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So I just finished removing my passenger side headlight bulb on my 04 Aveo and I'm having a hell of a time with the clip. I figured I could have it done in about 10 mins but now I might have to remove the air filter housing to get better access to it. I wish I had my camera but I'm at work.
So I found a link on " How to change the headlights on a 2004 Chev Aveo" and figured I would post it if it helps out anyone down the road.
http://www.ehow.com/how_4696039_change- ... -aveo.html
i have had this problem too, and a few hours later, i got it to go back in #-o
a lot of clips need a sweeping motion to have them go into the holder. or if you let them go past the 100 degree mark the clip will often bind on the hinge, which is your not allowing you to do?
take the bulb back out and put the clip back in the locked position with no bulb in there, this will let you giggle it around to get it in and feel how it works, then put the bulb back in and redo the clip.
Great! Got it done. After taking off the air filter housing it gave me alot more room to work and I managed to get it on. Even with the housing off it was a little tricky, I'm happy it wasn't -35c outside. [-o<
Hopefully I didn't touch the bulb to much it might shorten it's life expectancy. I gave it a quick wipe with a clean cloth before putting it back in.