GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1997 🢒 Corvette 🢒 Body and Accessories 🢒 Lighting Systems 🢒 Headlamp Opening Door Replacement

Removal Procedure

    Object Number: 64644 Size: SH
  1. Open the hood.
  2. Raise the appropriate headlamp manually.

    3. Turn the manual headlamp control knob counterclockwise.

  3. Disconnect the headlamp wiring harness electrical connector from the forward lamp wiring harness.

    4. Object Number: 64654 Size: SH
  4. Remove the headlamp bezel. Refer to Headlamp Bezel Replacement .
  5. Remove both of the headlamp opening door side retaining screws.

    6. Object Number: 64657 Size: SH
  6. Lower the headlamp manually.

    7. Turn the manual headlamp control knob clockwise.

  7. Remove the headlamp opening door rear retaining screws.
  8. Remove the headlamp opening door.

Installation Procedure

    Object Number: 64657 Size: SH
  1. Position the headlamp opening door to the headlamp assembly intermediate door bracket.
  2. Loosely install the headlamp door rear retaining screws.

    3. Object Number: 64654 Size: SH
  3. Raise the headlamp manually.

    4. Turn the manual headlamp control knob counterclockwise.

  4. Loosely install the headlamp door side retaining screws.
  5. Lower the headlamp manually.

    6. Turn the manual headlamp control knob clockwise.

  6. Inspect the fit of the headlamp opening door to the hood, the fender and the front fascia.
  7. Adjustment the fit as necessary. Refer to Headlamp Opening Door Adjustment .
  8. Tighten the headlamp opening door rear retaining screws.

    9. Tighten
    Tighten the headlamp opening door retaining screws to 1.9 N·m (17 lb in).

    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.

  9. Raise the headlamp manually.

    10. Turn the manual headlamp control knob counterclockwise.

  10. Tighten the headlamp opening door side retaining screws.

    11. Tighten
    Tighten the headlamp opening door retaining screws to 1.9 N·m (17 lb in).


    Object Number: 64644 Size: SH
  11. Install the headlamp bezel. Refer to Headlamp Bezel Replacement .
  12. Lower the headlamp manually.

    13. Turn the manual headlamp control knob clockwise.

  13. Connect the headlamp wiring harness electrical connector to the forward lamp wiring harness.
  14. Close the hood.