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

Removal Procedure

    Object Number: 777768 Size: SH
  1. Open the hood.
  2. Remove the headlamp motor/actuator knob cover.

    3. Object Number: 64657 Size: SH
  3. Remove the headlamp opening door rear retaining screws.

    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. Rotate the headlamp motor/actuator manual control knob counterclockwise to raise the headlamp.

    7. Object Number: 64654 Size: SH
  7. Remove the headlamp bezel. Refer to Headlamp Bezel Replacement .
  8. Remove the headlamp opening door side retaining screws.
  9. Remove the headlamp opening door from the headlamp.

Installation Procedure
  1. Position the headlamp opening door to the headlamp.

    2. Object Number: 64654 Size: SH

    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.

  2. Install the headlamp opening door side retaining screws.

    3. Tighten
    Tighten the screws to 2 N·m (18 lb in).

  3. Install the headlamp bezel. Refer to Headlamp Bezel Replacement .
  4. Rotate the headlamp motor/actuator manual control knob clockwise to lower the headlamp.

    5. Object Number: 64657 Size: SH

    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.

  5. Install the screws to the rear of the headlamp opening door.

    6. Tighten
    Tighten the screws to 2 N·m (18 lb in).

  6. Adjust the headlamp opeining door fit as necessary. Refer to Headlamp Opening Door Adjustment .

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