Instructions Created by an: DIY Underhood LED Lighting Kit (SKU# DIY-E-UHLK) Installation Instructions NOTICE: This Under Hood Light Kit was installed on a 2002 Toyota Tacoma. However, these instructions can easily adapt to any vehicle. CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. Suggested Tools: Combination Wrenches: 12 & 11mm. Needle Nose Pliers W/Wire Cutters Phillips Screwdriver (Optional) Power Hand Drill 5/16 Drill Bit (Supplied) Abrasive Paper Wire Crimpers Wire Strippers (for 26 & 20 Gauge Wire) Heat Gun (for heating the shrink tube) 1/6 Steel Welding Rod (for fishing the conductor through body cavities) Electrician s Tape Power Probe (or 12V Test Light) For additional copies of these and other instructions go to: www.lowrangeoffroad and click on the Instructions tab.
Wiring Diagram LED Light Bar Butt Connectors 26 gauge Conductors 20 gauge Conductors Fuse Block 1A + - Battery Female Spade Connector Hood Switch
Step 1 Insert the supplied (20 GWA) back and red wire through the hood cavity as shown. Step 2 Continue feeding the wire into the cavity until it becomes visible at the rear of the hood. Step 3 Pull the wire out of the hood cavity using needle nose pliers. Tech Tip 3 Wire pulled out of the hood cavity.
Step 4 Fish a piece of wire (welding rod, coat hanger, etc) through the hood cavity as shown. Step 5 Have the fish wire extend out of the hood cavity about 4 as shown. Step 6 Connect the black and red wire to the fish wire using electricians tape. Step 7 Pull the black and red wire through the body cavity as shown. Note: Keep the connection as small as possible, yet strong enough to be pulled the wire through the hood cavity.
Tech Tip 7 Wire pulled through. Step 8 Pull the black and red wire through for about 2 feet and un-tape the fish wire. Step 9 Feed the fish wire through the hood cavity as shown. Step 10 Tape the black and red wire to the fish wire.
Step 11 Pull the black and red wire through the hood cavity. Continue pulling until you have about 1 foot of wire showing. Step 12 Disconnect the fish wire. Step 13 Determine the location of the light strip. The location should be based on the following considerations: Apply to a clean flat surface. Install where the lights will shine on the engine compartment. Lights will not be damaged when the hood is closed. Light strip will not extend past the hood. Once the light strip location is determined, clean the area using brake cleaner and a cloth. Note: This is so the light strip will adhere to the hood better.
Step 14 To further enhance adhesion of the light strip, wipe down the area with the alcohol wipes provided in the kit. Step 15 Adhere the light strip to the hood. Starting with the end of the light strip where the black and red wires are, begin pealing off the backing. Step 16 While pealing off the backing, stick the light strip to the hood. Press the light strip firmly into place insuring good adhesion. Step 17 Remove excess 26 gauge wire from the light strip using wire cutters. Caution: Do not cut too short. Leave yourself plenty of length to work with. We recommend 6 to 8 inches at least.
Step 18 Separate the two wires so they can be stripped. Step 19 Remove about 3/4 of insulation from both (Black and Red) wires using a 26 gauge wire stripper. Step 20 Twist the conductor strands together and wrap the conductor back around the insulation on both (black and red wires) as shown on the black wire here. (See Tech Tip 20) Tech Tip 20 Shows how to wrap the conductor around the insulator. Note: We wrapped the conductor around the insulation to make a better connection.
Step 21 Place the wire inside the supplied butt connector as shown. Note: Be sure the wire fits all the way down inside the metal part of the butt connector. Step 22 Crimp the butt connector on to the black wire. Then install a second butt connector on the red wire in the same manner as you did the black wire. Note: Be sure the crimping tool fits over the metal part of the butt connector. After crimping, tug gently on the connectors to be sure they are secure. Step 23 Strip both (black and red) 20 gauge wires. Step 24 Connect the red 20 gauge wire to the red 26 gauge (LED) wire and the black 20 gauge wire to the black 26 gauge (LED) wire. Note: Tug gently on each connection to be sure they are tight and secure.
Step 25 These butt connectors can be heated to shrink them down tight on the wire making a weatherproof connection. This can be done with a heat shrink heating tool, a cigarette lighter or even a match. Be careful not to overheat. It is easy to met the heat shrink material. Step 26 If possible, tuck the wires and butt connectors inside the hood cavity. Step 27 Remove any excess slack in the wires by pulling the wires back down through the hood. Tech Tip 27 This shows the slack being removed from the wire. Caution: Be careful not to pull too hard so as to break the wires loose from the butt connectors.
Step 28 Route the 20 gauge (black and red) wire such that it will not be damaged when the hood is closed. Also, make sure the wires are routed away from any other potentially damaging parts. Tech Tip 28 Notice how the windshield washer hose is routed and try to do something similar with the under hood 20 gauge wires. Step 29 Secure the 20 gauge wires in several places with the supplied zip ties. Step 29 Continued This shows the second zip tie location.
Step 29 Continued This shows the third zip tie location.
