Retrofitting Valeo HID Xenons to H7 Headlight
Decided to go for Valeo HID Ballast Kit and fit them in my H7 Halogen Headlight units. These kits are readily available in the US and I have recently found a supplier UK based.
I have previously had Slimline Ballasts fitted in this Healdight unit, but still get the intermittent "Brake Warning/ABS" errors on the DIS when switching the Lights on - Re-routing the crash sensor screened cables can reduce this error occurence but I have not been able to get rid of it 100%. Aftermarket HID kits rely on bulb connections from a Ballast or intermediate box using HT cables to the bulb, I believe these HT cables emit an RF interence spike which interferes with the crash sensor communication cables. (Note that this slimline ballast kit never gave me bulb out warnings on the DIS only the occasional Brake/ABS errors.)
The Kit I received (postmarked from San Fransico?) had the following parts:
plus H7/D2S adaptor rings and 12x Torx screws.
I am using my original H7 Projector Headlights (o/s RHD shown):
From my previous Slimline HID kit fit I had already cut a hole between the OEM Ballast recess
and the inside of the headlight.
Dimensions are here if you need to do this:
The Valeo Ballast to fit:
Crimp some male spade connectors to the power supply cable and insert the plug into
the Ballast 4 pin terminal. Connect the "Low voltage" shielded igniter wire into the other socket.
The Ballast comes with a rubber gasket already in place. Feed the wires through the
headlight hole and position the Ballast:
Secure the Ballast with the Torx screws supplied:
Cables seen from inside the H7 projector headlight. Connect the 12v H7 bulb
feed plug to the two ballast spade connectors. (These connections do not seem
to be polarised.)
The D2S bulb (4300K) - note that the H7 metal adaptor ring is already fitted.
Normally you have to trim a small part of the bulb base to make the bulb fully
compatible with the H7 fitting.
I was advised to do the following: "There is some further installation information that I would like to make you aware of although I think it will be obvious what needs to be done when you handle the items. The HID bulb should be orientated and fitted with the ceramic tube at the lowest position. The H7 adapter is fitted to the base of the bulb but in order to fit in your headlights the base will need to be modified slightly. The rim of base of the bulb will need to be trimmed off (with a dremel or clippers) so it doesn't obstruct the H7 adapter. "
I used a Junior hacksaw very carefully!
Picture from the "HID Origin" email H7 plate instructions showing the parts to trim with the H7 metal adaptor plate fitted:
HID Concept also have this bulb modification documented if you purchase their H7/D2S Adaptors.
The bulb in position and fully retained with the original H7 spring clip. This clip will
fit but needs a little persuasion to seat in correctly - you just need to wiggle it over
the bulb bayonet lugs.
You can now connect the braided cable to the Valeo Igniter unit and then push
this onto the bulb:
The Valeo Igniter will lock in position with a 45 degree clockwise twist action.
All done and locked in place:
Bulb access cover fitted in place:
Repeat for the other headlight unit.
Fitted both headlights and no DIS bulb out errors.