Spot Lamp Replacement RPO 7X6, 7X7

1. Remove the cover from the instrument panel (IP) fuse block.
2. Remove the LH spotlamp fuse #15, or the RH spotlamp fuse #6 from the IP fuse block.
3. Raise the spotlamp from the stowed to the operating position.
4. Release the windshield side garnish molding from the windshield pillar, to access the spotlamp electrical connector.

Grasp the molding, pull and use a slight rocking motion to disengage the retaining clips.




5. Disconnect the electrical connector from the spotlamp.



6. Loosen but do not remove the bolt (1) retaining the handle to the outer tube.

(Loosen the bolt until almost removed.)

7. Using a plastic tipped hammer, gently tap the head of the handle retaining bolt (1) in order to loosen the opposing wedge nut.
8. Remove the handle to outer tube retaining bolt (1) and the opposing wedge nut.
9. Remove the handle from the outer tube.
10. Remove the windshield side garnish molding from the spotlamp outer tube.




Important: Support the head of the spotlamp while loosening the head assembly clamp screw.

11. Loosen the clamp screw (1) at the base of the spotlamp head assembly.



12. Carefully remove the spotlamp head with the intermediate and inner shafts from the outer tube and mounting bracket.



13. Remove the screws retaining the spotlamp mounting bracket to the windshield pillar.
14. Remove the spotlamp outer tube and mounting bracket from the windshield pillar.




Important: Only separate the outer tube from the mounting bracket if it is necessary for component replacement, the bushing on the outer tube is retained in a specific detent position.

15. Remove the set-screw (1) retaining the outer tube bushing to the mounting bracket, only if necessary for component replacement.

Important: The outer tube and bushing must be aligned properly to the mounting bracket to ensure proper spotlamp positioning and operation.

1. Carefully align and install the spotlamp outer tube and bushing to the mounting bracket, if removed for component replacement; ensure that the dimple (2) on the bushing is lined up with the set-screw hole on the bracket.

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.

2. Install the outer tube bushing to mounting bracket set-screw (1), if removed for component replacement.

Tighten
Tighten the spotlamp outer tube bushing to spotlamp mounting bracket set-screw to 6 N·m (53 lb in).




3. Install the spotlamp outer tube and mounting bracket to the windshield pillar.
4. Install the spotlamp mounting bracket to windshield pillar retaining screws.

Tighten
Tighten the spotlamp mounting bracket to windshield pillar retaining screws to 3.3 N·m (29 lb in).

5. Carefully lift the edge of the secondary door seal along the windshield pillar to expose the spotlamp outer tube.
6. Apply a small amount of clear sealer, GM P/N 1052915 (or equivalent), to the base of the outer tube.
7. Install the secondary door seal into position.



8. Align and carefully install the spotlamp head with the intermediate and inner shafts to the outer tube and mounting bracket until the head assembly bottoms out on the outer tube.



9. Tighten the spotlamp head assembly clamp screw (1) in small increments, while testing the effort required to rotate the spotlamp between the stowed and operating positions; stop tightening the clamp screw when the spotlamp can maintain any desired position.



10. Position the windshield side garnish molding onto the spotlamp outer tube.
11. Position and maintain the spotlamp head in the operating (vertical) position.
12. Install the spotlamp handle to the outer tube:

12.1.

Position the spotlamp handle in the operating (downward, close to vertical) position to the outer tube.

12.2.

There a two detent positions to which the handle must line up and engage; rotate the knob of the handle and the handle base to aid in engaging each of the detents.

Using the wedge nut opening on the handle for visual aid, rotate the handle as necessary while installing, in order to bring the flat detent on the intermediate shaft into view along the bottom of the opening.

12.3.

Continue to install the handle until it bottoms out.

13. Install the wedge nut and the retaining bolt (1) to the handle.
14. Tighten the handle to outer tube retaining bolt (1).

Tighten
Tighten the spotlamp handle to outer tube retaining bolt to 6.5 N·m (58 lb in).




15. Connect the electrical connector to the spotlamp.



16. Align and secure the windshield side garnish molding to the windshield pillar.
17. Install the LH spotlamp fuse #15, or the RH spotlamp fuse #6 to the IP fuse block.
18. Install the cover to the IP fuse block.



19. Inspect the operation of the spotlamp to ensure that the range of movement is correct:

•	Using the handle, rotate the spotlamp from the operating position to the stowed position and back. Ensure that the lamp will maintain the desired position.

•	The stowed position should be just above the windshield and the operating position should be vertical to slightly outboard.

•	Using the knob of the handle, rotate the head (1) of the spotlamp around on its axis.

•	The spotlamp head (1) must rotate 360 degrees on its axis.

20. If the spotlamp stowed and operating positions are incorrect, refer to Spot Lamp Travel Adjustment .
21. If excessive effort is required to rotate the spotlamp between the stowed and operating positions, or if the spotlamp will not maintain the desired operating position, refer to Spot Lamp Travel Adjustment .
22. If the spotlamp head (1) does not rotate 360 degrees on its axis, or if excessive effort is required to rotate the lamp head on its axis, perform the following:

22.1.

Remove the handle and inspect for damage to the inner shaft and the gears in the handle.

Repair or replace any damaged components as necessary.

22.2.

If no damage is present to the inner shaft or the gears in the handle, reinstall the handle and reinspect the operation of the lamp.

22.3.

If the spotlamp head (1) still does not properly rotate 360 degrees on its axis, remove the cover from the end of the spotlamp head assembly and inspect for damage to the gears in the head assembly.

Repair or replace any damaged components as necessary.

23. Lower the spotlamp to the stowed position.