LED Headlight Module

Replace factory sealed-beam or halogen headlight assemblies with aftermarket LED headlight modules, including wiring adapter installation and headlight aiming verification.

Warnings

Tools required

Parts

• LED headlight module (driver side) × 1 — Aftermarket 7-inch round or match OEM mounting pattern
• LED headlight module (passenger side) × 1 — Aftermarket 7-inch round or match OEM mounting pattern
• H4 to factory headlight wiring adapter harness (pair) × 1 — Use with LED module kit if required
• Headlight mounting ring or retainer (if not included with LED kit) × 2 — Use OEM specification or kit-supplied

Preparation

1. Park vehicle on level surface and turn off ignition.
2. Allow headlight assemblies to cool completely if vehicle was recently operated.
3. Open hood and secure with prop rod.
4. Disconnect negative battery terminal to prevent short circuits during wiring work.
5. Mark current headlight aim position on wall or garage door 25 feet in front of vehicle using masking tape (optional but recommended for re-aiming reference).

Procedure

1. 1

   Access Headlight Assembly Fasteners
   Locate the headlight retaining ring or bezel at the front of each headlight assembly. The 1992 Viper uses fixed exposed rectangular composite headlamps mounted in the front fascia. Confirm the actual lamp shape and mounting method against the specific vehicle before proceeding, as the LED module must match the OEM housing/mounting pattern. Identify the retaining screws around the perimeter of the headlight bezel. Do not confuse these with the headlight aiming adjustment screws; on this vehicle the vertical and horizontal aim adjusters are typically accessed at the rear of the composite headlamp housing. Verify their location before beginning.
2. 2

   Remove Headlight Retaining Ring
   Using a flathead screwdriver or appropriate tool, remove the retaining ring screws that secure the headlight trim bezel. There are typically 3-4 screws around the perimeter. Set screws and retaining ring aside in a clean location. Do not disturb the headlight aiming adjustment screws at this time.
3. 3

   Extract Factory Headlight Unit
   Carefully pull the headlight assembly forward out of the headlight bucket. The composite halogen headlamp unit will still be connected by the wiring harness at the rear. Support the assembly with one hand while accessing the connector.
4. 4

   Disconnect Factory Headlight Connector
   Locate the wiring connector at the rear of the headlight assembly. Note the orientation and polarity markings on the connector (mark with tape if necessary for LED module installation reference). Depress any locking tabs and pull the connector straight back to disconnect. Remove the factory headlight assembly completely and set aside.
5. 5

   Inspect Headlight Bucket and Mounting Hardware
   Examine the headlight bucket interior for corrosion, debris, or damaged adjustment mechanisms. Clean any dirt or moisture from the bucket. Verify that the headlight aiming adjustment screws (vertical and horizontal) operate smoothly. Check that the factory wiring connector is in good condition with no corrosion on terminals.
6. 6

   Prepare LED Module Wiring Adapter
   If your LED headlight kit requires a wiring adapter harness, verify the factory bulb connector type (likely 9004/9007-style, not H4) and connect the matching adapter to the factory vehicle wiring harness now. Ensure the connection is secure and any locking tabs are fully engaged. If the LED module has a direct plug-in design matching the factory connector, proceed to next step. Apply dielectric grease to connector terminals if desired for corrosion protection.
7. 7

   Install LED Headlight Module
   Connect the LED module to the wiring harness or adapter. Verify correct polarity if module is polarity-sensitive (consult LED kit instructions). Carefully guide the LED module into the headlight bucket, ensuring wiring is not pinched or kinked. Align the module mounting tabs or adjustment points with the factory bucket adjustment mechanism. The module should sit flush against the bucket mounting surface.
8. 8

   Secure LED Module with Retaining Ring
   Position the headlight retaining ring or bezel over the LED module. Align the screw holes with the headlight bucket mounting points. Install and hand-tighten the retaining screws in a crossing pattern to ensure even pressure. Tighten screws securely but do not overtighten, as this can crack plastic bezels or distort the mounting ring. Final torque should be snug (finger-tight plus 1/4 turn).
9. 9

   Repeat for Second Headlight
   Perform steps 1 through 8 for the opposite side headlight assembly. Ensure both LED modules are installed with the same orientation and wiring configuration for consistent beam pattern.
10. 10

    Reconnect Battery and Test Operation
    Reconnect the negative battery terminal and tighten the clamp snugly (approximately 5-7 ft-lbs); do not overtighten. Turn ignition to ON position (do not start engine). Activate headlights and verify both LED modules illuminate. Check low beam and high beam operation. Verify turn signals and parking lights still function; on this vehicle these are typically separate fixtures from the headlamp. If modules flicker or do not illuminate, check polarity and adapter connections.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
11. 11

    Perform Headlight Aiming Adjustment
    With headlights on low beam, park vehicle 25 feet from a flat wall or garage door on level ground. Measure the height of the headlight center from ground and mark corresponding height on wall. Activate low beams and observe beam pattern. The top edge of the beam cutoff should be at or slightly below the marked height. Use the vertical and horizontal headlight aiming adjustment screws on each headlight bucket to adjust beam pattern. The horizontal aim should be slightly to the right of center to illuminate road edge without blinding oncoming drivers. Adjust both headlights to match beam pattern and aim.

Reassembly

1. Verify all headlight retaining ring screws are secure and bezel is properly seated.
2. Ensure no wiring is pinched or exposed outside the headlight bucket.
3. Close hood and verify headlight operation one final time before driving.

Verification

• Turn on headlights and verify both LED modules illuminate in low beam and high beam modes.
• Check that beam pattern has a clear horizontal cutoff on low beam setting without excessive scatter or glare.
• Verify headlight aim does not point upward into oncoming traffic or downward to reduce visibility.
• Confirm turn signals, parking lights, and any other lighting circuits remain functional.
• Test-drive vehicle at night and verify adequate road illumination and no dashboard warning lights related to lighting circuits.
• Have an assistant verify from outside that both headlights produce symmetric, properly aimed beam patterns.

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