Method of Connecting the Red (or Positive) Wire to a Positive Power Source - Option 1 Comprising Steps 30-32 Step 30 Locate a blank space in the fuse box that does not have a fuse in it and has power to one side with the ignition switch in the OFF position. This can be determined by using a common 12V test light or Power Probe as shown here. Step 31 Insert the supplied spade fuse box tap in the location determined in the previous step. Fuse Tech Tip 31 This shows a spade fuse box tap. Step 32 Connect the 20 gauge red wire to this fuse box tap. It may be necessary to modify the fuse box lid to allow the wire to pass through.
Method of Connecting the Red (or positive) Wire to a Positive Power Source - Option 2 Comprising Steps 33-34 Toward Light Strip Toward Battery + Step 33 The 20 gauge red wire could be connected directly to the positive connection on the battery. Step 34 If you choose this option. Be sure to place the supplied fuse in series, to protect the circuit. Method of Connecting the Red (or positive) Wire to a Positive Power Source - Option 3 Comprising Steps 35-35B Step 35 Select an unused connection on this add on fuse block. Since this fuse block was already installed this is the option we chose. Tech Tip 35A This is the auxiliary blade fuse block that was already installed on this vehicle. It works very well when adding extra components to a vehicle. Note: Click HERE if you are interested in purchasing one of these fuse blocks from Low Range Off-Road.
Connect to this Screw Fuse Tech Tip 35B We made our connection here. Keep in mind you will need to add a fuse to make this work. 1A is what we recommend.
Connecting the Red (or positive) Wire to the Positive Power Source Step 36 Separate the black and red wire as far as needed to route the red wire properly. Note: Make sure the wires are routed in a safe place; away form any moving parts, sharp edges or heat sources. Step 37 Route the red wire to the 12V power source selected earlier using option 1, 2 or 3. Step 38 Estimate the length needed. Step 39 Cut the red wire to length. Note: Always cut the wire a bit longer than you really need to insure the wire will reach once you have added the connector.
Step 40 Strip the insulation from the wire. Usually about 1/4 is sufficient. Step 41 Install and crimp the supplied eyelet electrical connector. Step 42 Shrink the insulation by applying heat. Step 43 Connect the eyelet connector to the fuse block. Caution: It is best to leave the fuse out for now. This will guard against any accidental short circuiting.
Installing the Ground Wire Step 44 Determining where to install the ground switch. We recommend placing the switch as close to the hood stop as possible. This will give you a good idea as to how high to adjust the switch. Be sure that the switch has enough room below the installation location to extend downward without obstruction when the hood is in the closed position and the switch is fully depressed. The area of the hood that contacts the switch should be as flat (horizontal) as possible so as not to force the switch in a lateral (side-to-side) direction. Hood Stop Step 45 Drill a 5/16 hole in the location selected for the switch using the supplied 5/16 drill bit. We chose to drill this hole about 2 inboard of the hood stop. Bottom Nut and Washer Step 46 Remove the paint around the hole so the switch can make a good electrical ground. Step 47 Remove the bottom nut and washer.
Step 48 Insert the switch in the hole. Step 49 Install the washer and nut. Note: If the switch will not fit in the hole, you may need to ream the hole a bit more with the drill bit. The drill bit we supplied was sized a little small to insure a good, snug, electrical ground. Step 50 While holding the top nut with a 12mm open end wrench, tighten the bottom nut with a second 12mm wrench. Step 51 Check for proper adjustment. When the button is depressed all the way, it should be about 1/4 below the hood stop. Adjust as needed.
Step 52 Now push the switch all the way down and check under the mounting surface to see that there is no obstruction. If the switch hits ANYTHING you will need to make some sort of adjustment. You may need to bend the body a bit to gain the necessary clearance. Although it is not likely, you may need to relocate the switch by drilling the hole in another place. Step 53 Estimate the length of the ground wire. Be sure to leave plenty of length. Then, cut, strip and crimp the supplied female spade connector. Tech Tip 53 Female Spade Connectors. Step 54 Connect the female spade connector to the bottom of the ground switch.
Step 55 Install a 1A fuse. Step 56 With the ground switch in the up position the under hood lights should come on. If the lights come on go to the next step. If not check all connections and the fuse for proper condition and repair as needed. Step 57 Slowly lower the hood about 1/2 way and check to see that the wire near the hood hinge is routed in a safe place. Step 58 Continue closing the hood. When the hood is approximately 1 away from completely closing, the lights should go out. If they do, move on to the next step. If not, open the hood and adjust the switch up a little and try again.
Step 59 Close the hood all the way. If it closes properly with out obstruction and the lights go out as they should, the switch is properly adjusted. Congratulations! You have successfully installed an Under Hood LED light Kit. We hope these instructions have been helpful. If you have suggestions on how to make these instructions (or products) better, please email us at: sales@lowrangeoffroad.com
As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at 801-805-6644 M-F during regular store hours. Thank you for purchasing from Low Range Off-Road. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at 801-805-6644 or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use. Revised 12/03/14 Copyright 2014 Low Range Off-Road, LC All Rights Reserved