This procedure covers the removal and replacement of the headlight assembly on a 2023 Chevrolet Bolt EUV, including proper disconnection of electrical connectors and adjustment.

Warnings

Tools required

Parts

• Headlight assembly (left or right as needed) × 1 — Use OEM specification
• Push pin retainers (if damaged) — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off vehicle and remove key fob from proximity
3. Open hood and secure with prop rod
4. Disconnect 12V accessory battery negative terminal and wait 2 minutes for system discharge
5. If working on driver side, remove washer fluid reservoir cap to relieve pressure

Procedure

1. 1

   Access headlight assembly
   Remove the plastic push pin retainers securing the upper radiator cover panel directly above the headlight assembly. Gently pull the cover forward to access the top of the headlight assembly. On some models, you may need to partially fold back the front fender liner for additional clearance.
2. 2

   Disconnect electrical connectors
   Locate the main headlight electrical connector at the rear of the assembly. Press the locking tab and pull straight back to disconnect. There will be multiple connectors for low beam, high beam, and turn signal functions. Note the position of each connector for reinstallation.
3. 3

   Remove adjustment screws
   Locate the headlight adjustment screws at the rear of the assembly (typically one for vertical and one for horizontal aim). These do not need to be completely removed but should be loosened to release tension on the ball-socket mounts. Back out each screw several turns.
   Torque spec

   Adjuster Screws3 Nm (2 lb-ft)
4. 4

   Remove headlight mounting bolts
   Locate and remove the three headlight assembly mounting bolts. Two are typically accessible from the top of the assembly, and one is located on the outboard side near the fender. Use a 10mm socket to remove these bolts completely. Keep bolts organized for reinstallation.
   ℹ️Support the headlight assembly with one hand while removing the final bolt to prevent it from falling.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
5. 5

   Remove headlight assembly
   Carefully pull the headlight assembly forward and away from the vehicle. The assembly is located on alignment pins and may require gentle wiggling to disengage. Tilt the assembly as needed to clear any obstructions. Place the old assembly on a clean, soft surface to avoid scratching the lens.
6. 6

   Inspect mounting area
   Clean the mounting surface on the vehicle body where the headlight seals against the panel. Remove any dirt, debris, or old sealant. Inspect the alignment pins for damage. Check that the adjustment mechanism ball sockets are clean and not damaged.
7. 7

   Install new headlight assembly
   Align the new headlight assembly with the mounting pins on the vehicle body. Carefully guide the assembly into position, ensuring the adjustment screws engage with their ball sockets. Push firmly but gently until the assembly is fully seated against the body panel with even gaps all around.
8. 8

   Install mounting bolts
   Thread in all three headlight mounting bolts by hand first to ensure proper alignment. Once all bolts are started, tighten them in a cross pattern using a torque wrench to the specified value. Do not overtighten, as this can crack the housing.
   Torque spec

   Headlight Assembly Bolts10 Nm (7 lb-ft)
9. 9

   Reconnect electrical connectors
   Reconnect all electrical connectors to the rear of the headlight assembly, ensuring each locks into place with an audible click. Apply a small amount of dielectric grease to the connections if desired for corrosion protection. Verify each connector is fully seated.
10. 10

    Adjust headlight aim screws
    Turn the headlight adjustment screws clockwise until they make contact with the ball sockets but do not overtighten. These will be used for final aiming. Tighten to the specified torque value to maintain proper adjustment.
    Torque spec

    Adjuster Screws3 Nm (2 lb-ft)
11. 11

    Reinstall trim panels
    Reinstall the upper radiator cover panel and any fender liner components that were removed. Ensure all push pin retainers are fully seated and secure. Replace any damaged retainers with new ones.
12. 12

    Reconnect battery and test
    Reconnect the 12V accessory battery negative terminal. Start the vehicle and verify all headlight functions operate correctly: low beam, high beam, turn signal, and daytime running lights. Check for any warning lights on the instrument cluster.
    Torque spec

    Battery Terminal Bolts7 Nm (5 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify headlight assembly sits flush with body panels and has even gaps
3. All mounting bolts must be torqued to specification to prevent vibration and misalignment
4. Schedule headlight aiming service or perform aim adjustment using proper equipment on a level surface

Verification

• Turn on headlights and verify low beam, high beam, and turn signal functions work correctly on the replaced side
• Check that daytime running lights illuminate properly
• Inspect for even light output and no dark spots indicating internal damage
• Verify no condensation is visible inside the headlight lens after installation
• Check that headlight assembly is securely mounted with no movement when gently pressed
• Verify no warning lights appear on instrument cluster related to headlight system
• Have headlight aim professionally adjusted or use headlight aim gauge to verify proper aim

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