[size=200]HID Fitment Guide[/size]

[size=150]Parts:[/size]
Headlamps
HID Kit
Cable ties

[size=150]Tools:[/size]
Drill and 12mm bit
Snippers
10mm socket
PVC Tape

[size=150]Removing Headlamps[/size]
There are 3 bolts holding each headlamp into the car. One on the top, two on the front – one of the front ones is hidden near the wing. See here:
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image1.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image1.jpg[/img][/url]

Remove these bolts with your 10mm socket. Once these are removed, disconnect the headlamp from behind. You need to disconnect both the beams and the adjustment wiring. Here are the connectors you need to unplug
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image2.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image2.jpg[/img][/url]

Once your headlamps are disconnected, you can remove them from the car. They’re a snug fit, so the easiest way is to push them out diagonally, away from the centre of the car. See the following images
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=100_5782.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_100_5782.jpg[/img][/url] [url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=100_5783.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_100_5783.jpg[/img][/url] [url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=100_5787.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_100_5787.jpg[/img][/url]

[size=150]Removing the standard bulbs[/size]
This part is pretty straight forward really, but here’s an explanation anyway.

Remove the plastic cap on the back of the headlight by twisting it anti clockwise
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image3.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image3.jpg[/img][/url]
With the cover removed, you can disconnect and unclip the standard filament bulb. Simply disconnect the wiring from the bulb, then unclip the clips circled in yellow, the bulb will come out.
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image4.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image4.jpg[/img][/url]
Take note of the shape of the bulb hole. There are two notches, which are different shapes. These correspond with notches on the bulb. The bulb will only fit in one way, so be sure to get this correct rather than trying to force it in!

[size=150]Modifying the plastic cap [/size]
You will need to pass an extra 4 wires through the plastic cap, so you need to make room to do so. The easiest way I found is to drill an extra 12mm hole in the back of the cap for the existing wiring, then enlarge the existing hole either with a larger drill bit (16mm) or some wire cutters. I didn’t have a larger drill bit, so I used wire cutters.

Pull the existing wiring and the gromit out of the original hole. Take the plastic cap, and drill a 12mm hole into the back as pictured. Note the trust that _stuz_ has in me! Oh and that tobacco tin in the background has tobacco in it, nothing else!
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image5.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image5.jpg[/img][/url]
Next you need to enlarge the existing hole. There’s not much to explain really, just make the hole bigger with anything you can! Here is the gromit we’re proposing to fit into the hole!
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image6.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image6.jpg[/img][/url]
Once you’re done, push the HID gromit into the hole, ensuring the bulb is on the inside of the cap. It sounds obvious, but I’ve done it the wrong way around before!
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image7.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image7.jpg[/img][/url]

You should end up with this. The hole doesn’t need to be particularly neat, as it’s hidden and sealed by the gromit anyway. Next, you need to push the old wiring through the new hole in the back. Make sure the bulb connectors are on the inside. Then connect the bulb connectors to the new HID spade connectors. Make sure black is connected to black, then red is connected to whatever other colour your HIDs come with (usually red or blue). Here is what you should end up with:
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image8.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image8.jpg[/img][/url]

[size=150]Fitting the new bulbs into the lens[/size]
As you can see in a few of the pictures, we’ve left the plastic container on the bulbs. This is important, as if you touch the bulb itself you can very easily damage it.

Remove the plastic container from the bulb, along with the plastic washers and such holding it in place. Then fit the bulb into the lens, the same way the old one was removed. If you find the wires are particularly short, and the cap is getting in the way, you can pull the wires through the gromit to give yourself some more room.
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image9.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image9.jpg[/img][/url]
Once the bulb is fitted, pull the bulb wiring back through the gromit, and do the same to the original wiring to ensure there is as little wire as possible inside the cap. Don’t pull it too tight obviously, you just don’t want too much wire inside the cap – it will make it more difficult to refit the cap. Refit the cap now by screwing it clockwise.
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image10.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image10.jpg[/img][/url]
Here is the result. You have the original wiring and connectors still – all you’ve changed is the connection to the bulb. Instead of going straight to the bulb, it will now to the ballast, then to the new HID bulb.

[size=150]Mounting the ballasts[/size]
Underneath where each light was in the car, should be a nice gap, perfect for hiding your ballasts. Most HID kits come with brackets and such to attach them to the car – use these if you can, or if not, cable ties will do the job nicely. I prefer to fit the ballasts in these gaps behind the bumper, as it means you can’t see them when you open the bonnet.
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image11.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image11.jpg[/img][/url]
As you can see, I just cable tied them into place. Nothing wrong with doing that, they’re not going anywhere Your ballasts may not have 2 boxes like these - if they do have 2, only clamp the main one like I have – clamping the other one gives you less wire to work with!

