Automotive Manual PDF

Installation Procedure
1. Remove Stock Headlamps by removing the three flathead screws securing headlamp bezel in place. Disconnect and discard stock headlamp.
2. Notch the back side of the housing to obtain additional clearance for HID wiring harness to pass through. (Please See Fig. 1)
3. Insert the projection HID lamps into the housing and reinstall Headlamp Bezel. Ensure that the top of the HID lamp is facing up before securing in place.
4. Install the two wiring harness to vehicle with both black wires secured to a common vehicle ground and the two red wires secured to the batteries positive terminal post located on drivers side engine firewall.
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Working Theory. The Chemical gases, most of which are xenon and iodides, are filled the quartz tube of the light. Through the ballast, then the voltage of 12V DC will be increased to 23KV immediately: the electrons of the xenon in the tube will be dissociated because of the voltage swing and thus an electrical arc happens between the two poles. Xenon light is power saving, safe and has long life, high luminance. In addition of the use of the UV-cut quartz tube, the light is crystal forever.
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This is an install document for a High Intensity Discharge Kit for the Volvo S40. This is a fairly simple procedure and should take approximately 45 minutes to install.
Kit Details
DDM HID Kit including:
2 – Ballasts and Igniter assemblies
2 – HID Bulbs w/wire assemblies
2 – Ballast to Bulb connecting wires
2 – 3M Double sided adhesive tape
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1. Take the kit out of the box and lay everything out. You can install either the ballasts or bulbs first but typically it is easier to install the bulbs first.
2. Remove the access cap from the rear of your headlight housing as shown.
3. Drill a hole in the center of the cap as shown. If you use a hole saw that will be all you need. If you use the small drill bit you will need to use your dremel to cut a 1″ hole. You may want to use some sand paper just to smooth the edges you have cut.
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The tools you needs:
A drill with a smaller bit such as a 1/4″
A dremel or similar to cut a hole in plastic
T27 Torx bit and driver with 4” extension
Extendable magnet
Pliers

1. Take the kit out of the box and lay everything out. You can install either the ballasts or bulbs first but typically it is easier to install the bulbs first.
2. There are 3 T27 torx screws holding the headlight on. The 2 on top are visible in this picture.
3. with the 2 screws removed…
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I decided to install HID’s in place of standard halogen bulbs for a little more light and I guess exterior looks. I won’t be able to see them much so I hope you other driver’s like them. Here’s the kit, a standard 35 watt HID nothing fancy conversion kit. The only extra I bought where some load resistor to clear up any “check fog light” errors I may receive.
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