Directed Energy, Inc.

Transcription

1 Directed Energy, Inc. Congratulations on your purchase of the most innovative headlight system available for the C5 Corvette. Your new, low-opening headlights will give your Corvette an updated, European look while adding considerably brighter output. Installation is fairly straightforward and is completely reversible, should you choose to remove this lighting system in the future. Tools Required 10mm wrench, 10mm socket (preferably deep), 8mm wrench, Torx 15 driver, Torx 20 driver, small Phillips screwdriver Standard Parts Included 2 High & low beam fully-adjustable projector headlights mounted to aluminum frames 2 HID low beam light bulbs 2 HID ballasts 2 Headlight stop brackets (patent pending) 2 Stabilizing bars 1 Headlight harness 1 HID low beam resistor Instructions 1. You can remove the ancillary wires from the HID bulb harnesses. Carefully cut through the rubber grommet to remove the red and black spaded wires that terminate in a male weather tight connector (Fig. A). These wires aren t needed, but you can save them for future projects. 2. Replace the bulbs with the HID bulbs supplied. Make sure the bulbs are properly seated and snugly clipped in. 3. Open your Corvette s hood. 4. Disconnect the negative (black) cable from your battery. Remove black & red wires Fig. A

2 5. Remove the two screws at the back of the headlight cover using a Torx 15 driver (Fig. B). 6. Starting on the driver s (left) side, raise the headlight unit by turning the knob on the back (Fig. C). Later models may have a rubber boot over the knob - remove this to access the knob. Fig. B 7. Remove the three screws that retain the headlight bezel to the headlight cover using a Torx 15 driver. Pull the bezel forward and downward to remove it. 8. Remove the remaining two screws that are holding the headlight cover on, one on each side, using a Torx 15 driver. 9. Remove the two pivot pin nuts on the top of the headlight unit with a Torx 20 driver and an 8mm wrench (Fig. D). While supporting the headlight unit with your hand from underneath, remove the two pivot pin bolts. You may need to relieve pressure slightly on the headlight unit by lowering it via the headlight knob. Be careful not to lose the plastic pivot pin bushings that are on the pivot pin bolts. Gently lower the headlight unit while turning it down to reveal the back side. 10. Remove the pivot pin retaining clip and slide the pivot pin out, freeing the headlight unit (Fig. E). 11. Disconnect the low and high beam connectors and remove the headlight unit from the car. Fig. C Fig. D Fig. E 12. On a workbench or convenient table area, make sure that the horizontal and vertical adjusting screws work smoothly, as these are necessary in order for proper alignment of your new projector headlights. Use a Torx 20 driver inserted into the end of the adjust-

3 ing screws to check for proper movement. If these adjusting screws fail to move the headlights in either direction, they must be disassembled and lubricated. 13. Remove the four bolts that hold the headlights to the frame, using a 10mm socket wrench. Remove stock headlight units from the frame. Fig. F Horizontal alignment knob Vertical alignment knob 14. Place projector assembly on frame and attach to the same holes using a 10mm socket and 10mm wrench. 15. Remove backing tape on the included stabilizer bars and place them on the headlight frame approximately 1.25 from the trailing edge of the waffle (Fig. G). 1-1/4" 16. Back at the car, remove the two headlight motor mounting screws and the one swing arm retaining nut (Fig. H, yellow arrows). The front screw and middle nut require a 10mm socket or wrench while the back nut requires a 10mm wrench and socket or two 10mm wrenches. Remove the swing arm. Remove the lower stop cushion (Fig. H, red arrow). Fig. G 17. Place the included stop bracket in position and replace the front screw and rear nut (Fig. I). The rear hole on the stop bracket is enlarged to allow for up/down adjustment of the headlight opening, so position the rear of the bracket about halfway through its travel path. Tighten moderately as these will be adjusted later. Fig. H 18. Replace the swing arm without its retaining nut. Rotate the manual headlight-raising knob full cycle, causing the swing arm to travel its full path. Note that there is adequate clearance of the swing arm ear and that it does not rub on the mounting bracket. On early model C5s the supplied bracket may not fit flush against the wall due to the rear mount- Fig. I

