Headlight Relay Installation

Headlight relays shorten the length of the power supply wire to the lights. This results in less voltage drop to the headlights and therefore brighter lights. It also reduces the voltage through the instrument panel wire harness. The Headlight Relay kit from M.A.D. comes with all the necessary hardware. http://www.madelectrical.com/catalog/rly-1.shtml

The relays were installed next to the additional junction block on the driver side fender. See article on LS1 Fan Installation. http://www.angelfire.com/planet/74camaro/LS1_fan_install.htm Disconnect the battery. Move the fuel vapor canister and fender brace off to the side. Remove the headlight wires from the harness casing along the driver side fender. Build 2 relay harnesses using the wire, connectors, fuseable link, and shrink tubing supplied in the kit. For all connections crip first, then solder. (Don't forget to put the shrink tube on before you put both end clips on.)
On each harness, use about 4" of wire for the connection to the splice at the switch side of the relay (yellow) and about 4" for the 12V source (red). Then add the fuseable link (blue) to the 12v wire. The ground wire (black) can be left about a foot long so it can be attached to a good ground source on the radiator support. Snap the wires into the relay socket according to the kit instructions. The last wire will come from the headlight socket. (For this car it's the tan wire for low beams and green wire for high beams.)
	Schematics for relay connections of high and low beams.
Cut the feed wires from the instrument panel (headlight switch and dimmer switch). Cut about 6" before the relay switches. Cut them about an inch apart from each other so the connections you make on each wire are not in the same place along the harness. This location is also before the wire splits for left and right headlight. You'll need to add about 6" of wire between the cut and the relay. Do this on the switch side of the relay. Slide the (4) shrink tubes down both sides of the wires you cut. Connect the socket harnesses to the switch side wires you cut using butt connectors. Slide the shrink tube into place and heat. Here the yellow wires are wrapped in green and tan electrical tape just to keep the wiring color consistent.
Put the female spade connectors on the ends that go into the relay socket. Slide the shrink tube into place and heat.
Test fit the relay sockets onto the plugs so you can determine the neatest routing for the ground and headlight wires (headlight side of the relay). Remove the sockets from the relays and snap the headlight wires into the respective relay sockets.
Connect the RED 12v wire to the 12v source (here an added junction block on the driver side fender was used). Connect the BLACK ground wire to a good ground source on the radiator support using a little dielectric grease. Plug in the relays.
Connect the battery. Test the low beams and high beams. Put the wires back in the harness casing and re-attach to the fender. Label the relays.		Here are the relays all wired, cased, and clipped.