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KENSUN HID AUTOMOTIVE HEAD LAMP CONVERSION KIT INSTALLATION MANUAL 2
CONTENTS A. Before Installing B. Installing the Bulbs C. Installing the Ballasts D. For Bi Xenon Only: Installing the Relay Harness E. After Installation F. Warnings and Correct Usage Information APPENDIX 1 MODIFICATIONS NEEDED FOR SOME VEHICLES MODELS APPENDIX 2 Trouble shooting APPENDIX 3 9004-9007 WIRING ISSUE APPENDIX 4 ALIGNING YOUR HEADLIGHTS 3
KENSUN H.I.D HEADLIGHT INSTALLATION MANUAL Thank you for purchasing your KENSUN HID light kit. Most vehicles are compatible with our kits however there are variations for each car, make and model. Please check Appendix 1 for any modifications that may be needed for your vehicle for correct running of the kit. Also please refer to our FAQ in Appendix 2 that may address any difficulties you have with installation. GENERAL WARNING - This is a system that produces high voltage electricity. Installation by an inexperienced person is not recommended. Be sure to consult a professional technician for installation. Faulty or insecure installation can result in electrical problems and shock. A. Before Installing Please read this installation guide carefully before installing the system. For most vehicles installation is straight forward. We may decline to accept responsibility for any damage caused by not following the instructions properly. 1. For safety please wait for the car lighting and engine to cool down completely before attempting to install the HID lights 2. Place the vehicle in either the N or P gear 3. Make certain the lighting switch in the vehicle is off before starting installation 4. It is advised to wear gloves while installing the kit to reduce the risk of electric shock and abrasion 5. Avoid unnecessary or rough handling of bulbs. Also touching the bulbs with bare fingers may cause oil spots 6. If the bulbs are not clean you may wipe the bulbs with a dry cloth or rubbing alcohol, however don t immerse in any liquid 4
COMPONENTS: 5
B. Installing the Bulbs 1. You can open the hood, remove the dust cap and remove the original bulbs from the headlight housing. If there is not enough room you may need to remove the headlight housing assembly to continue with the installation 2. Your Kensun bulbs come well packed so they should not be damaged in shipping. All the protective packaging should be removed. Remove the plastic cap covering the HID bulb being careful not to hit the vacuum tube. If your bulb has a plastic washer, it too will have to be removed. To remove the washer; remove the red rubber grommet, remove the plastic ring and then roll back the grommet until it is under the ledge, as in the pictures below 6
3. Place the HID headlights into the headlight housing. The bulb should go in the same location that your halogen bulbs had been in originally. (For some vehicles, size H1 and H7 bulbs may require a bulb holder to replace the factory bulb holder. This is not included in the kit) 4. OPTIONAL: Seal tight with the dust cover. Our bulbs come with a black rubber grommet around the wires before the bulb, to weather seal your lights with the dust cover. Drill a hole in the middle of the back dust cap with a 1 cutter. Slide the plug end of the wires through the dust cap and fit the grommet into the hole that you drilled. 7
C. Installing the Ballasts Fix the ballasts to any solid place in the engine cavity close to the headlights using the fixing brackets. You can also use zip ties and double sided tape if needed. Avoid placing ballasts next to parts that operate at high temperatures The single beam HID kits plug directly from the ballasts to the bulbs. 8
D. For Bi Xenon Only: Installing the Relay Harness At this stage you will need to install the relay harness. There are eight connections to complete in order to install the harness and connect the power supply: A & B. Connect to the In port on the left and right ballasts. C. Connects to plug of your vehicle s halogen bulb on either the left or right side. D & E. Connect to left and right HID bulbs ports. F & G. Connect to car body as an earth. H. Connects to the positive terminal of the battery. 9
E. After Installation Make certain that all connections are tight and secure Make certain that all parts dismantled beforehand are returned to their original places. Check that other vehicle parts are going correctly (e.g. lamps, sound systems, wind screen wipers, etc.) Ensure you are using 20A fuses for the HID lights. 10
