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Bob
Bob, Auto Tech
Category: Chevy
Satisfied Customers: 4087
Experience:  Plus 40 years GM, over 30 certified with Chevrolet, ASE certified Master Tech. (Expired, Retired)
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Submitted: 9 years ago.
Category: Chevy
Expert:  Bob replied 9 years ago.

Hello, below you will find instructions from GM on replacing your headlamp bulb. If you have problems or questions on any of it, just drop me a note. Thanks

Document ID# XXXXX
2002 Chevrolet Cavalier

Headlamp Assembly or Headlamp Bulb Replacement

Removal Procedure
Object Number: 280073  Size: SH

  1. Remove the hood close out filler panel.
  2. Remove the park/turn signal lamp.
  3. Remove the bolts (6) from the headlamp.
  4. Remove the headlamp from the headlamp mounting panel.
  5. Disconnect the electrical connector from the headlamp.
    Object Number: 740477  Size: SH

  6. Remove the headlamp bulb/socket retainer ring from the headlamp.
    Object Number: 740476  Size: SH

  7. Remove the headlamp bulb/socket from the headlamp.
    Object Number: 740475  Size: SH

  8. Remove the bolts from the headlamp adjuster mechanism, if required.
  9. Remove the headlamp adjuster mechanism, if required.
Installation Procedure

    Object Number: 740476  Size: SH

  1. Install the headlamp bulb/socket to the headlamp.
    Object Number: 740477  Size: SH

  2. Install the headlamp bulb/socket retainer ring to the headlamp.
    Object Number: 740475  Size: SH

  3. Install the headlamp adjuster mechanism to the headlamp housing, if necessary.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the bolts to the headlamp adjuster mechanism, if required.

    Tighten
    Tighten the headlamp adjuster mechanism bolts to 6 N·m (53 lb in).


    Object Number: 280073  Size: SH

  5. Connect the electrical connector to the headlamp.
  6. Position the headlamp to the headlamp mounting panel and lower mounting bracket.
  7. Install the bolts (6) from the headlamp.

    Tighten
    Tighten the headlamp bolts (6) to 10 N·m (89 lb in).

  8. Install the park/turn signal lamp.
  9. Install the hood close out filler panel.
  10. Check and adjust the headlamp aim as necessary.

Document ID# XXXXX
2002 Chevrolet Cavalier