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Home >> Saturn >> 2002 >> SC2 Automatic, MP6 >> Repair and Diagnosis >> External Pages >> Different car >> Section 139 (Lighting Systems) >> Repair Instructions >> Headlamp Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2003 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the passenger side front floor kick up panel to access the IP electrical center.
    Fig 1: Passenger Side Front Floor Kick Up Panel
    G01453281Courtesy of GENERAL MOTORS CORP.
  2. Remove the cover from the IP electrical center.
    Fig 2: Removing Cover From IP Electrical Center
    G01453282Courtesy of GENERAL MOTORS CORP.
  3. Remove the HDLP Maxi circuit breaker #54, from the IP electrical center.
  4. Raise the hood.
    Fig 3: Removing HDLP Maxi Circuit Breaker #54, From IP Electrical Center
    G01453283Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the headlamp wiring harness electrical connector from the forward lamp wiring harness.
    Fig 4: Disconnecting Headlamp Wiring Harness Electrical Connector
    G01453284Courtesy of GENERAL MOTORS CORP.
  6. Remove the headlamp actuator knob cover.
  7. Raise the headlamp by turning the headlamp motor/actuator manual control knob counterclockwise.
    Fig 5: Headlamp Actuator Knob Cover
    G01453285Courtesy of GENERAL MOTORS CORP.
  8. Remove the headlamp bezel. Refer to HEADLAMP BEZEL REPLACEMENT .
    NOTE: Refer to NOTICE - APPLY TAPE WHEN REMOVING BODY PANELS in Cautions and Notices.
  9. Apply tape to the fender and hood edge to protect the paint.
  10. Remove the front fascia lower closeout panel. Refer to CLOSE OUT PANEL - FRONT BUMPER FASCIA LOWER in Bumpers.
  11. Remove the brake caliper cooling duct. Refer to BRAKE CALIPER COOLING DUCT REPLACEMENT - FRONT in Bumpers.
  12. Disconnect the electrical connectors from the headlamp automatic control module, RH side only.
    Fig 6: Disconnecting Electrical Connectors From Headlamp Automatic Control Module
    G01453286Courtesy of GENERAL MOTORS CORP.

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

  13. Remove the headlamp bracket to the frame rail bolts.
    Fig 7: Removing Headlamp Bracket To Frame Rail Bolts
    G01453287Courtesy of GENERAL MOTORS CORP.

    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 .
    Fig 8: Removing Headlamp Bracket Nuts From Headlamp Stud Plate
    G01453288Courtesy of GENERAL MOTORS CORP.
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