4 ing bolt not being in the same plane as the front one. If this is the case and you see that the ear is contacting the bracket, you will need to bend the swing arm s ear out slightly in order to clear the bracket. Repeat this step until the ear travels smoothly, only stopping at the rear stop (up position) and the front stop (closed position). Replace the swing arm retaining nut and tighten with fingers only. 19. Replace the headlight assembly by inserting it into the headlight cavity, lenses facing down with one hand underneath to steady it, and sliding the pivot pin into position and through the swing arm. A towel placed in the bottom of the headlight cavity will ensure that the lenses don t get scratched. Don t install the pin retaining clip at this point (Fig. E). 20. Swing the headlight assembly up into position and reinsert the two pivot pins from Fig. D, but don t replace the pivot pin retaining nuts at this point. 21. With the hood up, replace the headlight cover and insure that it sits flatly on the headlight assembly. Rotate the headlight knob (Fig. C) so that the headlight is in its full open position. 22. Measure the opening on each side of the headlight at the point where the bumper meets the fender on the outside, and where the bumper meets the hood on the inside. You are looking for approximately 3-1/2" on the inside and 2-3/8" on the outside. At this point, cutting out a couple of cardboard measuring sticks (Fig. K) at these sizes will help in making adjustments quicker. ~3-1/2" Fig. K ~2-3/8" 24. If your measurements are within 3/16" of these, then you re almost done with this side. Proceed to Step # Your measurements are off by more than 3/16", so adjustments to the stop bracket should be made. Remove the headlight cover and headlight assembly (Steps # 9-11). Loosen the two stop bracket mounting screws (Fig. I) and move the back of the stop bracket up or down a slight amount. If your measurements are less than those shown in Fig. K, move the back of the stop bracket down slightly. This will allow the headlight to come up further. A small change here will yield a greater difference of the headlight opening amount. Conversely, if your measurements are more than in Fig. K, moving the back of the stop bracket up will decrease the headlight opening amount. 27. Repeat Steps #19 through # Remove the headlight cover and headlight assembly completely.

5 29. Tighten up the stop bracket mounting screws and the swing arm pivot nut (Fig. I) 30. In the headlight cavity, locate a spot in which to fasten your ballast. It can be placed anywhere as long as it doesn t interfere with the operation of the headlight assembly and its wires can still be connected to the headlights. You can use the included screws (drilling required) or 3M double-sided tape. If using tape, thoroughly clean the mounting surfaces, Fig. L including the ballast and resistor. Also wipe the mounting areas with rubbing (isopropyl or ethyl) alcohol to remove any residue. Fig. L shows the ballast mounted to the frame rail and back of the headlight cavity with 3M doublesided tape. If you are now working on the passenger side lights (you ve already done the driver s side), skip to Step # Mount the resistor in the headlight cavity where convenient, allowing its male connector to connect to the driver s side ballast. Refer to Fig. M for the electrical connections. 32. Connect the male connector on the resistor to the female connector on the driver s side ballast. 33. Place the long wiring harness along the passenger side inner fender well, with the red power lead in the vicinity of the fuse box. Route the harness along the top of the passenger frame rail, across the front just behind the bumper, with the long single-connector ending up in the driver s side headlight cavity. The two equal-length connectors (1 male & 1 female) should align along the right side of the passenger side headlight. Don t worry yet about making these connections. 34. Connect the driver s side end of the harness to the resistor. 35. Replace the headlight assembly by inserting it into the headlight cavity, lenses facing down with one hand underneath to steady it, and sliding the pivot pin into position and through the swing arm. A towel placed in the bottom of the headlight cavity will ensure that the lenses don t get scratched. Replace the pivot pin retaining clip. 36. The electrical connections are made by mating up the two small male and female connectors from the ballast to the low beam projector. The stock high beam connector (green and black wires) is plugged into the high beam projector. The stock low beam connector is not used for this installation and can be taped up to prevent moisture from causing corrosion. 37. Swing the headlight assembly up into position and reinsert the two pivot pins from Fig. D. Replace the pivot pin retaining nuts. It is advised to use a drop of thread locker on these nuts.

