How To... Fit A Xenon Conversion Kit

[Welshguy]

Report:

 

Xenon Conversion Kit

 

Fitting Time: 2 Hours

Tools: Couple of Screwdrivers and a Drill, nothing more.

Difficulty: Relatively painless, although having small hands & fingers is a bonus

 

Overview:

 

The kits arrived Wednesday morning, and my brother wasted no time in fitting his conversion kit to his Seat Ibiza, with impressive results – unfortunately due to the winter darkness my conversion was left to the Thursday morning.

 

Arrived at the parent’s house Thursday morning, and after a quick cup of tea my brother got underway. I have got to give him credit here – I had 3 or 4 layers on and was still freezing, while he worked away with just a jumper and no gloves! The car port gave us a little bit of protection against the rain, but I recommend not doing this job in bad weather!

 

Below is a picture of my lights as standard:

 

http://i24.photobucket.com/albums/c32/streettech/DSC02777.jpg

 

First thing was to inspect the kit – I was impressed with the quality – everything that was required to fit the kit was included, and all parts were solid and well built. All connections had waterproofing as well, although we were aiming to fit the kit in an area where water could not reach it.

 

http://i24.photobucket.com/albums/c32/streettech/DSC02778.jpg

 

It was decided the front bumper needed to be removed, along with the lights, in order to fit the ballasts and install the bulbs easily. This turned out to be a good decision – this would not have been an easy job if the lights had not been removed.

 

The front bumper is “held” onto the car by literally a few popclips and one or two screws. A quick look under the bumper was all that was needed to find the popclips – these came away easily with a little force. The screws were slightly more difficult, as they are hidden away behind the front of each wheel arch. With some force the arch will bend, allowing access to each screw.

 

http://i24.photobucket.com/albums/c32/streettech/DSC02771.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02772.jpg

 

The bumper was then removed, and the lights could be inspected.

 

http://i24.photobucket.com/albums/c32/streettech/DSC02773.jpg

 

There are 2 or 3 screws holding each light cluster onto the car – each screw is easily visible, and once removed, the lights were removed. No problems here, although it’s a good idea to have somebody hold the lights while the screws are being removed, as they could fall out of their holes and break/scratch. The wires into the lights are simply unclipped – a flat head screwdriver comes in handy here.

 

http://i24.photobucket.com/albums/c32/streettech/DSC02774.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02802.jpg

 

Once the front bumper and lights were removed, it was onto the bulbs…

 

http://i24.photobucket.com/albums/c32/streettech/DSC02791.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02789.jpg

 

The light clusters were inspected, and an annoying feature found. The bulb holders are recessed quite a bit into the cluster, and the “access” point is a round hole that is slightly offset to the holders – this makes it quite fidderly to remove and replace the bulb correctly, particularly if you’ve got large fingers!

 

http://i24.photobucket.com/albums/c32/streettech/DSC02792.jpg

[Welshguy]

The waterproof casing was removed, and the bulb holder clip was moved to one side. The old bulb was simply pulled out between finger and thumb, and placed to one side. The new bulb was then placed into the holder, and the holding clip moved back into place. This was quite fidderly, and took several attempts. The clip had a tendency to fall out of place, and needed to be moved past the new thicker wires of the new bulbs. A hole then needed to be cut in the waterproof casing to allow the wires to pass through. A hole slightly bigger than a 10p piece was cut, and the casing was slid over the wires into place. The kit comes with a “seal” on the wires that plugs the hole (allowing the wires through at the same time) and makes for a neat look, along with ensuring no water can enter the light casings.

 

http://i24.photobucket.com/albums/c32/streettech/DSC02793.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02794.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02795.jpg

 

Once both bulbs were installed, it was onto installing the ballasts needed for the initial surge of electricity required to power up the lights. One ballast was provided for each bulb, along with a mounting bracket, and sticky backed foam pads to go between the bracket and ballast to ensure no rattling takes place. The idea location for the ballasts was decided as the front chassis, and the brackets were lined up and holes drilled. I was impressed with the strength and thickness of the metal – it took a bit of muscle and two drill bits to get the holes that were required. The brackets had the foam pads attached, and the ballasts fitted, and then were screwed into position. The brackets come with three attaching points, so they were very securely fitted.

 

http://i24.photobucket.com/albums/c32/streettech/DSC02802.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02801.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02799.jpg

 

Once each ballast was fitted, it was time to plug the lights back in. A small problem encountered here was that the kit provided had red colour plugs for both positive and negative connections, and thus a multimetre was required to figure which was which. The new bulb connections were plugged into the ballasts, which were plugged into the standard connections, and the screws replaced in the lights.

 

The front bumper was then re-installed, although this was slightly fidderly, and definitely a job for two people.

 

The result?

