Suggested Installation Instructions for Headlights 303-016, 303-091, 303-101
NOTE: For ease of installation, please review these instructions carefully before you begin the 3 Chamber Sport Headlight System
installation, which will take the better part of a day for a novice.
Note: Due to the many differences and modifications over the years, some instructions may vary from your particular application.
Tools Required:
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Phillips Head Screwdriver
Flat Blade Screwdrivers (one regular size, one small)
Wire Stripers/Crimpers
Power Drill, Small Drill Bit
Needle Nose Pliers
8mm Wrench/Socket
13mm Wrench/Socket
Circuit Tester Light
Preparing Your New Headlights For Installation:
Caution 1: Do not touch the glass with your fingers, as the oils from your skin
can shorten the bulb’s life expectancy.
Caution 2: Manufacturer recommends use of the following bulb wattages:
H4, 12V 60/55W and H3, 12V 55W. Installing more powerful bulbs may
melt your plastic housing and will void your warranty.
Installing Your Bulbs:
1. Remove the small bulb holder from the upper area of the lamp assembly,
taking care not to break off the connector. Push the small bulb in the
socket and twist until it hooks at the bottom. Replace the bulb holder in the headlight body.
2. Remove the large rubber cap, clip and large plastic cap, covering the bulb socket. Three tabs are located on the larger H4 Bulb,
one of them being a bit wider that the other two. This wider tab must be pointing straight up at the LHD arrow on the body.
Securely replace hold down clip.
3. Place the H3 in the lower bulb socket, making sure the rounded slot is directed down and the square slot is
facing up.
4. Tighten the black ground wire in the assembly with a screwdriver.
5. Prepare the black rubber cap by using a sharp object to poke a hole for the black ground wire and the H3 bulb wire.
Next cut 3 little slots for the H4 bulb connectors. Now, press on the rubber cap.
6. Wiring the ground wire: Cut a 13" piece of the black wire, then strip 1/4" of insulation off each end. Crimp a small eyelet
connector on one end and a blue female spade connector on the other end. Push the female spade onto the outer connector
of the small bulb (#1501). Then, snip off the wire ground lead from the hole in the rubber cap. Connect these two wires with
a blue scotch connector.
7. Drill a small hole toward the upper front section of the headlight bucket for the ground wire. Attach the black ground wire from
the headlight assembly to this hole with one of the supplied screws.
IMPORTANT! Disconnect The Positive Cable From Your Battery before Proceeding with the installation!
1. Remove the screw that attaches the headlight rim to the car. Once the screw is out,
very carefully pry up from the bottom of the rim to loosen.
2. Remove screws from the headlight retainer, pull the retainer out and unplug your headlight.
This retainer will not be reinstalled so set it aside.
3. Choose one of following two options to run a length of each of the red wire and yellow wire through
the tube from the headlight bucket to the inside of the car.
Option One: Simply work the wires through however they fit.
Option Two: Cut the plug off about 2" from the connector and remove the rubber tube to make more room for the wires. Once
complete, use the provided butt connectors to reconnect the wires, then replace the tube back into the bucket and body.
The 3 original headlight wires and the red and yellow wires should now run from the headlight bucket into the
trunk area.
Hooking Up The Yellow Running Light Wire:
A. Remove the cover from the turn signal assembly on the fender.
B. Remove the two 8mm nuts that attach the assembly to the fender, found beneath the fender.
C. Feed the yellow wire from inside of the car, through the tube that runs to the turn signal assembly. If too difficult,
remove the tube from the body and try feeding the wire through, or cut the connectors from the wires at the assembly
to create even more working room.
D. Pull the yellow wire completely through the tube, then tighten the turn signal assembly back to the body using the two
8mm nuts.
E. Cut the yellow wire off to the proper length and strip 1/4" of insulation from the end. Take one of the small female
spade connectors and crimp it on. Push this connector on small terminal below the side marker light bulb.
Hooking Up The Fog Light Switch (May Be Mounted One Of Several Ways):
1. Once you have mounted the switch, run the red wire that came into the trunk area from the headlight assembly along
the main wire loom. Tape or wire-tie the red wire about every 8 inches.
2. Run the red wire to the inside of the vehicle by figuring the approximate length of wire needed to reach your switch,
and cutting the wire to these specs.
3. To run wires inside the vehicle, tape the red wire attached to the fog light, the piece of red wire you cut off and the
black wire tightly with electrical tape.
4. Find a wire loom that is entering into the inside of the vehicle and feed through.
5. Strip 1/4" of insulation from the end of each wire. Crimp on a blue female spade connector to the end of each wire.
6. On the back of the switch, terminals are marked: ground, power and accessory. Black wire goes to the ground terminal,
red wire from the fog light assembly goes to accessory terminal, the other red wire goes to the power terminal.
Hooking Up The Power & Ground Connections:
1. Ground Connection: Stretch the black wire down to the bolt, holding the gas tank down. Cut the wire and strip 1/4" of
insulation off, crimp on the large eyelet, place bolt through and tighten.
2. Power Connection: Take the fuse holder and crimp the piggyback female spade connector onto one end. Then take a blue
butt connector to the other end. Take the red wire that you hooked to the power terminal of the switch, cut it off and
strip off 1/4" of insulation. Crimp this end into the butt connector.
3. Next, find a hot terminal on the fuse box using a test light, remove the connector from this terminal, push on the
piggyback connector and then push on the original connector on the piggyback male spade.
Follow previous steps for other headlight
The only variation involves running the red wire from the fog lights over to the first wire that links the accessory side of
the switch. Take a blue scotch connector and connect the two red wires together. Now, position the fuse in the fuse
holder and attach your battery cable.
Test your lights (note: key may need to be on in order to function)
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