IT IS IMPORTANT TO PLEASE READ THIS SECTION BEFORE USING THE HID LIGHTS F. Warnings and Correct Usage Information 1. Do not disassemble or modify the ballasts or wire harnesses. This product produces high pressure electricity and tampering with these components may result in electric shock. We are not responsible for malfunction or hazardous conditions caused by tampering and modification with the system. 2. Be certain that all ballasts, bulbs, wires and sockets are installed securely to the car body before operation. 3. Do not touch the lights after use until they have cooled. The bulbs emit heat at high temperatures and can cause burns 4. Keep the system and its components away from paper, cloth and inflammables such as lacquer, thinner and solvents to prevent fires. 5. Be certain you have your lights turned on only while the engine is running. Having your lights on before starting the engine causes battery drainage and may cause problems starting your vehicle. 6. Avoid looking directly into the xenon light to prevent potential damage to your eyes. 7. Do not position the lights in an upward direction or at oncoming drivers eye level so as to ensure their safety and visibility. 8. For repairs or replacement of components consult a professional technician. Do not attempt them yourself. 9. In a vehicle accident, be sure to turn off the vehicle s power to prevent high voltage electric leakage from the damaged product components. The system produces high voltage electricity which might interact with electronic components. Therefore in the case of vehicles equipped with advanced electronic control like for example board computers it is strongly recommended to consult with a specialist before installation. The manufacturer will decline claims resulting from inappropriate installation or application. Kensun will not be responsible for damages to automobiles resulting from the use, misuse, or inability to use a Kensun product. YOUR HID LIGHTS ARE NOW READY TO GO! 11
APPENDIX 1 MODIFICATIONS NEEDED FOR SOME VEHICLES MODELS The following electronic systems installed in some vehicles can affect the correct running and performance of the HID lights. Please read the modifications recommended here and consult with a specialist. A. Vehicles with Daytime Running Lights Daytime running lights use the HIGH or LOW beam driven at a lower voltage to save power. If you want to retain this option you need to install a relay harness as described in section D for Bi Xenon kits. Please be aware that the HID system will come on with the DRL at full power since it is relay driven. This is fine, although it will limit the life of the HID bulbs as it adds hours of usage. HID systems cannot be dimmed and to attempt to do so by reducing voltage will cause added current draw to compensate for this. To Bypass Alternatively you can remove the fuse to disable the DRL saving hours of HID light use. B.Lamp out Sensing In some vehicles the Lamp out Sensing is achieved by supplying a low voltage current to sense if the headlight lamp has blown. This may cause the HID lights to flash on and off. Modification Kensun recommends installing either Resistors or Warning Cancellers to prevent this. Both of these items can be purchased separately from Kensun and their function is to provide a steady power voltage to the HID lights. To Bypass Alternatively you can have a specialist disable the Lamp out Sensing electronics in your vehicle. C. Security Systems If your headlights flash when the alarm is armed and disarmed, as long as you are not frequently using the alarm disarm mode, it is fine to use the HID system in this manner Note that frequent alarm activation shortens the life of the HID bulbs 12
APPENDIX 2 Trouble shooting I turn on the light but H.I.D won t turn on 1. Check the fuse in fuse box (Please upgrade to a 20A fuse) 2. Check and secure all connections 3. Some vehicles have reversed polarity. Change the polarity of the ballast connector. Reverse the connector from + to - and from - to + 2. Check if the bulb is faulty (i.e. swapping the bulbs to test if it works on other side) When driving, the lights vibrate on the road 1. Check to see if the bulb is securely attached in socket 2. Check the bulb to see if it is broken I turn on the lights and the headlight flashes erratically 1. Make certain the battery has a minimum of 12 volts 2. The voltage in your vehicle may be unsteady (you won t notice this except that the HID lights flash on and off periodically). Kensun recommends installing a Relay Harness to keep the voltage steady to the HID system. You can purchase a relay harness separately from Kensun and install as described in section D I turn on the lights and only one headlight turns on My engine compartment has no room for the ballast 1. Remove bumper and mount within 2. Zip tie or use double sided tape to secure With the lights on, one looks brighter than the other 1. Clean headlight lens 2. Check for damage of housing 3. Have lens cleaned professionally 1. Check the connection of bulb/igniter/ballast 13
