LOOSE OR MISSING HEADLAMP DOOR BEZEL PLUG. Chevrolet Corvette 1997

SUBJECT: LOOSE OR MISSING HEADLAMP DOOR BEZEL PLUG (INSTALL NEW PLUG)

MODELS: 1997-98 CHEVROLET CORVETTE BUILT PRIOR TO VIN BREAKPOINT W5119887

CONDITION:

SOME OWNERS MAY COMMENT THAT THE PLASTIC PLUG THAT COVERS THE HEADLAMP AIMING ADJUSTMENT SCREW ON THE INBOARD SIDE OF THE HEADLAMP DOOR BEZEL IS LOOSE OR MISSING.

CAUSE:

DURING ASSEMBLY THE ORIGINAL PLUG MAY NOT HAVE BEEN FULLY INSTALLED (SEATED) IN THE HEADLAMP DOOR BEZEL OPENING (HOLE).

CORRECTION:

TWO DIFFERENT SIZE PLUGS HAVE BEEN USED IN PRODUCTION. EARLY PRODUCTION 1997 VEHICLES USED A PLUG WITH A DIAMETER OF 24 MM (15/16 IN), WHILE LATER 1997 VEHICLES AND ALL 1998 VEHICLES USE A LARGER 54 MM (2 1/8 IN) DIAMETER PLUG. SEE FIGURE 1.

VEHICLES WITH LOOSE OR MISSING 24 MM (15/16 IN) DIAMETER PLUGS ARE TO BE SERVICED WITH THE ORIGINAL DESIGN SERVICE PLUG (P/N 10297460). VEHICLES WITH LOOSE OR MISSING 54 MM (2 1/8 IN) DIAMETER PLUGS ARE TO BE SERVICED WITH A NEW SERVICE PLUG (P/N 10417504).

IMPORTANT:

WHEN REPLACING A LOOSE OR MISSING PLUG OF EITHER SIZE, IT IS RECOMMENDED THAT BOTH HEADLAMP PLUGS BE REPLACED (ONE PLUG PER HEADLAMP) ON THE VEHICLE.

SERVICE PROCEDURE:

1. OPEN ENGINE COMPARTMENT HOOD.

2. TURN HEADLAMP SWITCH TO THE "ON" POSITION (HEADLAMP DOORS WILL OPEN AND LAMPS WILL ILLUMINATE).

3. TURN HEADLAMP SWITCH BACK TO THE "PARK" LAMP SETTING (HEADLAMP DOORS WILL REMAIN OPEN).

4. REMOVE LOOSE PLUG FROM THE INBOARD SIDE OF THE HEADLAMP DOOR BEZEL. SEE FIGURE 1.

5. POSITION NEW PLUG INTO BEZEL OPENING.

IMPORTANT:

ONE SOME VEHICLES, THE BACKSIDE EDGE OR LIP OF THE PLUG MAY COME IN CONTACT WITH THE HEADLAMP AIMING SCREW. IF THIS CONDITION IS FOUND, USING A SHARP UTILITY KNIFE, CAREFULLY MAKE A NOTCH IN THE BACKSIDE LIP OF THE PLUG WHERE CONTACT IS OCCURRING.

6. USING YOUR THUMB, APPLY EVEN PRESSURE AROUND THE COMPLETE OUTER EDGE OF THE PLUG UNTIL THE PLUG SNAPS INTO PLACE. CONTINUE APPLYING PRESSURE AROUND THE PLUG TO FULLY SEAT IT INTO THE HEADLAMP DOOR BEZEL OPENING.

7. VERIFY THAT THE PLUG IS SEATED BY FEELING THE BACKSIDE OF THE PLUG IN THE BEZEL OPENING WITH YOUR FINGER.

IMPORTANT:

WHEN PROPERLY INSTALLED (SEATED), THE PLUG WILL HAVE A DIMPLED (CONCAVE) APPEARANCE IN THE CENTER AND WILL REQUIRE CONSIDERABLE EFFORT TO PUSH OUT.

8. REPEAT STEPS 4-7 ON THE OTHER HEADLAMP.

9. TURN THE HEADLAMP SWITCH TO THE "OFF" POSITION (HEADLAMP DOORS WILL CLOSE).

10. CLOSE ENGINE COMPARTMENT HOOD.

PARTS INFORMATION:

PKG. QTY. NEEDED PER P/N DESCRIPTION SIZE QTY. VEHICLE ======== ============= ================ ==== =============== 10417504 PLUG 54 MM (2 1/8 IN) 2 2 (1 PER HEADLAMP

10297460 BEZEL (PLUG) 24 MM (15/16 IN) 10 2 (1 PER HEADLAMP)

PARTS ARE CURRENTLY AVAILABLE FROM GMSPO.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION LABOR OPERATION NUMBER DESCRIPTION TIME ================ =========================== ===============

B7270 PLUG, HEADLAMP AIMING SCREW 0.2 HR REPLACE ONE OR BOTH

FIGURES: 01

ATTACHMENTS: 00

FIGURE 1 - LEFT HEADLAMP BEZEL SHOWN (RIGHT SIDE OPPOSITE) 1. 24 MM (15/16 IN) DIAMETER HOLE 2. 54 MM (2 1/8 IN) DIAMETER HOLE 3. PLUG WHEN PROPERLY INSTALLED IN BEZEL HOLE

Object Number: 336478 Size: FS

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.