Replace sealed beam in popup headlight 1996 SC2

Ive changed the relay and the headlight switch on the dash .. still wont turn off headlights ? Just changing parts won't fix it , need to test . Hooking up a professional scan tool , one that can read codes in the BCM - body control module is the way to start to find the problem . Then familiarize yourself with how they work.

Headlamps
Major components of this system are the body control module (BCM), headlamp relay, beam select relay, ambient light sensor, headlamp and panel dimmer switch, turn signal/multifunction switch, park brake switch, and the low and high beam headlamps.
The headlamps may be turned ON in 2 different ways. First, when the driver places the headlamp switch in the ON position, normal operation occurs. Second, when the headlamp switch is placed in the AUTO position, automatic lamp control (ALC) operation occurs. During ALC control, the headlamps will be OFF in daylight conditions or in low/high beam operation in low light conditions.
The headlamp relay receives battery positive voltage directly from the battery. The BCM supplies a ground signal to the headlamp relay for normal headlight operation. The BCM also supplies voltage to the beam select relay coil for high beam headlight operation. When the driver places the headlamp switch in the ON position and the dimmer switch is in the low beam position, the headlamp relay supplies current flow through the left and right low beam headlamp fuses to both low and high beam headlamps. Both low beam headlights are grounded through the beam select relay. When activated, the dimmer switch sends a ground signal to the BCM in the high beam position and a momentary ground signal in the flash-to-pass (FTP) position from G106. The BCM then energizes the beam select relay which switches the headlamp grounds from the low beam headlight bulbs to the high beam headlight bulbs illuminating the high beam headlights. With the headlights in the low beam position, the high beams may be momentarily turned ON or flashed by activating the FTP portion of the switch.
The instrument panel cluster (IPC) illuminates the high beam indicator when the BCM detects that the high beams are requested. The IPC receives a class 2 message from the BCM requesting illumination.
The Headlamps On at Exit and Perimeter Lighting modes can be adjusted using the steering wheel controls to select the function as displayed in the driver information center (DIC). The Headlamps On at Exit selection will allow the driver to customize the period of time that the headlamps remain illuminated upon exiting the vehicle. This period can be adjusted from 0-180 seconds. The Perimeter Lighting feature allows the driver to select if they want the headlamps and backup lamps to illuminate when the door UNLOCK button on the key fob is activated. This feature can be turned ON or OFF by using the DIC steering wheel control buttons.

DTC B2575 Headlamp Control Circuit

Circuit Description
When the body control module (BCM) senses a request for headlamp or daytime running lamp (DRL) illumination, the BCM sends a ground signal to the headlamp relay through the low beam headlamp relay control circuit. The headlamp relay will illuminate the low beam headlamps.

Install a scan tool.
Turn ON the ignition, with the engine OFF.
With a scan tool, command the headlamps ON and OFF.
Does the headlamp relay turn ON and OFF with each command?

Do you know what bi-directional control means ? Need a professional scan tool to do these type of test .

DTC B2602: Daytime Running Lamp Control Circuit Low or Open
DTC B2603: Daytime Running Lamp Control Circuit High

Without this type of info. from service repair manual an using a scan tool your missing the big picture .

Get flat screwdriver and star screwdriver

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How to Adjust a Headlamp Beam on a 2005 Chevrolet Cavalier...

When you replace the headlamp assembly in the 2005 Chevrolet Cavalier, you must also adjust the headlamp beams. Like most vehicles, there are two screws located on the headlamp assembly that control the vertical and horizontal direction of the headlamps. Proper adjustment is necessary for adequate visibility during nighttime driving; bad adjustment can make it difficult for you to see or make it difficult for oncoming drivers to see, creating a potentially dangerous situation. You can adjust the headlamp beams yourself with a screwdriver in about 15 minutes.
Park the Chevrolet Cavalier on a flat surface facing a wall or garage door approximately 15 feet away. Park the Car so that it is perpendicular to the wall.

Lift the hood and remove the plastic trim panel above each of the headlights. There are three plastic fasteners that secure the trim panel; pry the fasteners out using a flathead screwdriver. Lift the trim panel up to remove. There are two adjusting screws beneath the trim panel, one on the top of the headlamp assembly and one along the outer side of the headlamp assembly.

Turn the headlights on so that they shine on the wall. Ensure the headlights are on the "dim" setting.

Adjust the vertical bolt, located on the top of the headlight assembly near the center of the vehicle to raise or lower the headlight, using a crosspoint screwdriver. Turn the screw counterclockwise to lower the headlamp beam; turn the screw clockwise to raise the headlamp beam. Adjust the headlamp so that the beam is below a driver's eye level.