The lights keep on flickering and making clicking noises 1. Check that the HID bulbs have been connected to the ballasts correctly and tightly 2. Check the condition of the battery, that it is not too old or has a low charge 3. Check if your car has daytime running lights and disable the DRL by removing the fuse or purchase and install a relay harness The HID bulbs change color when first turned on 1. This is normal; at the beginning the ballasts are storing the power from the battery of the vehicle. Since the power has not been stabilized yet the bulbs may have different colors or even flicker. However, as soon as the power is stabilized by the ballast the bulbs will become normal. The color or lighting effects of the bulbs aren t matching Ballasts make electric noise when first turned on 1. This is normal, the ballasts are absorbing power from the battery to start up HID will only work when the high beam is turned on 1. This situation mostly happens with kits that have three prong plug rather than just + and - (H4, H13, 9007 and 9004 kits). Make sure you have plugged those three wires correctly to their positions. This occurs particularly with the 9004 and 9007 kits and we have attached a separate appendix on how to wire the 3 pronged plug correctly, please refer to 9004 and 9007 wiring Issue Appendix 3 1. The level of the two sides bulbs in the headlight housing aren t even. Ensure both are at the same height and angle. Refer to Aligning Your Headlights Appendix 4 2. For new bulbs the colors may vary for the first few hours after being turned on. The color will become normal after that 3. Inspect for damage in the headlight housing. You may need to replace the housing 4. The headlight housing is dirty. Clean the lens or have the lens cleaned professionally 14
APPENDIX 3 9004-9007 WIRING ISSUE: High beam shines when Low beam on, or High beam isn t working or both The HID 9004 and 9007 Bulbs have the same product specifications, unlike Halogen bulbs where there is a difference in these two sizes. Therefore HID 9004 and 9007 kits are not manufactured separately. However the wiring is different and there can be issues with bulbs being wired as 9007 when your vehicle needs 9004 or vice versa. Incorrect wiring will not damage your bulbs or vehicle. You should install the bulbs the way they came out of the box and if your bulbs are not functioning then switch the wires around until it works correctly. Do not adjust the wiring if the bulbs are going correctly. Instructions on how to change the bulbs from 9004 to 9007 or 9007 to 9004 1. Hold the blue connector with the front facing you and the straight side up (As shown in the diagram) 2. You will see three pins in the connector. One to the right, one to the left and one to the center 3. It may be helpful to label the wires to prevent confusion. (i.e. by attaching masking tape to the wires labeled with A, B, and C) Please note the coloring of the wires can vary 4. You then need to take the pins out of the connector. You can do this easily by bending the pins slightly up and down and then pulling the wires back 5. Now re-insert the pins in the correct order. The order should be: The right wire stays on the right The left wire goes in the center The center wire goes on the left 6. Afterwards you should have kept the right wire in place and swapped the left and center wires. Then re-install the bulbs 15
APPENDIX 4 ALIGNING YOUR HEADLIGHTS This is only a guide how to adjust the alignment of your headlights. We recommend you see a specialist for the best alignment for your HID headlights 1. Park your car on a level surface 20 feet behind another vehicle 2. Remove the trim around the headlights and locate the adjusting screws. These screws are typically found adjacent to the headlight 3. There should be one screw at the top of the headlight to adjust vertically and another screw to one side of the headlight to adjust horizontally. In some cars there may be adjusting bolts rather than screws 4. Turn on your headlights 5. Use a screw driver or socket to adjust the screws or bolts. Turn the upper screw or bolt clockwise to raise the headlight, and counterclockwise to lower it. Turn the side screws or bolts to move the headlight right or left 6. Adjust the headlight so the cut off of the beam is just above the bumper of the car in front (as in picture) 7. Be certain that the headlights are aligned evenly, point the lights at a flat wall at a distance of 20 feet and adjust until the beams are level 16
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