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In short, it is pretty easy. I have a 1998 Chevy Astro that I bought in 1999. I love it but have always wanted the composite look. I recently went to a junkyard and found an Astro with composite headlamps. I made an offer for the parts and we struck a deal. Here are the instructions based on my experience
1. Remove the corner light assembly. (almost triangular clear lights on each side of the headlight) Raise the hood and you can access a 10MM bolt that holds the lamp in place. Incidentally, this is just for looks, there is no light.
2. Remove headlamp assembly. This is the black plastic frame that the headlamps attach to. This is attached with 3 10MM bolts. At this point, cut the headlamp wiring harness off deep inside the frame of the van so that you will have enough slack to wire to your van.
3. Remove the parking lamp assemblies. Each is held on with 2 Philips screws. You do not need to take these with you if your parking lights are in good shape. Your existing parking lamps fit the composite style grill just fine. No wire cutting is required, your existing wiring will be just fine.
4. Remove the composite grille. About 10 1/4" bolts hold the grille in place and the mounting pattern is the same as your van.
5. Check that you have taken the grille, headlamp assemblies, corner lights and the wiring harness for the composite lamps. (as I said, the parking lamps are optional)
6. Remove existing sealed beam lights, adjustment bracket and screws.
7. Install the composite grille and parking lamps.
8. Time to do the wiring. Cut the sealed beam harness. (3 wires, brown, green and black) The composite lamps have 2 lights each. (black and brown and black and green) Twist the 3 black wires (Grounds) together with wire nuts. Then connect brown to brown and then green to green.
9. Mount the composite headlamp assemblies to your van. (The holes are pre-drilled at the factory for a perfect fit) Then mount to corner lights. Test your lights and maybe take to a shop to have headlights aimed professionally.
Works perfectly. Took me only about an hour and a half. Cost me about 100 dollars. It was a nice upgrade that really looks sharp.
What else can I help you with?
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