[size=150]Refitting the headlamps[/size]
Ok now you can put your headlights back in. It’s pretty much just the reverse of the removal process, only you need to connect up the ballasts too. There’s really no way you can go wrong here, as each connector will only fit into its partner in one direction – if it’s not clicking into place, it’s the wrong way around. You have the larger connector which obviously connects to the larger connector of the ballast. You also have the two smaller connectors, which connect to the two smaller connectors coming from the ballast. Push the headlamp unit back into the car, and connect up the standard beam and adjustment connectors. Go ahead and test your new lights before bolting them in (if you have a problem, it saves unbolting them again!) If all is well, go ahead and bolt the lights back into place, and marvel at your lovely bright headlights
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image12.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image12.jpg[/img][/url]
Well done, you’ve just fitted your HIDs. I strongly recommend you pop to a garage and get them to adjust the beam patterns for you, as you will probably find yourself blinding everyone. Or you can do this yourself, using the adjustment screw on the back of the headlamp. This is a separate process, I may write up a guide at some point. I also recommend you fit LEDs into the sidelights, as it will bug you having lovely white headlights, and yellowy sidelights!
Now have yourself a huge cup of tea and a sit down!
[url=http://s764.photobucket.com/albums/xx287/hughiew/hid%20guide/?action=view&current=image13.jpg][img]http://i764.photobucket.com/albums/xx287/hughiew/hid%20guide/th_image13.jpg[/img][/url]

Good job and well done!
I must do it myself next time.
thanks for your sharing!

Thank you very much, i hope i can undo my HID-botch and install the new ones with this guide.
Great work

Awesome guide shugs, love the silly photos in it too

What a cup of tea that was too

was an immense cup of tea, both in quality and quantity

Great guide fellas. Used it to fit mine today, and made it soo much easier!

Nice one

Good stuff Mark

Okay, did my install today to replace my old HID setup, replacing the large old style gen 1 kit with one of the newer slimline kits like Hughie has above, took some pics and did it differently so I thought it worth posting as a) a replacement of full kit guide and b) a different ballast mounting solution..... Here goes... oh yeah, nearly forgot, this took about an hour and a half to do including thinking time and 2 smokes and I was done for the start of the Abu Dhabi F1 GP, just

P.S. Hughie, aplols for hijacking your guide chap, but I thought this the best place for this

Okay, here we go then...

Firstly, the obligotary comparision shot, drivers side, Halfords All Weather 30% Brighter H3 Halogen bulb vs. 4300K 35w H3 HID with origional large ballast.

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130001copy.jpg[/img]

Here's the equipment I used not including the cable ties I used...

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130017copy.jpg[/img]

Since I've had the new 4300K bulb and the temp halogen in, i've done about 300 miles mostly in the dark, to be honest, this halogen is a replacement for the first which went pop after an hour, I might as well have not bothered because the one 4300K HID b*tch slapped it into nothingness

Okay, so, these are the ballasts I'm replacing, brought for me as a pressy about 4 years ago by M1tch, thanks chap As you can see, they're quite bulky compared to the more modern kits with the separate transformer.

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130003copy.jpg[/img]
[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130002copy.jpg[/img]

They're mounted to the loom covers over the headlamps because of that bulk and becasue I was working away in Tunbridge Wells at the time and didn't have the time or facilities for a proper job, however, they've done pretty well there and I'm only replacing them because of this....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130004copy.jpg[/img]

Basically whats happened here is the big thick high voltage wire on my old driver side ballast has come loose from where it was wedged down the side of the light and come into contact with the power steering pully or belt, resulting in a nice snack for the belt and £50 worth of replacement cost for me (thought the bulb had blown and ordered replacements bofore I realised what had really happened, still I now have a spare set of both 4300K and 6000K bulbs and a spare ballast )

Moving on, time to get the replacement done so, off with the old ballasts and out with the lights...

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130005copy.jpg[/img]

The only reason this pic is here really is to show off my natty headlamp fasteners, I think Hughie covered the removal process above quite adequatly Drivers side first then....

Undo the black block connector (headlamp leveller motor) and grey block connector (headlamp power) and remove the lamp, there are no other connections on this side because I'm using a temp halogen bulb, but you can see where I've modified the back of the plastic cup that covers the bulbs, covered with a bit of gaffer till today...

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130006copy.jpg[/img]

Okay, light out and on the ground, plastic cup twisted off, time to remove the halogen, wearing disposable gloves so as not to mark the bulb, which i've put in a sealed little baggy in case I need it again You may as well wear your gloves for the whole operation so you don't mark or touch the HID bulbs when you fit them. You can see how I've drilled a hole in the back of the plastic cup, the original kit needed a 30mm hole but all the bulbs i've had since use a 25mm hole, seems to work okay though

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130007copy.jpg[/img]
[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130008copy.jpg[/img]

Here's the new ballast, about twice as small as my old ones with a seperate transformer, looks like less wire to play with too...

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130010copy.jpg[/img]

Time to offer them up to my proposed mounting site, flat underneath the headlamps on the top of the recess that holds the indicator side lamp units...

