Well, I finally found out why the aim was messed up: the aiming ball joints were out of their sockets. Apparently Bill Jenkins' "inspection" was not as thorough as he implied. After some struggling, I got the joints back together on the passenger side, and now it aims perfectly. I haven't done this for the driver side yet because I have to remove the two filter boxes, and, as any PZEV owner who has done this can tell you, it's not a trivial task, since there are 8 bolts, many of which are in hard-to-access places.
Below are some pictures:
This picture shows the change I had to make to get the passenger side light housing to fit (well, I didn't take a picture of the original, but you get the point). Notice the two hoses are routed further back, and I cut the clamps that were holding them in place.
This picture shows the up/down internal hight adjustment ball socket before I fixed it.
Ditto for the left/right external adjustment.
I'm going to fix the driver side tomorrow. Then I can drive with the mach headlights
-- after 12+ hours of install time
. Hopefully the filter boxes will be easier to take off (and put back on) the second time around.
-David