6 38. Lower the headlight assembly completely using the knob (Fig. C). 39. Repeat Steps #5 through #30 for the passenger side headlight assembly. For step #22, reuse your measuring sticks to insure that both sides are equal in opening amount. 40. Replace the headlight assembly by inserting it into the headlight cavity, lenses facing down with one hand underneath to steady it, and sliding the pivot pin into position and through the swing arm. A towel placed in the bottom of the headlight cavity will ensure that the lenses don t get scratched. Replace the pivot pin retaining clip 41. Join the male connector on the harness to the female connector on the ballast. Join the female connector on the harness to the stock male connector which originally went to the stock low beam. Mate up the two small male and female connectors from the ballast to the low beam projector. Join the stock high beam connector (green and black wires) to the high beam projector. 42. Swing the headlight assembly up into position and reinsert the two pivot pins from Fig. D. Replace the pivot pin retaining nuts. It is advised to use a drop of thread locker on these nuts. R B Re B Brown & Black lo-beam wires Green & Black hi-beam wires Brown & Black lo-beam wires Negative Ground Positive Terminal low hi hi low Passenger Driver 43. Lower the headlight assembly completely using the knob (Fig. C). 44. Remove the three retaining nuts on the radiator overflow tank (two on top and one underneath towards the rear). Swing the tank upwards and prop it up in order to feed the harness underneath it. 45. The relay in the wiring harness will fit in the cavity provided by the shock absorber s upper mounting point. Run the harness so as Fig. M Stock wiring Female connector Male connector Ballast Resistor Relay B R Re

7 to end up near the battery compartment wall s right forward corner. 46. Lower the radiator overflow tank back into position, secure with its three retaining nuts. 47. Loosen the battery compartment wall retaining pin by prying it out with a small screwdriver (Fig. N). Loosen the battery compartment wall by pulling it slightly to the left. A gap should appear at the upper right corner of the battery compartment. Fig. N 48. Feed the positive lead and fuse holder through the gap from underneath and route the lead along the inside right of the compartment wall. 49. Remove the cover to the fuse box by turning the knob on top. 50. Remove the positive terminal nut on the lower left side of the fuse box and attach the harness positive lead to the terminal post (Fig. O). Replace the terminal nut. Replace the fuse box cover. 51. Refasten the battery compartment wall by pressing the retaining pin back in. The harness yellow fuse box will be nestled in between the fuse box and the battery compartment wall. Fig. O 52. Remove the negative ground retaining nut on the frame rail located at the foot of the hood prop (Fig. P). 53. Inspect the contact areas here to make sure there is a very solid grounding connection. Clean if necessary. Place the harness ground terminal loop over the frame s ground stud and replace the retaining nut securely. 54. Reattach the negative ground to the battery. Fig. P

8 55. Close the hood. 56. Turn on the ignition while car is in Park/Neutral, and let car idle for at least 2 minutes. 57. Turn on the low beam headlights, two clicks forward on the end of the headlight stalk. Turn off headlights and then on again, making sure headlights open and close together smoothly. 58. With the low beams on, turn on the high beams (stalk pushed forward). Make sure both high beams come on. The low beams will go off at this time. 59. Turn off high beams (pull stalk back to center position). Turn off low beams, but leave the lights up (one click back on the end of the stalk). Turn off the ignition. Fig. Q 60. Carefully place the headlight covers in position. 61. Lower the headlights by turning the end of the stalk back one more click. 62. Check for alignment of headlight covers in relation to the fenders, hood and bumper. If necessary, remove the covers and make small adjustments to the four leveling studs on the top of the headlight assembly. Once each cover sits flush with its surroundings, replace the cover, but do not install the headlight cover retaining screws (Fig. Q). 63. On the inboard side of one headlight pair, use a Torx 20 driver in the end of the stock vertical adjusting screw (the long one), move the headlight pair up/down. This will be a visual alignment with the goal to have a fairly equal gap between the headlight cover to top Fig. R of projectors and the bottom of projectors to the bumper. As a guide, place a flat piece of cardboard on your bumper so that it comes close to your high beam projector. The cardboard should intersect the projector housing at it lowest point (Fig. R). 64. Adjust the headlight pair left or right using the stock horizontal adjusting screw on the outboard side of the headlight pair. The goal here is to visually ensure that the lights are pointing directly forward, parallel to the direction of travel. 65. Repeat Steps #63 and #64 for the other headlight pair. At this point, your headlights should

