Repair Procedures

Inspection

1. Check-points upon head lamp failure (HID)
(1) Check the battery voltage. (Low beam will be on when the battery voltage above 9V.)
(2) Check the fuse and relay.
(3) Check the polarity of ballast. (If the polarity are changed, low beam doesn't lighten)
(4) Check the bulb connector securely.
(5) Visually bulb checking (no filament): damaged glass, damaged for upper parts and lower parts of glass tube.
(6) After (1)~(5), replace the ballast and the ignitor. (ballast assembly).




2. Service procedure and warning (HID)






CAUTION:
HID lamp shall not be used on other cars.(Fire may occur.)
Fire may occur when HID lamp initially lights due to the fact that arc-discharge generates high voltage (max. 30,000V) and high current (12-13A), and are different from the halogen lamp specification.

3. Understanding of color change by replacement of HID bulb.
(1) The cause of HID color change.
(Change of color is HID feature)
A. The change of color occur during mixing three Elements in the HID bulb.




B. Color Coordinates by Lifetime




C. Chemical compounds in an arc tube :
1. Xenon gas(an inert gas , protection of arc tube)
2. Mercury( increase voltage, protection of arc tube, blue in the first 3 second )
3. Metal halide
- Natrium(Yellow) : 0.12mg
- Scandium(Blue) : 0.06mg
- Iodine(Halogen) : 0.02mg
(2) Change of Color by Lighting Up Time
A. It needs 4 seconds at least for stabilization.
At first, you can see the blue for 3 seconds because of Mercury.
B. After stabilization, change of color occur by metal halide.
- 0 Hour : Yellow( Na is more than Sc. )
- 10 Hour : Bright Blue (Na and Sc are similar ratio.)
- 1000Hour more : Blue ( Sc is more than Na.)
C. The end of lifetime : When HID used up Natrium and Scandium, a beam of light will be dark suddenly.
so you can see the red, purple and turn on and off.

Characteristic
1. Durable for vibration as there is no filament.
2. HID lamp had a more long life than halogen lamp.
3. Does not operate if polarity is changed.
4. Operating input voltage : 9-16V

Removal

Head Lamp Assembly
1. Disconnect the negative (-) battery terminal.
2. Remove the front bumper.

3. Remove the head lamp assembly(A) after loosening the mounting bolt(2EA).





NOTE:
Take care that holding clip (A, B) is not to be damaged.




4. Disconnect the head lamp connectors(A) (HID only).




5. Remove the bulb caps from the head lamp assembly after turning in the counter clock-wise direction.

Head Lamp Bulb (Low)
1. Disconnect the head lamp connector.
2. Remove the dust cover (A) after loosening the screw (HID only).




3. Remove the bulb connector (A) and Ignitor fixing clip (B) (HID only).




4. Remove the Ignitor & bulb (A) (HID only).





CAUTION:
Turn the head lamp switch off to avoid high voltage
Be careful not to damage the bulb and use genuine bulbs only
- Do not apply excessive force and fit it correctly.
- Confirm the bulb locking

Head Lamp Bulb (High)
1. Disconnect the head lamp connector.
2. Turn the dust cover (A) counterclockwise and remove it.




3. Turn the bulb socket (A) counterclockwise and remove it.





Head Lamp Bulb (Turn signal)
1. Disconnect the head lamp connector.
2. Remove the dust cover (A) after loosening the screw (HID only).




3. Turn the bulb socket (B) counterclockwise and the remove the turn signal bulb (A).





Ballast
1. Turn the head lamp switch off.
2. Remove the head lamp assembly.
3. Disconnect the head lamp connector.
4. Remove the ballast (A) after loosening the screws (3EA).





CAUTION:
- HID lamp shall not be used on other cars.(Fire may occur.)
- Fire may occur when HID lamp initially lights due to the fact that arc-discharge generates high voltage (max. 20,000V) and high current (12-13A), and are different from the halogen lamp specification.
- Install the dust cover after confirming the locking state between bulb and bulb holder.
- When testing the HID head lamp, turn the power on or off with switch between power supply and lamp because of high voltage.
- Do not operate the head lamp switch with the bulb not installed, because it generates spark momently.

Installation

Head Lamp Assembly
1. Install the head lamp assembly after connecting the connector.
2. Install the radiator under cover.
3. Connect the negative (-) battery terminal.

Head Lamp Aiming Instructions

The head lamps should be aimed with the proper beam-setting equipment, and in accordance with the equipment manufacturer's instructions.

NOTE:
If there are any regulations pertinent to the aiming of head lamps in the area where the vehicle is to be used, adjust so as to meet those requirements.

Alternately turn the adjusting gear to adjust the head lamp aiming. If beam-setting equipment is not available, proceed as follows:
1. Inflate the tires to the specified pressure and remove any loads from the vehicle except the driver, spare tire, and tools.
2. The vehicle should be placed on a flat floor.
3. Draw vertical lines (Vertical lines passing through respective head lamp centers) and a horizontal line (Horizontal line passing through center of head lamps) on the screen.
4. With the head lamp and battery in normal condition, aim the head lamps so the brightest portion falls on the horizontal and vertical lines.
Make vertical(A) adjustments to the lower beam using the adjusting wheel.





Front Fog Lamp Aiming
The front fog lamps should be aimed as the same manner of the head lamps aiming.

With the front fog lamps and battery normal condition, aim the front fog lamps by turning the adjusting screw(A) with a driver.





Head Lamp And Fog Lamp Aiming Point








1. General Type (VOR)
A. Turn the low beam on without driver aboard.
B. The cut-off line should be projected in the allowable range (shaded region) shown in the picture.
C. If head lamp leveling device is equipped, adjust the head lamp leveling device switch with 0 positions.




2. HID Type (VOL)
A. Turn the low beam on without driver aboard.
B. The cut-off line should be projected in the cut-off line shown in the picture.
C. If head lamp leveling device is equipped, adjust the head lamp leveling device switch with 0 positions.




3. Turn the front fog lamp on without the driver aboard.
The cut-off line should be projected in the allowable range (shaded region)