! Hella 90mm Headlamp Module Installation

Hella 90mm Lamp modules are designed for custom applications. The mounting system comprises of three adjuster screws with captive nuts. The nuts have a tri-lobular locking feature that engage the ears and lock in with a 30 degree rotation. The locking lug on the nut should snap between the detents on the ear of the lamp. This is often made easier by applying a small amount of petrolium jelly.

The ball on the end of the adjuster screw snaps into the black plastic Ball Socket. The Ball Sockets snap into either our mounting plate HL97300, or your mounting surface. If you are fabricating your own mounting surface, The holes for the Ball Sockets are 10mm diameter on a 120mm bolt circle.

The mounting surface material should be no thicker than .055 inches at the edge of the hole, or the barbs on the Ball Sockets will not be able to snap behind and the lamps will not be securely mounted. We recommend that the mounting plate be made of 18 gauge sheet metal although we have been told of installations where the mounting surface was made of thicker material and the holes chamfered so that the edge of the hole was of the proper thickness to engage the barbs.

Install the Ball Sockets into the mounting surface FIRST and THEN snap the ball end of the adjusting screw into the Ball Socket. The Ball Sockets have slots in them to allow them to collapse when being installed in the mounting plate. If you install the ball into the Ball Socket, the Ball Socket can not collapse and most likely you will shear the barbs off when it is inserted into the mounting surface.

If you need to remove the Ball Sockets from the mounting surface, remove the ball end of the adjuster screw from the Ball Socket FIRST and then remove the Ball Socket from the mounting surface. Try to avoid doing this as every time you snap the ball in and out of the ball socket, additional wear to the ball socket is created.

	Hella 90mm Headlamp Installation
Fleetwood, PA 19522, Voice 610-944-3233, Fax 610-944-3234, 866-480-2159 9AM-7PM, M-F Eastren Time mail.mosports@verizon.net, www.rallylights.com

Hella 90mm Headlamp Module Installation
Hella 90mm Lamp modules are designed for custom applications. The mounting system comprises of three adjuster screws with captive nuts. The nuts have a tri-lobular locking feature that engage the ears and lock in with a 30 degree rotation. The locking lug on the nut should snap between the detents on the ear of the lamp. This is often made easier by applying a small amount of petrolium jelly. The ball on the end of the adjuster screw snaps into the black plastic Ball Socket. The Ball Sockets snap into either our mounting plate HL97300, or your mounting surface. If you are fabricating your own mounting surface, The holes for the Ball Sockets are 10mm diameter on a 120mm bolt circle. The mounting surface material should be no thicker than .055 inches at the edge of the hole, or the barbs on the Ball Sockets will not be able to snap behind and the lamps will not be securely mounted. We recommend that the mounting plate be made of 18 gauge sheet metal although we have been told of installations where the mounting surface was made of thicker material and the holes chamfered so that the edge of the hole was of the proper thickness to engage the barbs. Install the Ball Sockets into the mounting surface FIRST and THEN snap the ball end of the adjusting screw into the Ball Socket. The Ball Sockets have slots in them to allow them to collapse when being installed in the mounting plate. If you install the ball into the Ball Socket, the Ball Socket can not collapse and most likely you will shear the barbs off when it is inserted into the mounting surface. If you need to remove the Ball Sockets from the mounting surface, remove the ball end of the adjuster screw from the Ball Socket FIRST and then remove the Ball Socket from the mounting surface. Try to avoid doing this as every time you snap the ball in and out of the ball socket, additional wear to the ball socket is created.

Assembly of H9 Connectors • Remove the gray inner housing from the black outer housing by releasing the two catches on the long side of the back of the connector. • Slip one of the silicone rubber seals on each wire, big end first. • Strip the end of each wire about 1/8” long. • Crimp the terminal onto each wire. Any standard crimping tool for non insulated connector will do the job. • Push each terminal into the round holes on the back of the plug. • Slide the silicone rubber seals down the wire and into the hole in the back of the plug to seal out moisture. • Push the blue plastic catch in to lock the terminals in place. • Snap the gray connector into the black housing. • Before assembling the plug to the bulb, you may wish to fill the female pins with dielectric grease to prevent moisture caused corrosion. Permatex manufactures a product that can be purchased in any good automotive parts store.