify all panel gaps around headlights are even and consistent with factory specification

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