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Disconnect battery before installing:

This installation is MUCH easier with the hood off the car. The installation is done with the headlight assemblies in the car, however some photos were taken of a disassembled headlight assembly for clarity. Both headlight sides install in the same way but the supplied front billet brackets are side specific and marked “P” for passenger side and “D” for driver side. The supplied rear brackets, electric actuators and electronic control boxes are identical for each side.

Remove the vacuum hoses from the vacuum actuators. Make sure you plug these hoses to prevent poor engine performance from the resulting vacuum leak.

Remove the body colored headlight surround covering (held with four screws). Remove the outer headlight bulb and bulb bucket. Your headlight housing should now look like this:

Remove the 3/4 “stubby shoulder bolt which connects the vacuum linkage to the headlight assembly. This bolt will be reused later (without its plastic bushing).

Remove all vacuum linkage components (see following picture) including:
--Four vacuum linkage springs (be extra careful not to scratch you paint from slipping pliers when removing these).
--Two spring perches (held in place with cotter pins).
--Vacuum actuator (held in place with four ½” nuts).
--Double humped stamped steel bracket (held in place with three short 1/2 “ bolts).

Drill a hole EXACTLY as marked in the next picture using a 3/16” drill bit. The center of this hole must be ¼” in from the edge and 1-7/16” down from the top of the headlight door. Drill straight through and make sure not to drill up, down or sideways.

Install the billet front bracket (driver or passenger side specific) reusing the ¾” stubby shoulder bolt (medium strength (blue) Loctite is recommended here). Notice that the 45 degree angled tab on the billet front bracket will be visible through the hole you just drilled. Drill again through the hole and through the front billet bracket tab (holding the billet bracket firmly against the headlight housing) and install the supplied 10-24 nut and screw through your drilled hole.

A slot must be cut in the in the headlight assembly where the vacuum actuator was mounted. Using a hack saw, cut-off wheel or narrow file cut the slot as shown below:

The rear billet bracket mounts to the four holes originally used to mount the vacuum actuator. Mount the billet rear bracket with the notch facing down using the four supplied 5/16 bolts and nuts.

Mount the electric actuator to the rear billet bracket and front bracket as shown below. Fine tuning of the door alignment in the closed position is done by un-screwing the actuator ram up to 5 full turns from screwed all in.

The control box must be installed on the shelf directly above the rear billet bracket and must be installed with the mounting tabs down. The control box can be attached using Velcro, 3M Car Accessory tape, silicone glue or epoxy. Connect the actuator/control box plug.

WARNING!:The battery MUST be disconnected before installing control boxes

WARNING!: Wires MUST be installed in the following order or damage may occur

Black wire - Is ground. Connect to any ground source (i.e. the headlamp housing).
Red wire - Is the power supply to the motor and must be connected to a permanent non-switched (always on) power source. Connecting directly to the battery or battery junction is recommended for the passenger side, while the horn relay works well for the driver side. The included 4 amp inline fuse must be used.
Yellow wire - Must be spliced to any low beam wire (tan wire on GM headlight plug).
White wire - Must be spliced to any high beam wire (green wire on GM headlight plug).

Re-connect the battery, install the headlamp assembly and enjoy your headlights.

Notes:

To leave the headlight doors in the open position (i.e. for cleaning or lamp change) turn the headlights on and disconnect the connector between headlight and connector, then turn headlight switch off.

Specifications

Disclaimer: Proper installation should provide years of trouble free use. However, Retro-Electro, LLC assume no liability for any accidents, injury, damage or misfortune resulting from the use of this product.