This procedure covers the removal and replacement of the headlight switch assembly located on the instrument panel to the left of the steering column on the 2023 Chevrolet Bolt EUV.

Warnings

Tools required

Parts

• Headlight switch assembly × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Ensure vehicle is powered off and key fob is removed from vehicle interior
3. Allow vehicle to sit for at least 2 minutes to allow capacitors to discharge
4. Open driver's door and leave it open for access throughout procedure
5. Gather all tools and replacement parts before beginning

Procedure

1. 1

   Disconnect 12V battery negative terminal
   Locate the 12V battery in the engine compartment. Using a 10mm socket, loosen the negative terminal bolt and disconnect the negative cable. Secure the cable away from the battery terminal to prevent accidental reconnection. Wait at least 2 minutes before proceeding to allow airbag system capacitors to fully discharge.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove lower steering column trim panel
   Locate the lower steering column cover beneath the steering wheel. Pull the tilt/telescoping lever fully down to lowest position for access. Using trim removal tools, carefully release the retaining clips around the perimeter of the lower trim panel. Start at the bottom edge and work around the sides. Gently pull the panel away from the column and set aside.
3. 3

   Remove left instrument panel end cap
   Open the driver's door fully. Locate the left end cap trim panel on the instrument panel (at the door opening edge). Using a trim removal tool, carefully pry the end cap away from the instrument panel starting at the rear edge. The panel is retained by push-in clips. Pull the panel straight out away from the dash and set aside.
4. 4

   Access headlight switch mounting screws
   With the left end cap removed, locate the headlight switch assembly mounted in the instrument panel to the left of the steering column. Use a flashlight to identify the mounting screws on the switch housing. The switch is typically secured by two screws accessible from the front of the panel.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
5. 5

   Remove headlight switch mounting screws
   Using the appropriate screwdriver or socket (typically Torx or small socket), remove the two mounting screws securing the headlight switch assembly to the instrument panel bracket. Keep screws in a safe location for reinstallation. Support the switch as you remove the final screw to prevent it from dropping.
6. 6

   Disconnect electrical connector
   Carefully pull the headlight switch assembly forward out of the instrument panel opening approximately 2-3 inches to access the electrical connector on the rear. Locate the connector locking tab on the wiring harness connector. Depress the locking tab while gently pulling the connector straight off the switch. Do not pull on the wires themselves. Remove the old switch from the vehicle.
7. 7

   Install new headlight switch assembly
   Position the new headlight switch assembly near the installation location. Connect the electrical connector to the rear of the new switch, ensuring it clicks fully into place and the locking tab engages. Verify the connection is secure by gently tugging on the connector. Carefully guide the switch into the instrument panel opening, ensuring no wires are pinched behind the switch housing.
8. 8

   Secure headlight switch mounting screws
   Align the mounting screw holes on the switch with the bracket holes in the instrument panel. Install both mounting screws and hand-tighten initially to ensure proper alignment. Using a torque wrench, tighten the screws to specification in a cross-pattern to ensure even seating of the switch assembly.
   Torque spec

   Cover Screws11 Nm (8 lb-ft)
9. 9

   Reinstall left instrument panel end cap
   Position the left end cap trim panel at the opening. Align the retaining clips with their receptacles in the instrument panel. Press firmly around the perimeter of the panel until all clips are fully seated and the panel is flush with the surrounding trim. Ensure there are no gaps or misalignment.
10. 10

    Reinstall lower steering column trim panel
    Position the lower steering column cover back into place around the steering column. Align all retaining clips with their receptacles. Press firmly around the perimeter of the panel until all clips engage and the panel is fully seated. Verify the panel is secure and properly aligned with the upper column cover.
11. 11

    Reconnect 12V battery negative terminal
    Return to the engine compartment and reconnect the negative cable to the 12V battery negative terminal. Position the cable securely on the terminal post and tighten the terminal bolt using a 10mm socket and torque wrench to specification. Ensure the connection is clean and tight.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure all trim panels are properly aligned and fully seated with no gaps
2. Verify no tools or parts were left in the vehicle interior
3. Check that the steering column tilt/telescoping adjustment still operates freely

Verification

• Turn the vehicle to ON/RUN position without starting (or press power button without pressing brake)
• Test the headlight switch through all positions: OFF, parking lights, and headlights
• Verify instrument panel illumination control (dimmer function) operates smoothly through full range
• Test automatic headlight function if equipped by covering ambient light sensor
• Verify turn signal lever operation was not affected by the repair
• Check for any warning lights or messages on the instrument cluster
• Confirm all interior trim panels are secure and properly fitted with no rattles

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