 

http://i24.photobucket.com/albums/c32/streettech/DSC02829.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02830.jpg

http://i24.photobucket.com/albums/c32/streettech/DSC02831.jpg

 

Overall I was extremely impressed with the lights, and no problems have been encountered after installation. The “Guide me Home” function still works perfectly, and the lights power up in milliseconds. They start off with a blue tint, but gradually get whiter as they warm up. Visibility is excellent, and I have noticed people love to stare at the lights now!

 

A short video has been included – see below!

 

http://i24.photobucket.com/albums/c32/streettech/th_MOV02827.jpg

[Ciaran2903]

SWEET!!!!!!!!!!!!!!! :lol: :o

I WANT!! :)

 

That is very very nice! :D

[Mike5483]

Looks highly impressive!!!

 

You just need to sort the side lights now, dey yellow man!!!

 

On a side note, this is just for the dipped headlamps isnt it, not full beam???

 

Maybe Wozza can sticky these, otherwise they are gonna get seperated.

[wozza]

Merged them into one topic so I can sticky it more easily.

 

Looks good though mate.

[Welshguy]

@ Mike

 

Agreed RE: the sidelights - I believe I need '501' sidelight bulbs...will be getting white/blue bulbs for Christmas..

 

@ Wozza

 

Cheers for the sticky!

 

On a side note, my brother is looking into buying these in bulk and selling them on...please let me know if your interested in a pair and I will see what price I could sort for you!

[Ciaran2903]

I would be very interested in the kit, but not sure i have the confidence to fit it! <_<

[CoolCarbon]

I would be interested...fitted a kit to my BMW Bike a couple of years ago...Brilliant, in every sense of the word.. :lol:

[Mike5483]

@ Mike

 

Agreed RE: the sidelights - I believe I need '501' sidelight bulbs...will be getting white/blue bulbs for Christmas..

They are W5W's for the Side lamp bulb

[cyberandy]

great job on the lights

 

thats going to be my next project. it would be easier to do the side lights the same time.

 

how much and where from. I'll see if santa will bring me a set.

[Sveta]

@ Mike

 

Agreed RE: the sidelights - I believe I need '501' sidelight bulbs...will be getting white/blue bulbs for Christmas..

 

@ Wozza

 

Cheers for the sticky!

 

On a side note, my brother is looking into buying these in bulk and selling them on...please let me know if your interested in a pair and I will see what price I could sort for you!

 

Hallo,

 

My English is not so good,sorry about that!!!

My name is Sveta and I'm from Serbia,but I live in Antwerp-Belgium!!!

I have Xsara Picasso from 2000year and 108000km.

Three days ago I was buy HID KIT H4 4300k via ebay from China,and I pay 9£ for HID KIT and 36£ for shipping,in total 45£.

Now I'm thinking can I install by my self,in other way I need to pay to mechanic same price like I pay HID KIT. :D

If somebody have script for installing,it will be great to post it,PLEASE!!!

I have one more question,do you have problem with POLICE or when you are going on TECHNICAL CONTROL?

 

Thank you,

Sveta

[Sveta]

@ Mike

 

Agreed RE: the sidelights - I believe I need '501' sidelight bulbs...will be getting white/blue bulbs for Christmas..

 

@ Wozza

 

Cheers for the sticky!

 

On a side note, my brother is looking into buying these in bulk and selling them on...please let me know if your interested in a pair and I will see what price I could sort for you!

 

Hallo,

 

My English is not so good,sorry about that!!!

My name is Sveta and I'm from Serbia,but I live in Antwerp-Belgium!!!

I have Xsara Picasso from 2000year and 108000km.

Three days ago I was buy HID KIT H4 4300k via ebay from China,and I pay 9£ for HID KIT and 36£ for shipping,in total 45£.

Now I'm thinking can I install by my self,in other way I need to pay to mechanic same price like I pay HID KIT. :D

If somebody have script for installing,it will be great to post it,PLEASE!!!

I have one more question,do you have problem with POLICE or when you are going on TECHNICAL CONTROL?

 

Thank you,

Sveta

[BigJohnD]

The light clusters were inspected, and an annoying feature found. The bulb holders are recessed quite a bit into the cluster, and the “access” point is a round hole that is slightly offset to the holders – this makes it quite fidderly to remove and replace the bulb correctly, particularly if you’ve got large fingers!

And that's with the whole headlight assembly out of the car!

[Johndouglas]

What happens at MOT time about retro fitted Xenons? I thought a car fitted with them also had to have self-levelling and washers fitted.

[BigJohnD]

What happens at MOT time about retro fitted Xenons? I thought a car fitted with them also had to have self-levelling and washers fitted.

In word, yes.

 

(HID = High Intensity Discharge, commonly known as Xenon, headlights.)

