This procedure covers the removal and replacement of the LED headlight module on a 2023 Chevrolet Bolt EUV, including proper electrical disconnection and alignment.

Warnings

Tools required

Parts

• LED Headlight Module Assembly × 1 — Use OEM specification - specify left or right side
• Headlight module mounting seal/gasket (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn off all vehicle systems and remove key fob from vehicle
3. Open hood and secure with prop rod
4. Disconnect 12V battery negative terminal and wait minimum 2 minutes for system discharge
5. Allow headlight module to cool completely if recently operated (minimum 15 minutes)
6. Determine which headlight module requires replacement (driver or passenger side)

Procedure

1. 1

   Remove front wheel well liner clips
   Turn the steering wheel to full lock (opposite direction of the headlight being serviced) to improve access. Remove the plastic clips securing the front portion of the wheel well liner to access the rear of the headlight assembly. Typically 3-4 clips need removal. Fold the liner back and secure with tape if necessary.
2. 2

   Disconnect headlight electrical connector
   Locate the main headlight module connector at the rear of the assembly, accessible through the wheel well opening. Press the release tab and carefully pull the connector straight back from the module. Do not pull on the wiring harness itself. If connector is tight, gently wiggle while pulling.
   ⚠The connector may have a secondary locking tab. Ensure both tabs are released before pulling to avoid breaking the connector.
3. 3

   Remove upper module mounting bolts
   From the engine bay, locate the upper mounting bolts securing the headlight module to the front fascia support structure. There are typically 2 upper bolts accessible from above. Remove these bolts completely and store them safely.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
4. 4

   Remove lower module mounting bolt
   Through the wheel well access area, locate the lower mounting bolt at the bottom of the headlight assembly. Remove this bolt completely. The headlight module should now be free from all mounting points but may still be held by alignment tabs.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
5. 5

   Remove headlight module from vehicle
   Carefully pull the headlight module forward and outward from the vehicle. The module has locating tabs that fit into the front bumper cover and fender. You may need to gently manipulate the module at different angles to clear these tabs. Support the module with both hands and avoid dropping or impacting it.
   ⚠The module weighs approximately 8-10 lbs. Ensure you have a secure grip before fully removing from the vehicle.
6. 6

   Inspect mounting surfaces and seal
   With the headlight removed, inspect the mounting surface on the vehicle for damage, corrosion, or debris. Clean the mounting surface with a shop towel. Check the rubber seal/gasket on the back of the headlight module for damage, cracks, or compression set. Replace if damaged to prevent water intrusion.
7. 7

   Prepare new headlight module
   Remove the new LED headlight module from its packaging. Verify it is the correct side (driver or passenger). If the module came with protective films or covers over the lens, leave them in place until installation is complete. Transfer any necessary components from the old module if required (verify with parts supplier).
8. 8

   Install new headlight module
   Align the new module with the mounting tabs in the fender and bumper cover. Insert the module at an angle to engage the rear tabs first, then pivot into position. Ensure all alignment tabs are properly seated before attempting to install mounting bolts. The module should sit flush against the mounting surface.
9. 9

   Install lower mounting bolt
   From the wheel well area, install the lower mounting bolt finger-tight first to hold the module in position. Verify the module is properly aligned before tightening. Torque the lower mounting bolt to specification using a torque wrench.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
10. 10

    Install upper mounting bolts
    From the engine bay, install the two upper mounting bolts finger-tight. Check that the module is properly aligned with the adjacent body panels and has even gaps. Once alignment is confirmed, torque the upper mounting bolts to specification.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect electrical connector
    Connect the main headlight electrical connector to the module. Push firmly until you hear and feel a positive click. Gently tug on the connector to verify it is fully locked. Ensure the wiring harness is routed properly and not pinched or stretched.
12. 12

    Reinstall wheel well liner
    Reposition the wheel well liner to its original location. Install all retaining clips, ensuring each is fully seated. Verify the liner does not interfere with any moving components or the tire at full steering lock.
13. 13

    Reconnect battery and initialize system
    Reconnect the 12V battery negative terminal and torque the terminal bolt to specification. The vehicle may require a brief initialization period. Do not immediately turn on headlights; wait for the system to fully boot.
    ⚠Do not overtighten the battery terminal bolt. Excessive torque can damage the battery terminal.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Remove any protective films from the headlight lens after verifying proper operation
2. Return steering wheel to center position
3. Close hood and ensure all tools are removed from engine bay

Verification

• Turn the vehicle to ON position (do not start) and activate the headlights to verify the new module illuminates properly
• Test low beam, high beam, and daytime running light functions on the replaced side
• Check for any error messages or warning lights on the instrument cluster
• Verify the headlight is properly aligned with the opposite side by observing the light pattern on a wall or garage door from 25 feet away
• Inspect for proper fitment - check that gaps between the headlight and adjacent body panels are even and consistent
• Schedule or perform a professional headlight aim adjustment to ensure proper beam pattern and compliance with safety standards
• Test drive the vehicle in a safe area at night to confirm proper illumination and no abnormal operation

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