9 look fairly centered within their openings, and look similar on each side. 66. Replace the headlight covers, securing them with their four (each cover) screws. Lower the headlights unless you re ready to aim them. Aiming your SUN GUNS This procedure should be performed at dusk or later, depending on available ambient light. Refer to Fig. S for a visual of the alignment setup. 67. Find a flat, level area with a vertical wall, with a distance of at least 50' from the wall. 68. Place a 10" piece of tape vertically on the wall with the bottom of the tape approximately 18" from the ground. 69. With a piece of tape, mark a line on the ground parallel to the wall at a distance of 25' from the wall, and in line with the tape on the wall. Place another piece of tape on the ground perpendicular to the first one so that it points directly at the tape on the wall. 70. Align your Corvette so that the front edge of your front bumper is above the 25' mark and as perpendicular to the wall as possible. To help in aligning your car, you can put a small piece of tape vertically in the center of your windshield and another in the center of your back window. By moving your car so as to align these two pieces of tape to the vertical tape on the wall (as viewed from behind your car), you will be assured of perfect alignment. 71. Measure the distance from the ground to the center of one of your low beam projectors (they should be the same, within a fraction of an inch). This will be referred to as V. As a Fig. S

10 reference, a stock C5 lowered all the way on stock bolts will have a V of approximately 24". An unmodified, stock C5 will have a V amount greater than this, while a slammed C5 will have a V of less than 24". 72. On the wall, put a 6" piece of tape horizontally, intersecting the vertical tape so that the point of intersection is at a distance of V from the ground. 73. On the wall, measure out 27" from the vertical piece of tape and put a second 6" piece of tape vertically on the wall such that its midpoint is approximately distance V from the ground. Repeat for the other side. Fig. T V 74. On one of these vertical pieces of tape, measure up from the ground the V amount and place a horizontal piece of tape 6" long. Repeat for the other side. You now have 3 crosses of tape on the wall indicating the center of your car and the centers of your low beam headlights, all at a distance V from the ground. 75. Turn on your headlights, low beam only. You will see a backwards Z-pattern projected on the wall for each light. 76. Cover one light with a towel or shield it from showing on the wall. NOTE: These lights become very HOT. Make sure your towel doesn t touch the light for any length of time! 77. Using a small Phillips screwdriver, adjust the three adjusting screws (Fig. T) that hold the low beam projector in place so that the lower horizontally projected line is approximately 2" below the V amount line on the wall. Although this amount can vary, it is a recommended starting point. 54" V Driver s High Beam Passenger s High Beam Centerline of car 54" V-2 Driver s Low Beam Passenger s Low Beam Fig. U

11 78. Using the same adjusting screws, horizontally adjust the point where the step up begins, 2" below the cross on the wall (Fig. U). 79. Repeat Steps #76 - #78 for the other low beam projector. 80. Turn on your high beams by pushing forward on your light stalk. Your low beams will turn off. Your halogen high beams will project a circular pattern on the wall for each light. 90. Again, cover one headlight. Using a small Phillips screwdriver, adjust the three adjusting screws that hold the high beam projector in place so that the center of the beam coincides with the center of the respective cross on the wall. Repeat for the other headlight. 91. Prior to installing the headlight shrouds, drive around various streets and in varying traffic conditions to see if you get flashed by oncoming cars. If all goes without incident, proceed to Step #92, otherwise lower your low beams another inch and try again. 92. Position your headlight shroud over the projector headlights and check for a uniform fit within each turtleneck. Fine adjustments can be made using the three screws holding each headlight. If the lights need to moved forward or back within the turtlenecks, adjust all three screws the same amount. 93. If any adjustments were made in Step #92, make sure that your lights are still properly aligned by checking against the wall markings. 94. Once all alignments have been made to your satisfaction, install the stock bezel retaining screws into the headlight shroud. Congratulations! You are now the proud owner of the latest in high performance lighting available for the C5 Corvette - Directed Energy s Sun Guns. For technical assistance, questions or concerns please call: Michael Bassett at or Mike Guyette at Directed Energy, Inc.