2004 2007 Chevrolet Malibu Headlight Replacement 2004 2005 2006 2007 Repair Guide

Difficulty

Moderate

Steps

Time Required

                          40 minutes

Sections

Headlight
9 steps

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Introduction

Be sure to be careful when cutting the wire and/or twisting the wires together. If you are not careful you can poke yourself with the exposed wire, wearing gloves will help prevent this but they are not needed. I recommend using wire cutters because it can take the rubber around the wire off without damaging the wire. The scissors might take you a longer time trying to remove the rubber. Don’t worry you do not need any type of certification or degree to do this, just take your time, breathe and you’ll be done before you know it.

Before beginning the repair, make sure your car is off and you disconnect the battery of the car.

What you need

Step 1

              Removing Screws

First pop the hood of the car and locate the headlight. They are towards the front of the car.

First pop the hood of the car and locate the headlight. They are towards the front of the car.

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Step 2

Use a Phillips #0 screwdriver to remove the 10 mm screws attaching the headlight to the car.

Use a Phillips #0 screwdriver to remove the 10 mm screws attaching the headlight to the car.

Step 3

              Take out the headlight

Remove the headlight so you can see all wiring going from the car and to the headlight.

Remove the headlight so you can see all wiring going from the car and to the headlight.

Step 4

              Safety Caps

Remove the safety caps to get a good a view of your bulb wiring.

Remove the safety caps to get a good a view of your bulb wiring.

Step 5

              Remove the Bulb

Turn the bulb counter clockwise then pull it out.

Turn the bulb counter clockwise then pull it out.

Step 6

              Separate the bulb and pigtail

Pull back the clip that’s holding the bulb (top half) and the pigtail (bottom half) together.
Pull apart the two, exposing the inside of the damaged pigtail.

Pull back the clip that’s holding the bulb (top half) and the pigtail (bottom half) together.

Pull apart the two, exposing the inside of the damaged pigtail.

Step 7

              Cutting Wires

Now that you have separated the bulb and pigtail, detach the pigtail end from the car wires using wire cutters or scissors.
How To Cut With Wire Cutters
After cutting the wires, grab your new pigtail and pull back the rubber surrounding the wire. Pull back the rubber so there is enough wire to twist (connect) to the car wire.

Now that you have separated the bulb and pigtail, detach the pigtail end from the car wires using wire cutters or scissors.

How To Cut With Wire Cutters

After cutting the wires, grab your new pigtail and pull back the rubber surrounding the wire. Pull back the rubber so there is enough wire to twist (connect) to the car wire.

Step 8

              Electrical Tape

Once you’ve connected the pigtail back to the car be sure to wrap the wire in electrical tape.
Then grab your new bulb and attach it to the new pigtail by pushing it together until the clip has clicked.
Put the safety caps back on.

Once you’ve connected the pigtail back to the car be sure to wrap the wire in electrical tape.

Then grab your new bulb and attach it to the new pigtail by pushing it together until the clip has clicked.

Put the safety caps back on.

Step 9

              Almost Done

Take your new bulb and place it back inside the headlight by twisting clockwise and making sure it doesn’t come out or disconnect.
Reattach the headlight to the car with the 10 mm screws using a Phillips #0 screwdriver.

Take your new bulb and place it back inside the headlight by twisting clockwise and making sure it doesn’t come out or disconnect.

Reattach the headlight to the car with the 10 mm screws using a Phillips #0 screwdriver.

To replace your headlight, follow these simple instructions.

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                    Nadia Simpson

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                       University of Memphis, Team 50-20, Willis Fall 2021                        

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