Adjust the horizontal bolt, located on the outer side of the headlamp assembly to move the headlamp beam right of left, using a crosspoint screwdriver. Turn the screw counterclockwise to move the headlamp beam right; turn the screw clockwise to turn the beam left. Adjust the headlamp so that the beam shines straight ahead or slightly toward the center of the vehicle.

Replace the plastic trim panel and fasteners and close the hood. Warning: raising the lights too high can make it difficult for other drivers to see you.

Dealing With Headlights and Directional Signals ' Military.com

www.military.com/.../dealing-with-headlights-and-direction...

Military.comMost turn over within 1.5 sec. ... If you experience problems with other lights, it's usually just a matter of changing ... If a headlight doesn't work on Low beam but does work on High, you have to replace the whole sealed-beam unit or headlamp. ... Pull out the bulb assembly, remove the old bulb, and install the replacement.

Mechanical Violations - FindLaw

Headlamps Inoperative - Low Beams

Step

Action

Value(s)

Yes

No

DEFINITION: This diagnostic procedure should only be used if the high beam headlamps are operating properly and the low beams are inoperative.

1

Did you perform the Headlights System Check?
--
Go to Step 2
Go to Headlight System Check

2

1. Turn the headlamp and panel dimmer switch to the ON position.
2. Move the headlamp dimmer switch to the LOW position.
3. Backprobe the headlamp dimmer switch connector with a J 35616-200 from cavity A to ground.

Does the test lamp light?
--
Go to Step 3
Go to Step 5

3

1. Remove the daytime running lamp relay.
2. Connect a J 35616-200 at cavity G5 to ground.

Does the test lamp light?
--
Go to Step 4
Go to Step 6

4

1. Re-install the daytime running lamp relay.
2. Backprobe cavity B at the high/low beam headlamp with the headlamp dimmer switch in the LOW position.

Does the test lamp light?
--
Go to Step 7
Go to Step 8

5

Replace the headlamp dimmer switch.

Is the repair complete?
--
Go to Headlight System Check
--

6

Repair the open in CKT 359 (PPL) between the headlamp dimmer switch and the daytime running lamp relay.

Is the repair complete?
--
Go to Headlight System Check
--

7

Replace the high/low beam headlamps.

Is the repair complete?
--
Go to Headlight System Check
--

8

1. Inspect for an open in CKT 12 (TAN) between the daytime running lamp relay and S120, repair as necessary.
2. Replace the daytime running lamp relay if no open was found in CKT 12 (TAN) between the daytime running lamp relay and S120.

Is the repair complete?
--
Go to Headlight System Check
--

1989 Toyota Camry

A little personal tip - if you get fingermarks on a halogen headlamp, you can wipe them off with rubbing alcohol (isopropyl alcohol) or, if you want to do what mechanics do, keep a number of 2X2 alcohol wipes in your automotive toolbox just to wipe off halogen headlight bulbs.

HEADLAMP REMOVAL & INSTALLATION

Sealed Beam Headlamps

See Figures 2 and 3

Before making a headlight replacement, make sure that the headlight switch is in the off position.

1. Loosen the screws, release the clips and remove the headlight door. To release the clips, insert a flat blade screwdriver into the jaws of the clip and pry on the jaws.

2. Remove the beam unit retaining ring screws and remove the beam unit.

Fig. 2: Headlamp door clip removal

3. Compress the lock releases and disconnect the wire connector from the headlight. If the connector is tight, wiggle it while holding in the lock releases and pulling out.

Fig. 3: Do not remove the adjusting screws when removing the head lamp sealed bulb

Never try to loosen the aim adjusting screws. If the screws are loosened, the headlights will have to be re-aimed by a qualified technician.

4. When installing, use only a sealed beam unit with the same part number and wattage.

Composite Headlamps

See Figures 4, 5 and 6

Fig. 4: Headlight bulbs are inside the sockets located in the engine compartment

Fig. 5: Detach the wiring from the back of the headlamp bulb

This procedure only applies to replaceable halogen headlight bulbs (such as Nos. 9004 and 9005); it does not pertain to sealed beam units.

1. Open the vehicle's hood and secure it in an upright position.

Fig. 6: Twist and pull the bulb out, but do not touch the bulb if it is still good

2. Unfasten the locking ring which secures the bulb and socket assembly, then withdraw the assembly rearward.

3. If necessary, gently pry the socket's retaining clip over the projection on the bulb (use care not to break the clip.) Pull the bulb from the socket.

To install:

4. Before installing a light bulb into the socket, ensure that all electrical contact surfaces are free of corrosion or dirt.

5. Line up the replacement headlight bulb with the socket. Firmly push the bulb onto the socket until the spring clip latches over the bulb's projection.

