DIY: HID Harness for H4 (02/03)
OK, first, I am NOT going to take credit for this DIY. This is Ocelaris' original DIY (the write up part at least) from the "pre-crash" ep3hatch. Ocelaris deserves the credit. When I did my HID install I saved the whole DIY to my computer for reference. Since it hasn't been done up yet, I thought I'd post it so everyone can benefit. Again, this is not my DIY.
I added some pics from my install to help out a little though.
Remember:
DON'T INSTALL HID'S WITHOUT A RELAY HARNESS!!!
Factory wiring (like 22AWG I think) is not made to handle HIDs, so the harness will help that out. Use 11/12 AWG wire.
CTR Headlight Owners:
For those of you like myself that were able to get the CTR HIDs, you can't use the clips on the headlights that come from the hi-beam motor. Also make sure you have the ballast clips. Mine didnt come with any so I had to do some hunting for em.
http://i10.photobucket.com/albums/a1...r/IMG_0043.jpg
I do not recommend using taps if you decide not to solder. Crimp directly and tape it up to keep it clean. If you do choose to soder, DO NOT SODER ANYTHING WITHOUT TESTING! I take no responsibility for anything you read on here then go do.
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//// BEGIN DIY /////
This will tell you how to easily make a wiring harness for your 02/03 Si to connect to any HIDs. This is long, but not because it is difficult, but becuase I wanted to be VERY complete and make sure I covered everything step by step.
For the parts you can either soder them on or crimp them on. I will explain both ways but I HIGHLY RECOMMEND SODERING!!!
Tools
**Sodering Iron
**Pliers
**Electrical Tape
**Duct tape
**Sharpie
Parts (All found at radioshack)
**12 Automotive Wire (25 ft was 5 bucks)
**5/16 inch Ring connectors (You will need 10, but buy a few extra) They will be insulated Spade/Ring connectors in a bag. I got the ones you can crimp and then sodered those for extra strength
**1 spade connector to plug into your wiring harness. If you buy the assorted bag of insulated Spade/Ring connectors, use the smaller spade connector
** (5) Bag of insulated wire connectors (Look like a small tube where you can but 1 wire in each end and then crimp them together to make a secure connection)
**1 30 amp Automotive Relay (Make sure on the back the connections are 87, 86, 85 and 30/51)
**1 25 amp automotive fuse
**1 Insulated inline automotive fuse holder
Cost me 21 dollars with tax
Directions
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For the Ballasts
1. Use a connector to connect the black wire running from the ballast (Negative wire) to 3 feet of 12 gauge wire. Crimp the connector down to make sure the wires are connected and then wrap that in electrical tape. (The length will vary depending on where you want to mount these ballasts but three feet is enough to get to any grounding point) Wrap a few strips of duct tape around this wire and the same wire on the next ballast so you can easily tell that this is the Negative wire.
2. Use another connector to connect the red wire from the ballast (Positive wire) to 5 feet of 12 gauge wire. Crimp and wrap in electrical tape.
3. On the end of each of the wires crimp on a 5/16th inch ring connector and then soder if you are able to and then wrap in electrical tape.
4. Repeat these steps for the other ballast as well.
5. Then take the 5/16th ring connectors at the end of each of the positive wires and wrap the 5/16th ring connector around the "87" prong on the relay. (This is the top prong when "30" is on the bottom and I will use this "87" prong to help you orient yourself on the rest of the prongs) The back of the relay's box will have a diagram on it of which prong is 87 and it is also written on the relay. This is where soder is pretty vital. You want those connectors to stay tight on the prong. Once they are attached, wrap them in electical tape.
6. Take the negative wires with duct tape on them and attach the ring connectors to the negative terminal on your battery or to any ground near the ballast. I used a bolt on the manifold and on the side fender wall near the washer fluid bottle cause it was close for me.
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For the Fuse
1. Plug the 25 amp fuse into the fuse relay, you will see where it fits in and it only goes in one way so you can't do it wrong.
2. Use a connector to connect one end of the wire coming out of the inline fuse holder and attach that to 2 feet of 12 gauge wire. Crimp it down and wrap in electrical tape.
3. At each end of the wire attach a 5/16 ring terminal and crimp that down (soder if you can) and wrap in electrical tape.
4. One end will attach to your positive terminal on the battery and the other end will attach to the "30" prong on your relay. (Should be the bottom prong when "87" is on top) Make sure that connection on the relay is tight, (soder if possible) and wrap in electrical tape.
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For the Negative Wire
1. Take a 3 foot length of 12 gauge wire and crimp (soder if possible) a 5/16 ring connector on each end and wrap with electrical tape.
