 Most viewed - Passat HID install |
351 viewsXentec - The kit I used. Also, remove the DRL (Daytime Running Lights) relay, #173. It's located where the fuses are but a little deeper behind the dashboard -- it easily pulls straight out. Yes, you'll have to manually turn on your lights when you drive now. You can drive with the relay intact and the lights will come one (well, ours did), but the HIDs are getting a reduced voltage and may not turn on, they could even turn off while driving due to the reduced voltage feeding them. By removing the relay you insure that they get full voltage when you turn on the headlights.
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344 viewsSeat the wiring gasket as so...pretty dang obvious. How it should look.
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The install342 viewsLiquid electrical tape used to fill in and insulate crimps. High-quality ratcheting crimpers make the difference!
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325 viewsFor the particular bulbs that came in this kit (an early version), I had to cut the wires and then feed them through the gasket. I used butt connectors and high-quality crimpers (expensive) to secure the wires.
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323 viewsTo hold the cover up while cutting, I used a 1/2" socket underneath. Use a very sharp Xacto blade and cut s-l-o-w-l-y and carefully.
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Through the rubber cover322 viewsThe following is the method I used on the left side after trying the right side by using the hard cover (described after this procedure). This is SO much easier to install and route wires, however, you MUST make sure you seal the gasket to the rubber boot so as to keep water out. I personally think this is the best way to do it with the kit I used.
I used a scrap piece of cardboard, cut in a 7/8" diameter circle, and traced the back side of the low beam rubber cover using a permanent marker.
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313 viewsThe plug wouldn't lock into the stock connector so I used a supplied zip-tie to bind it and electrical tape to keep it together. Notice that the RED wire mates with the YELLOW (+12 volts) bulb connector wire and the BLACK wire mates with the BROWN (ground) bulb connector wire.
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309 viewsTo make a nice 7/8" circle use a compass and set it to 7/16" (about 11mm).
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308 viewsHere's the rubber boot turned inside-out to get a better view of the inside of the gasket and the wires running through it.
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307 viewsThe interior.
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307 viewsLocation where I placed the left side electronics. Attached by using the supplied double-sided tape (strong stuff!).
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305 viewsFeed the harness through the rubber cup from the front side.
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300 viewsViewing inside after applying the RTV.
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299 viewsThe original bulbs came with a plastic ring to help hold them in their shipping case. I split it and put it behind the bulb, then carefully pushed the bulb retaining tangs onto the plastic ring. This kept the tangs more even. Without them you'll need to push the tangs down a little bit as well as bend them inward in order to retain the bulb. I oriented the bulb just like the halogen it replaced, tab pointing up. No shadows were cast, full light is output.
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Through the hard cover299 viewsJust an FYI: I do NOT recommend this method! PITA if you have any issues. Go through the rubber cover.
Make a template that is 7/8" in diameter and trace with a permanent marker. Or put a nail or screw into the center of the circle and tap it so it leaves a dimple -- that's where you will drill. I used this location because it gave me the most slack in the wiring. The shop that does this recommended not putting the gasket in the center of the hard cover because there wouldn't be enough wiring slack.
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298 viewsThe bulb I originally had for the left side was bad so I got a replacement. This had the wires through it but no connector. Overall, it is better as there was no need for me to cut the wires, push them through the gasket, and butt-crimp them. For the connection, I pushed the spade connectors into the stock connector, dabbed liquid electrical "tape" around it to electrically insulate it as well as help hold the connectors, then wrapped the connector in electrical tape to further hold the connectors in. Not ideal at all but it works.
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296 viewsAnother view of the completed assembly. Notice that the bulb is on the inside of the rubber boot and that the bulb is still in the container. You don't want to expose the bulb until you absolutely have to, it must stay clean! You can use rubbing alcohol to wipe the bulb down if it gets dirty or you touch it -- oil from your skin is bad for the bulb!
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292 viewsBoth wires installed and ready to go.
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291 viewsWith the rubber cover turned inside-out, lift up the gasket and apply a continuous bead of silicone sealant a.k.a. RTV. This will insure a water-tight seal. Return the boot to its original state.
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290 viewsMy kit came with holders that the wires clip into -- notice the orientation of the tang, it faces inside so it will lock in place.
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