WARNING
Do not touch the glass bulb with your fingers. Oil from your fingers can severely shorten the life of the bulb. If necessary, wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation.

6. To ensure that the replacement bulb functions properly, activate the applicable switch to illuminate the bulb which was just replaced. (If this is a combination low and high beam bulb, be sure to check both intensities.) If the replacement light bulb does not illuminate, either it too is faulty or there is a problem in the bulb circuit or switch. Correct if necessary.

7. Position the headlight bulb and secure it with the locking ring.

8. Close the vehicle's hood.

Fig. 1 - various automotive lamps



Fig.2 - Headlamp Door Clip Removal



Fig. 3: Do not remove the adjusting screws when removing the head lamp sealed bulb




Fig. 4: Headlight bulbs are inside the sockets located in the engine compartment




Fig. 5: Detach the wiring from the back of the headlamp bulb




Fig. 6: Twist and pull the bulb out, but do not touch the bulb if it is still good.

Changing the headlight bulb is a little bitdifficult for those not familiar with the vehicle. Both the high and low beamsare encased in a sealed unit, which also contains the turn signal, parkinglights, and side reflector. To change a single headlight, the entire headlightcompartment must be removed from the car. Once you understand how to remove thesealed headlight unit from the car, replacing the bulb is relatively simple.Follow the steps below on how to change the headlamp bulb in this car. Removal 1. Open the hood of the Jeep and locate thelong, headlamp jackscrew. The screw is located almost directly above theheadlight unit and can be removed using a 7-mm socket wrench. This will allowyou to remove the bezel from the grill opening panel. Remove the three screwsattached to the retaining ring to the headlight console. The screws are locatedon the bottom front and side of the unit. In some models the screws have beenreplaced with ball-stud alignment posts, enabling you to remove the headlightunit by simply wiggling it loose. 3. Disconnect the headlamp bulb wireharness connector located at the front of the headlight unit. This is locateddirectly above and between the parking and turning bulbs. 4. Separate the sealed headlight unit fromthe vehicle; disconnect and replace the old bulb. The high beam is locatedtoward the center of the car. The low beam is the bulb on the outermost edge ofthe unit. This is how to Install 1. Reconnect the headlamp bulb's wireharness-connector. Then Replace the headlight unit in the headlight canister. Positionthe retaining ring back in its original position and install the three screwsagain. If you wiggled the unit out, ensure that it is replaced firmly. 2. Install the headlamp bezel by replacingthe 7-mm jackscrew on the inside of the hood. Make sure all connections aretight before starting the car and inspecting the replacement.

there is to tabs right behinde the headlamp you pull up an can remoce headlight to replace bulb easier. then just twist bulb out an make sure not to touch the new bulb with your fingers. but if your have what they call a sealed beam then there is 4 screws in front of headlight that hold it in.

Sealed Beam Type

1. Disconnect the negative battery cable.
   
2. Unfasten the headlight bezel attaching screws, then remove the bezel.
   

Remove the headlight bezel

To avoid turning the vertical or horizontal aiming screws, refer to the illustration before removing the headlight retainer.

1. Unfasten the headlight retainer attaching screws, then remove the retainer.
   

Remove the headlight trim screws then...


... pull the trim off while holding the bulb

4. Pull the headlight out, then carefully detach the electrical connector.


Pull the bulb out far enough to disconnect the wiring


To install:

1. Attach the electrical connector to the new headlamp.
   
2. Place the headlamp into the socket.
   
3. Install the retainer, then tighten the attaching screws.
   
4. Connect the negative battery cable, then turn the headlight switch on, to be sure the headlights are operating.
   
5. Install the headlight bezel and secure using the attaching screws.
   

LIGHTING Headlights REMOVAL & INSTALLATION Non-Aerodynamic
Fig. 1: Replacing a sealed beam headlamp

1. Disconnect the negative battery cable.
2. Remove the front grille and/or headlight bezel.
3. Remove the headlight bulb retaining rim, headlight and disconnect the wiring.
4. Before installing, spray some silicone grease into the bulb socket.
5. Connect the wiring and install the bulb.
6. Install the retaining rim and grille.
7. Adjustment: turn the adjusting screw (A) for vertical adjustment. Turn the screw (B) for horizontal adjustment.

Aerodynamic

Fig. 2: Replacing a headlamp bulb

ive had 2 camaros and both did this. remove the headlight and take the bulb out of the back of the sealed beam. be careful not to break it as its glued in, but it is possible. just be gentle and patient. replace the bulb with an aftermarket 9006 bulb (hi beams are 9005) and silicone it back into the housing. i haven't had one burn out yet after doing this