GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Corvette 🢒 Body and Accessories 🢒 Lighting Systems 🢒 Headlamp Replacement

Removal Procedure

    Object Number: 71195 Size: SH
  1. Remove the passenger side front floor kick up panel to access the IP electrical center.

    2. Object Number: 777763 Size: SH
  2. Remove the cover from the IP electrical center.

    3. Object Number: 777765 Size: SH
  3. Remove the HDLP Maxi circuit breaker #54, from the IP electrical center.
  4. Raise the hood.

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

    6. Object Number: 777768 Size: SH
  6. Remove the headlamp actuator knob cover.
  7. Raise the headlamp by turning the headlamp motor/actuator manual control knob counterclockwise.

    8. Object Number: 64648 Size: SH
  8. Remove the headlamp bezel. Refer to Headlamp Bezel Replacement .

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

  9. Apply tape to the fender and hood edge to protect the paint.
  10. Remove the front fascia lower closeout panel. Refer to Front Bumper Fascia Lower Close Out Panel Replacement in Bumpers.
  11. Remove the brake caliper cooling duct. Refer to Front Brake Caliper Cooling Duct Replacement in Bumpers.
  12. Disconnect the electrical connectors from the headlamp automatic control module, RH side only.

    13. Object Number: 64649 Size: SH

    Important: Before removing the fasteners, support the headlamp assembly.

  13. Remove the headlamp bracket to the frame rail bolts.

    14. Object Number: 64650 Size: SH

    Important: The headlamp assembly will have to clear the studs extending from the headlamp stud plate.

  14. Remove the headlamp bracket nuts from the headlamp stud plate.
  15. Lift the headlamp assembly out of the vehicle.
  16. Remove the headlamp intermediate bracket from the headlamp. Refer to Headlamp Intermediate Bracket Replacement .
  17. Remove the headlamp motor/actuator from the headlamp. Refer to Headlamp Motor/Actuator Replacement .
  18. Remove the headlamp capsule from the headlamp. Refer to Headlamp Capsule Replacement .

Installation Procedure
  1. Install the headlamp capsule to the headlamp. Refer to Headlamp Capsule Replacement .
  2. Install the headlamp motor/actuator to the headlamp. Refer to Headlamp Motor/Actuator Replacement .
  3. Install the headlamp intermediate bracket to the headlamp. Refer to Headlamp Intermediate Bracket Replacement .

    4. Object Number: 64650 Size: SH
  4. Position the headlamp assembly onto the studs extending from the headlamp stud plate.
  5. Loosely install the headlamp bracket to the headlamp stud plate nuts.

    6. Object Number: 64649 Size: SH
  6. Install the headlamp bracket to the frame rail bolts.

    7. 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.

  7. Beginning with the upper location, tighten the headlamp bracket to the frame rail bolts.

    8. Tighten
    Tighten the headlamp mounting bolts to 20 N·m (15 lb ft).

  8. Beginning with the upper inner location, tighten the headlamp to stud plate nuts.

    9. Tighten
    Tighten the headlamp mounting nuts to 10 N·m (89 lb in).


    Object Number: 64648 Size: SH
  9. Connect the electrical connectors to the headlamp automatic control module, RH side.
  10. Install the brake caliper cooling duct. Refer to Front Brake Caliper Cooling Duct Replacement in Bumpers.
  11. Install the front fascia lower closeout panel. Refer to Front Bumper Fascia Lower Close Out Panel Replacement in Bumpers.
  12. Install the headlamp bezel. Refer to Headlamp Bezel Replacement .

    13. Object Number: 64644 Size: SH
  13. Connect the headlamp wiring harness electrical connector to the forward lamp wiring harness.
  14. Rotate the headlamp motor/actuator manual control knob clockwise to lower the headlamp.

    15. Object Number: 777768 Size: SH
  15. Install the headlamp motor/actuator knob cover.
  16. Remove the protective tape installed during removal of the headlamp.
  17. Close the hood.

    18. Object Number: 777765 Size: SH
  18. Install the HDLP Maxi circuit breaker #54 into the IP electrical center.

    19. Object Number: 777763 Size: SH
  19. Install the cover to the IP electrical center.

    20. Object Number: 71195 Size: SH
  20. Install the floor kick up panel.
  21. Check the alignment of the headlamp opening door. Refer to Headlamp Opening Door Adjustment .
  22. Check and adjust headlamp aim as necessary. Refer to Headlamp Aiming .