GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Corvette 🢒 Body and Accessories 🢒 Lighting Systems 🢒 Headlamp Capsule Replacement

Removal Procedure

    Object Number: 777768 Size: SH
  1. Open the hood.
  2. Remove the headlamp motor/actuator knob cover.
  3. Rotate the headlamp motor/actuator manual control knob counterclockwise to raise the headlamp.

    4. Object Number: 64644 Size: SH
  4. Disconnect the headlamp wiring harness electrical connector from the forward lamp wiring harness.

    5. Notice: When removing body panels, apply tape to corners of panel and adjacent surfaces to help prevent paint damage.

  5. Apply tape to the area around the headlamp opening to protect the paint.

    6. Object Number: 64682 Size: SH
  6. Remove the headlamp bezel. Refer to Headlamp Bezel Replacement .

    7. Important: Support the headlamp capsule while removing the retaining screws.

  7. Remove the headlamp capsule retaining screws.
  8. Disconnect the headlamp bulb/socket electrical connectors.
  9. Remove the capsule from the headlamp pivot and adjusting bracket.

    10. Caution: Halogen bulbs contain gas under pressure. Handling a bulb improperly could cause it to shatter into flying glass fragments. To help avoid personal injury:

       • Turn off the lamp switch and allow the bulb to cool before changing the bulb.
       • Leave the lamp switch OFF until the bulb change is complete.
       • Always wear eye protection when changing a halogen bulb.
       • Handle the bulb only by its base. Avoid touching the glass.
       • Keep dirt and moisture off the bulb.
       • Properly dispose of the used bulb.
       • Keep halogen bulbs out of the reach of children.

  10. Remove the headlamp bulb/sockets from the capsule.

Installation Procedure

    Object Number: 64682 Size: SH
  1. Install the headlamp bulb/sockets to the headlamp capsule.
  2. Connect the headlamp bulb/socket electrical connectors.
  3. Position the headlamp capsule to the headlamp pivot and adjustment bracket.

    4. 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.

  4. Install the headlamp capsule retaining screws.

    5. Tighten
    Tighten the headlamp capsule retaining screws to 4 N·m (35 lb in).

  5. Install the headlamp bezel. Refer to Headlamp Bezel Replacement .

    6. Object Number: 64644 Size: SH
  6. Connect the headlamp wiring harness electrical connector to the forward lamp wiring harness.
  7. Remove any protective tape applied during the removal procedure.

    8. Object Number: 777768 Size: SH
  8. Rotate the headlamp motor/actuator manual control knob clockwise to lower the headlamp.
  9. Install the headlamp motor/actuator knob cover.
  10. Check and adjust the headlamp aimas necessary. Refer to Headlamp Aiming .
  11. Close the hood.