 

From the Dept for Transport, December 2006 http://www.dft.gov.uk/pgr/roadsafety/drs/hidheadlamps

A HID headlamp unit sold in the after market should:

 

1. be type approved to ECE Regulation 98 as a component.

 

2. when fitted to the vehicle should enable ECE Regulation 48 to be complied with (although no government inspection will take place).

 

3. Comply with RVLR as far as "use" is concerned.

 

In practice this means:

 

1. The headlamp unit (outer lens, reflector, bulb) shall be type approved to ECE 98 and be "e-marked" to demonstrate this. That can only be done by the headlamp supplier - Hella, Valeo etc. who must test the headlamp in an independent laboratory.

 

2. Once fitted to the vehicle it must have headlamp cleaning and self-levelling (which can be for the headlamp or can be in the vehicle suspension - some expensive estate cars have "self-levelling suspension" and that is adequate). Also the dipped beam must stay on with the main beam.

 

3. The headlamp must be maintained in good working order, kept clean, and aligned/adjusted correctly like any other headlamp.

 

Under the Road Traffic Act 1988 it is an offence to supply, fit or use vehicle parts which are not legal.

 

In summary it is not permitted to convert an existing halogen headlamp unit for use with HID bulbs. The entire headlamp unit must be replaced with one designed and approved for use with HID bulbs and it must be installed in accordance with the rules stated above.

Also, watch this video from Autoexpress: http://www.autoexpress.co.uk/videos/featur...xenon_test.html

 

Edmund King - RAC Foundation Executive Director:

Motorists out there who think they are buying Sportier, Rallying, Safer Bulbs.............

........the reality is, they could be dazzling, bringing danger and, indeed, death to our roads

So while you can easily fit an after market kit, you're not getting the best from them by fitting them in reflectors designed for halogen and you could easily dazzle on-coming drivers; they need to be self-cleaning and self levelling.

 

There is no guarantee they will satisfy the MOT examiner and they could run foul of type approval regs.

[BigJohnD]

What happens at MOT time about retro fitted Xenons? I thought a car fitted with them also had to have self-levelling and washers fitted.

In word, yes.

 

(HID = High Intensity Discharge, commonly known as Xenon, headlights.)

 

From the Dept for Transport, December 2006 http://www.dft.gov.uk/pgr/roadsafety/drs/hidheadlamps

A HID headlamp unit sold in the after market should:

 

1. be type approved to ECE Regulation 98 as a component.

 

2. when fitted to the vehicle should enable ECE Regulation 48 to be complied with (although no government inspection will take place).

 

3. Comply with RVLR as far as "use" is concerned.

 

In practice this means:

 

1. The headlamp unit (outer lens, reflector, bulb) shall be type approved to ECE 98 and be "e-marked" to demonstrate this. That can only be done by the headlamp supplier - Hella, Valeo etc. who must test the headlamp in an independent laboratory.

 

2. Once fitted to the vehicle it must have headlamp cleaning and self-levelling (which can be for the headlamp or can be in the vehicle suspension - some expensive estate cars have "self-levelling suspension" and that is adequate). Also the dipped beam must stay on with the main beam.

 

3. The headlamp must be maintained in good working order, kept clean, and aligned/adjusted correctly like any other headlamp.

 

Under the Road Traffic Act 1988 it is an offence to supply, fit or use vehicle parts which are not legal.

 

In summary it is not permitted to convert an existing halogen headlamp unit for use with HID bulbs. The entire headlamp unit must be replaced with one designed and approved for use with HID bulbs and it must be installed in accordance with the rules stated above.

Also, watch this video from Autoexpress: http://www.autoexpress.co.uk/videos/featur...xenon_test.html

 

Edmund King - RAC Foundation Executive Director:

Motorists out there who think they are buying Sportier, Rallying, Safer Bulbs.............

........the reality is, they could be dazzling, bringing danger and, indeed, death to our roads

So while you can easily fit an after market kit, you're not getting the best from them by fitting them in reflectors designed for halogen and you could easily dazzle on-coming drivers; they need to be self-cleaning and self levelling.

 

There is no guarantee they will satisfy the MOT examiner and they could run foul of type approval regs.

[Johndouglas]

There is no guarantee they will satisfy the MOT examiner

 

That's what I thought! IMHO, not worth the risk to end up with a failure notice.

[john h]

Very enlightening, definitely giving them a miss, if you are desperate for blue tinged light there are plenty halogens from big name companies which 'allegedly' increase the beam range, something I did not find when I tried a set from Ring

[Johndouglas]

Since this topic opened in 2008 a lot of water has gone under the bridge. New testing rules for Xenon lights have been added to the MOT in recent years. Kits such as those shown will not pass an MOT unless the lamps are self-levelling and have their own washer system for each lamp.