Removal and replacement of the tail light assembly on a 2023 Chevrolet Bolt EUV, including proper disconnect and reinstallation procedures.

Warnings

Tools required

Parts

• Tail light assembly × 1 — Use OEM specification
• Push-pin retainers (if damaged) × 3 — Use OEM specification

Preparation

1. Park vehicle on level surface and ensure power is OFF
2. Remove key fob from vehicle vicinity (at least 15 feet away)
3. Open rear liftgate to access tail light assembly from interior side

Procedure

1. 1

   Access interior trim panel
   From inside the cargo area, locate the interior trim panel on the side of the tail light requiring service. Carefully pull back or remove the rear cargo trim panel to expose the tail light assembly mounting nuts. On the Bolt EUV, this may require removing push-pin retainers along the panel edge.
2. 2

   Disconnect electrical connector
   Locate the tail light wiring harness connector behind the assembly. Press the release tab and pull the connector straight back to disconnect. Do not pull on wires. If connector is tight, gently wiggle while pulling to release.
3. 3

   Remove tail light mounting fasteners
   Using a 10mm socket with extension, remove the tail light mounting bolts securing the assembly to the body. There are typically 2-3 bolts accessible from the interior side. Keep track of any washers or spacers.
   Torque spec

   Tail Light Bolts8 Nm (6 lb-ft)
4. 4

   Remove tail light assembly from exterior
   Move to the exterior of the vehicle. Carefully pull the tail light assembly straight back away from the body. The assembly may have locating pins that fit into grommets in the body panel. Use gentle rocking motion if needed, but do not force. If resistance is felt, verify all fasteners have been removed.
5. 5

   Inspect mounting area and gasket
   Inspect the tail light mounting surface on the vehicle body for damage, corrosion, or debris. Clean the mounting surface with a shop towel. Inspect the tail light gasket or seal on the old assembly. If the new assembly does not include a gasket, transfer the old gasket if it is in good condition, or replace with new.
6. 6

   Install new tail light assembly
   Ensure gasket is properly seated on the new tail light assembly. From the exterior, align the tail light assembly with the mounting holes and locating pins. Carefully push the assembly into position, ensuring locating pins engage properly and the gasket seats evenly against the body.
7. 7

   Install mounting fasteners
   From the interior, thread the tail light mounting bolts by hand first to ensure proper alignment. Once all bolts are started, tighten them in a cross-pattern to 8.0 Nm (6.0 lb-ft) using a torque wrench. This ensures even pressure on the gasket and proper sealing.
   Torque spec

   Tail Light Bolts8 Nm (6 lb-ft)
8. 8

   Reconnect electrical connector
   Reconnect the tail light wiring harness connector, ensuring it clicks firmly into place. Gently tug on the connector to verify it is fully seated and locked.
9. 9

   Reinstall interior trim
   Reinstall the interior cargo trim panel, ensuring all push-pin retainers are properly seated. Replace any damaged retainers with new ones.

Reassembly

1. Verify tail light assembly is flush with body panel all around with no gaps
2. Ensure interior trim panel is fully secured with all clips engaged

Verification

• Power on the vehicle and test all tail light functions: running lights, brake lights, turn signals, and reverse lights
• Inspect exterior fitment to ensure uniform gaps around the tail light assembly
• Check for any light leakage around the gasket by observing the tail light in a dark environment with lights activated
• Verify no water intrusion after first car wash or rain event

More procedures for this vehicle