2. Attach one end to the "86" prong and soder if possible and wrap with electrical tape.
3. Attach the other end to your battery on the bolt around the negative terminal on the battery.
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Stock Harness Hook up
1. Take 3 feet of 12 gauge wire and crimp (soder if possible) a 5/16 ring connector down on one end and wrap in electrical tape. On the other end, take a ring connector that is smaller than 5/16, I couldn't find the size, but it is in the assorted ring/spade connectors, and attach that to the other end, crimp it, soder if possible and wrap in electrical tape.
2. Attach the 5/16th end to the "85" prong on the relay (Should be on the right if the "87" prong is on top). Make sure it is tight, soder if possible and wrap in electrical tape.
3. On the other end, take the smaller connector and use your pliers to make it more rectangular. You will plug that into the stock harness that you normally plug into your stock halogen lights. If you are looking at the stock harness from the front of the car it will go on the right side (The harness will look like this: |_|, you plug the end of the wire into the bold section)
Now All that is left is to mount your ballasts, connect the HID bulbs into their socket running from the ballast and you are all set.
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The picture below helps illustrate the wiring setup, you are looking at the prongs to help decide where it all goes.
http://i10.photobucket.com/albums/a1...torHarness.jpg
After this is all made. Just put the ballasts where you need to, connect the HID bulbs to the ballast, make sure all the relay wires are in the grounds, positive battery terminal and the one from "85" is in the stock harness, (either the left or right side, and just tape up the other side that isn't used). Once this is all done, turn on your headlights and you should be good to go!
////END DIY////
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OK, now for some tips from my own install which might help answer some questions so k_20's inbox doesnt get full :)
Wiring Diagram:
THANK YOU TALONXRACER!!! Here is Talon's wiring set-up diagram. Very Clean:
http://i54.photobucket.com/albums/g9...e_Bi-Xenon.jpg
Tips from my install (my thanks goes out to Mike for the help):
The H4 male plugs into the stock wiring harness via the H4 female plug. That's how it can all be controlled like stock. The clips for the ballasts can be purchased and I just cut off the other clips for the hi/lows and soldered on a clip of my choice.
The bulbs are directly connected to the ballast via the ignitor on the inside of the headlights. The clip coming from the bulb is actually there just to activate the hi beam motor. When you turn on the hi beams with these lights it just supplies power to this little motor that turns the reflector up to change the path of the beam.
You can get some Relays just like the ones on the diagram from Radioshack, or you can find some waterproof Bosch relays like Talonxracer has used on his. Just make sure you put an inline fuse on the + side from the battery. I think it needs to be within 12 inches from the battery.
When I was temporarily wiring mine together to make sure the lights worked out ok, I had a pair of wires come unconnected and ground out and pop the fuse.
I believe my relays are 30A, it's been a while since I've gotten it all done though. The wires on the bulbs should be red and black. The wire pigtails on the ballast clips should be labeled +/- whenever you get them.
One thing I will add, since I encountered this during my install of my CTR HID Headlights, if you go to turn on your Hi beams and the lights turn off, check 3 things first: 1.) your grounds 2.) your setup at the relays 3.) [this is the one that got me] make sure you didnt switch the Hi ground to the Lo ground spot on the H4 plug.
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Some install pics:
The ballast clip:
http://i10.photobucket.com/albums/a1...r/IMG_0111.jpg
The relays for the harness
http://i10.photobucket.com/albums/a1...r/IMG_0117.jpg
Harness with the ballast clip connected
http://i10.photobucket.com/albums/a1...r/IMG_0116.jpg
Inline fuse to the battery
http://i10.photobucket.com/albums/a1...r/IMG_0118.jpg
Placing the wires around everything
http://i10.photobucket.com/albums/a1...r/IMG_0124.jpg
http://i10.photobucket.com/albums/a1...r/IMG_0125.jpg
http://i10.photobucket.com/albums/a1...r/IMG_0126.jpg
http://i10.photobucket.com/albums/a1...r/IMG_0127.jpg
grounding the harness
http://i10.photobucket.com/albums/a1...r/IMG_0130.jpg
I installed the relays to a mount that is in the driver's side cubby hole of the fron bumper
http://i10.photobucket.com/albums/a1...r/IMG_0128.jpg
http://i10.photobucket.com/albums/a1...r/IMG_0129.jpg
And of course after everything is installed
http://i10.photobucket.com/albums/a1...IMG_0136-1.jpg
http://i10.photobucket.com/albums/a1...r/IMG_0239.jpg
Lo Beam
http://i10.photobucket.com/albums/a1...IMG_0131-1.jpg
http://i10.photobucket.com/albums/a1...IMG_0137-1.jpg
Hi Beam
http://i10.photobucket.com/albums/a1...IMG_0132-1.jpg
http://i10.photobucket.com/albums/a1...IMG_0138-1.jpg
