Gen. 1 to Gen. 2 Headlight Swap (Page 2/3)
Cliff Pennock MAR 13, 02:34 PM
...continued


The Gen. 2 harnass I used only had one connector for the (left) horn. Apparantly the 88 harnass has the wire for the right horn missing while the 87 harnass does not. So I cut the wire for the right horn from the old harnass and spliced that into the left horn wire in the new harnass. So before routing the new harnass, check if you need to add this wire too.
Now route the new harnass, and connect all connectors and bulbs. Do not reconnect the main connector just yet! Use the plastic retainers to hold the harnass in place. Screw the actuator relay to the front end panel:


The Actuator Relay

Once the new harnass is routed, test fit the headlight assemblies and move the lights up and down by hand, checking if they can move freely without catching the harnass. If you are satisfied both headlights can move freely, bolt them back in place and attach the link assembly to the headlight assembly. If you want, you can connect the headlight motors and the main connector to test if the headlight motors are actually working.

Now put the hood back on and bolt the hinges through the headlight holes. To align the hood, simply move it around. When the hood is aligned, fasten the bolts. Bolt the hood support and headlight doors back in. Finally, reconnect the harnass' main connector. There, you have just finished the swap!

So did I miss anything? Or does anyone have any suggestions?

GODFATHER MAR 13, 03:51 PM
Nice write up Cliff . I just did the swap a couple of weeks ago . Not to many people mentioned about the bolts holding the motors were different sizes . I found out after I installed my motors and was running them threw manually and the arm off the motor hit the bolt . I tried to mount my module in the same location as you did but I thought that water would get into the module easier so I mounted it in the stock location . I like how quiet the new motors are also .
theogre MAR 13, 10:00 PM
Great Job. I haven't messed with the book thing.

One warning... on early models with the two speed radiator fan, you will either loose the two speed setup or have to mess with the wiring more to keep it.

Looks like 88 also used a differnt style fan relay... that's good. The older ones are fairly delicate and not really very weather resistant. (Another what in hell were they thinking item.)

If you mark the hood/hinge with a bit of paint or an obvious scribe line, you won't have to fart with hood adjustment much. Match up the marks will usually get it. (You can do the same with the HL lifts if need be. Usually you can line up the hardware with the marks it leaves on the lift.)

If you take the hinges off the body instead of the hood you won't need to mess with the headlight doors at all.

For reference... the spot you undid to flip the light up is the same spot I recomend people disconnect to make lamp changing allot easier.

Only the 88 harness might be short the one horn connector. Folks want to check the 88 harness as early ones could possibly have the missing horn plug tho it could be burried in the harness. (I think someone else recently used an 88 harness and said they found both plugs. Or at least they were told it was an 88 harness. An 87 harness will definitely have both horn plugs.)

This answered questions I had about how the front wiring works... The lighting harness is separate from the heater/AC wiring like the tail light harrness splits from the engine harness at C500. (C100 is one of the very few plugs I haven't had a reason to mess with yet.)

The plugs on the module are MetriPack weather resistant type. Besides potential clearance problems some folks mentioned... I'd have to worry about water there myself. The MetriPack stuff takes occasion drenching fairly well but the module will have allot of water and in winter snow and ice dumped on it there.

I don't know about if it will have clearance for the wires... but right next to the fan relay might work... It will still get plenty wet but that might cut down on stuff sitting on it and having a chance to soak in.

If it's not already... I'd recomend unplugging and giving everything some dielectric grease. Work out the back seals, assuming this is bog standard MertiPack with soft wire seals, and work a little grease into there and push the seals back in.

Why GM chose the location they did I couldn't say. It does keep allof of crap away and hides the module. Probably felt there was some sort of benifit durring assembly as well. I would have put it somewhere in the spare tire/storage area myself. There were several places in there they could have used for it.

As much as the OE location is a pain in the ass... The modules are pretty reliable and the odds you'd ever have to mess with it again are low.

Cliff Pennock MAR 14, 02:26 AM

quote
Originally posted by theogre:

One warning... on early models with the two speed radiator fan, you will either loose the two speed setup or have to mess with the wiring more to keep it.[quote]

I noticed my radiator fan actually had four wires, and they were spliced together as pairs. So I guess this is one of those two speed fans then?

[quote]Looks like 88 also used a differnt style fan relay... that's good. The older ones are fairly delicate and not really very weather resistant. (Another what in hell were they thinking item.)


Is what I call the "actuator relay" really the fan relay?


quote
If you mark the hood/hinge with a bit of paint or an obvious scribe line, you won't have to fart with hood adjustment much. Match up the marks will usually get it. (You can do the same with the HL lifts if need be. Usually you can line up the hardware with the marks it leaves on the lift.)

If you take the hinges off the body instead of the hood you won't need to mess with the headlight doors at all.


Yes, I took the bolts of the hood because my hood needed a little realigning anyway. Plus it's much easier to remove the hood when it's laying flat than when it's standing upright.


quote
For reference... the spot you undid to flip the light up is the same spot I recomend people disconnect to make lamp changing allot easier.

Only the 88 harness might be short the one horn connector. Folks want to check the 88 harness as early ones could possibly have the missing horn plug tho it could be burried in the harness. (I think someone else recently used an 88 harness and said they found both plugs. Or at least they were told it was an 88 harness. An 87 harness will definitely have both horn plugs.)


Ok, that's good to know.


quote
The plugs on the module are MetriPack weather resistant type. Besides potential clearance problems some folks mentioned... I'd have to worry about water there myself. The MetriPack stuff takes occasion drenching fairly well but the module will have allot of water and in winter snow and ice dumped on it there.

I don't know about if it will have clearance for the wires... but right next to the fan relay might work... It will still get plenty wet but that might cut down on stuff sitting on it and having a chance to soak in.


I looked at the module with the plugs plugged in and it looked pretty waterproof to me. I don't think there will be many problems with water there but I will mention it anyway.

ZeroC MAR 14, 04:27 AM
Best Thing I Ever Did To My Fiero ..Other Than Buy And Stroke The Motor lol ...

You Put Your Control Module In The Same Spot I Did Cliff ..Were Like Brothers Now lol jk ..Im Sleepy

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"This car is so good looking its almost indecent. - AutoWeek on the new 1986 GT"

Chilliwack Fieros
MSN Messanger tylercaddick@hotmail.com

Custom88 MAR 14, 10:56 PM
Doesn't that spot get a lot of water when it rains? Think there would be any problems with water getting into the module?

[This message has been edited by Custom88 (edited 03-14-2006).]

Cliff Pennock JUL 10, 10:55 AM

quote
Originally posted by Custom88:

Doesn't that spot get a lot of water when it rains? Think there would be any problems with water getting into the module?




After a few years, I can safely conclude no water gets there at all (oddly enough). Besides, the module should be waterproof.
Leukay JUL 26, 03:30 PM
Great guide! Picked up some motors and a harnass for super cheap at a junkyard ($35 all together). I wouldn't have had the courage to take on the swap without this guide, since I am still only learning. Thanks alot!

Lucas

[This message has been edited by Leukay (edited 08-01-2012).]

NetCam AUG 18, 02:21 PM
Isn't it great when you can find a 7 1/2 year old post and shows you exactly what you need to know? I was able to do my complete swap in a couple of hours!
GMann20 JUN 19, 05:05 PM
Need step by step to lock 1986 headlights in upright position Till I replace motors. Thanks in advance. You can also send them to garymann@hotmail.com
Thank you in advance.
Saving up for 87 88 conversions.

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G L Mann CHICAGO ILLINOIS