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130009copy.jpg[/img]

Looks good, so time to mount the bulb and offer it up to see if it will all connect up okay

Push the bulb and the positive and negative wire through the hole in the plastic cup, then push inthe grommet making sure its a nice tight fit....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130012copy.jpg[/img]
[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130013copy.jpg[/img]

Twist the grommet around until all the wires in the cup are sitting nice and can be connected up without twisting or pinching them, make sure you connect red spade to red spade and black spade to black spade...

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130014copy.jpg[/img]

Then gently press the wires back into the cup and fit the bulb, make sure its the right way up, rectangular recess to the top and semi circular to the bottom and check the wire clamp is on tight and hasn't knocked the bulb out of true....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130015copy.jpg[/img]

Cap back on and its ready to offer up to see if it all connects poperly without pinching or stretching any of the cables...

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130016copy.jpg[/img]
[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130020copy.jpg[/img]

Which it seems to do quite nicely, so headlamp back out and clean the moutning point surface with a baby wipe then dry with a bit of tissue Same for the back of the new ballast too! I was going to screw the ballasts down with stainless self tappers but the ones I bought from Hellfrauds were to big to go in the holes (fail) so I decided to use double sided numberplate tape instead, this is the stuff we use for fitting wind delfectors so I know it will do the job Put two strips across the back, not only will this stick well but will also help keep the ballast isolated from vibration

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130018copy.jpg[/img]

Peel off the backing strip and press firmly in place....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130019copy.jpg[/img]

To keep the longer black wire from dropping down the hole while fitting and to keep it nicley in place, I've used a small cable tie to attach it firmly, but not so tight as to pinch the wire, to the bracket for the power steering coolant pipes...

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130021copy.jpg[/img]

Headlamp back in again and everything connects up nice and neatly with no wires anywhere near the power steering pully ....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130022copy.jpg[/img]

Quick test to see if it all works....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130023copy.jpg[/img]

Et viola, HID lighting restored to the drivers side One little thing, the red wire from the ballast tended to ride up over the corner of the metal where the bumper bolts to the chassis, easily solved by holding it to one side with a flat bladed screwdriver while I slid the lamp in place

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130025copy.jpg[/img]

So. the passenger side, this is the existing bulb (4300K) and old ballast....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130024copy.jpg[/img]

Removal and mounting are exactly the same for the passenger side so here's a pic of the new ballast in place....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130031copy.jpg[/img]

The only difference being I've cable tied the transformer wire to the existing loom for support and although you can't see it in the above pic (it was 5 minutes to GP start ), I had to cable tie the red cable to the black cable because no matterhow I tried I could not get the red cable to stay in place when I was sliding the lamp back in.

And so, both new ballasts and bulbs fitted in a hour and a half Here's the results....

[img]http://img.photobucket.com/albums/v244/andym323/HID%20H3%20Guide/PB130032copy.jpg[/img]

On thing I will say, in reading the comically translated Chinese instructions, it says there maybe some bulb flicker or colour change if the battery isn't high enough Ah rated and suggests upgrading to a 70Ah battery. When i first switched the drivers side light on to test it, it seemed to go up to temp and give a greeny white light but after a few seconds it dimmed to a yellow colour then came back again The passenger side doesn't seem to do it, so we'll see how it goes I'm already impressed with the silent start up with these ballasts, no whining once running unlike the old ones either

The flickering thing is true - in my 1.5, the battery is a bit crap (think a dodgy cell) and when it gets cold, the voltage dips too low and the HIDs go mental, strobe comes to mind. Once the engine is running though its all good.

My slim ballasts make a buzzing noise? Loudest when you first turn them on but mostly gone when they've warmed up, can only hear it with the bonnet open really though even after just turning them on so I've never really noticed other than when fitting/tinkering.

Glad its not just me then, thing is, my origional ballasts were fine, ok they buzed on start up quite loudly, but they never flickered Wonder if its the new ballasts that are at fault, had a tinker with the wiring tonight, didn't make any difference, still flickering and gong yellow then back to white Not best pleased I can tell you

The step by step process is very easy to understand.Thanx for share me this nice detail.[url=http://www.cabletiesandmore.com/cordcovers.php]cord covers[/url]

Used this today, extremely helpful, thanks!

Great guide, just used it, just found some number plate tape so think I'll be going back out to move ballasts!

Just a few quick questions, if i go out tomorrow and attempt to fit my hid kit as i am just fitting a kit already wired up....

1. do i have to remove the headlight? (then it should be set for the correct beam pattern once finished?)
2. does it matter exactly where the ballast is secured?
3. this is a second hand kit that should be plug and play, but if i dont like the light output, are the hid bulbs generic
or do i need specific bulbs for my set?

1. It's much easier if you do remove the headlights, lots more room to work with and it's only 3 bolts
2. Not really, just bolt it to metal so it grounds out
3. The bulbs determine the colour output so you can switch to other bulbs, they should be the same fitment normally just be careful of wattage (not sure it actually matters with bulbs but it does with ballasts)

cheer huggles