Mazda 6 Forums banner

1 - 20 of 60 Posts

·
Registered
Joined
·
1,780 Posts
Discussion Starter #1
I purchased a set of the Katsuro 5000K HIDs from XenonExperts current group buy. I received them in the mail a few days ago but I wasnt expecting to be able to install them until maybe Jan because of Xmas and New Years. Luckily, I was able to leave work Friday and drive home for Xmas and had Saturday afternoon free so I took the HIDs with me and installed them......

There are already a few good How-To-Dos written by
Rage: http://forum.mazda6club.com/index.php?showtopic=61688&hl
Monkeyboydrew and skatingzooyork: http://forum.mazda6club.com/index.php?showtopic=33330
and glare elimination by mmarfan: http://forum.mazda6club.com/index.php?showtopic=33330
so I will just refer to them and steal some parts from them and add some parts where I feel is needed.... there is no need to re-invent the wheel.... so thanks to them in advance for their previous how-tos.

The install for the Katsuro's is pretty much identical to the Xtec and Apexcone kit.

First you NEED to remove your bumper. I read a few posts about people talking about installing these without removing the bumper. Some people might be tentative about removing it but it seriously takes only 10-15 minutes to do it. You need to remove your bumper to get at the 2 lower screws on the headlights and to mount the ballasts.

First, examine your kit out of the box....

There should be 2 ballasts, 2 HID lights with wires, and 2 pieces of double sided tape. This kit is PnP so there is no wiring harness involved.....
--------------------------------------------------------------------------------------------------------------------------

Step 1: Removing your Bumper
http://www.mazda6tech.com/index.php?option...7&Itemid=49

A few comments on removing your bumper:

Personally, I did not jack the car up. You really dont need to. My car is lowered and I have a small stubby phillips head screwdriver which I use to unscrew the lower 8 bolts on the car. Also, getting at the 3 side pop out screws in the wheel well is difficult. I recomment parking your car with the wheels turned to the EXTREME right, then unscrewing the entire left side of the bumper then re-starting your car and turning your wheels to the EXTREME left, and then unscrewing the entire right side. This makes taking off the bumper a breeze. See picture below to understand what I am talking about:



As you can see, with your tire completely turned, its really easy to get at the 3 pop tabs and the screw under the wheel well liner.

--------------------------------------------------------------------------------------------------------------------------

Step 2: Removing your headlights

First, you need to remove the headlights. When removing the headlights, I removed 5 bolts and a pop up tab, for a total of 6 "bolts". There are 2 bolts on the top of the headlight, 2 bolts on the bottom, one bolt on the white part on the side of the headlights, and one black small pop up tab on the top which requires a knife to pop it up then you pull it loose with your fingers. See pictures below:



There is one electrical connection to the headlights that CAN or CANT be unplugged. For my left headlight, the plug came off easily so I removed it, however, for the right one, it was a little tough so I did the install on the right side with the cable still attached...... its your choice. I did it both ways. If you DO leave the cable plugged in though, make SURE you have a second set of hands as you will need someone to hold the headlight up while you work on it. Luckily my retired pops, who is a car guy himself, did not have much to do today and was eager to help his son play with his car.

Pics of the removed headlights:


And the rear of the headlights:


When your headlights are removed, and optional step would be to remove the beam reflector inside the headlights...... I did NOT remove my beam reflector. I planned on driving around and seeing how the light was before I decided if I was going to remove it.

Instructions for removing: (from mmarfan)
http://www.cardomain.com/ride/575036/7

--------------------------------------------------------------------------------------------------------------------------

Step 3: Removing and modifying the dustcaps
Next, you need to take off the dust cap to get to the H1 bulbs. To the left of the headlights is where the H1 low beams lie. To get to them you need to remove the dust cover:


Just twist it and it pops off. Dont lose the rubber circles around the inside of the dustcaps. Mine fell off but make sure you dont lose them because they keep the dustcap sealed tight.


Above is a picture of the inside of the lights with the dustcap off.

When your dustcaps are off, take your dustcap and drill a small pilot hole in the middle of them:


The other installation how tos call for a 7/8 inch butterfly drill bit..... I would recommend using something a little smaller. The rubber grommet that fits in the hole was a little loose using the 7/8th butterfly bit. If I went a size down, the grommet would have fit a bit snugger so I would recommend using a smaller bit.... you can always enlerge the hole but you cant make it smaller. Once your drill the hole, us some sandpaper around the edges to make it smooth.



--------------------------------------------------------------------------------------------------------------------------

Step 4: Removing the stock bulbs

Next, you need to take the positive and negative wires off the stock H1 headlights. There is a metal wire clip now holding the light in place. If you look to the bottom of the clip, you will see where it is hooked on a small hook. Pull the metal wire around the clip and it pops up and you can easily take our your stock H1 headlight. Remove your stock H1 headlights and put them in a safe place incase you ever want to revert back to stock.


--------------------------------------------------------------------------------------------------------------------------

Step 5: Re-installing the modified dustcaps

Now, when you have all the wires not connected, take the dustcap with the hole in it and put it OVER the wires and the HID light. Slide it past the rubber grommett and begin working on the power and ground connections. If you skip this step, you will go to put your headlights in, connect them, and then have to magically run wires through the dustcap. I ran the wires through, and because the rubber grommett was a little loose in the 7/8 inch hole in the dust cap, I covered it in electrical tape to ensure no moisture could enter the headlight housing.




--------------------------------------------------------------------------------------------------------------------------

Step 6: Connecting the HIDs

The positive wire from the Katsure kit fits in perfectly, however the ground wire does not. The stock metal holder is a little small and needs to be widened to fit in the stock clip. Be CAREFUL when doing this. Where the actual stock ground wire connects to the clip looks to be pretty fragile. I used a pair of needle nose pliars to hold the end of the clip and a small flathead screwdriver to enlarge the clip.



The RED arrow shows where the ground wire is connected. This is the holder that needs to be slightly enlarged. The YELLOW arrow shows where the wire is connected to the holder. This section is pretty fragile and is where I held it with my needne nose pliars. The BLUE arrow is where the power wire easily connects.

After I connected all the connections, I covered them TIGHTLY with electrical tape.


Then, once all the connections were connected, I tested the HIDs by turning on my headlights to make sure they were working properly. You dont want to install everything, put your bumper back on, and then realize you have a loose connection. The lights came on perfectly.

Now you get to connect everything to your car. I then connected the HID bulbs in the stock headlight housing. Be CAREFUL when sliding in the bulbs..... its a very tight fit. If you look at the bulb holder, there is a small circle cutout in it for putting in the bulbs. The bulbs only go in in one direction..... Once the bulbs are in, CAREFULLY clip down the metal clip. It was a pretty tight fit to re-connect the clip because of the larger rubber base around the HID bulb. I used a small flathead screwdriver to help "guide" the clip back into the holder. Once the light is in, screw in your dustcap and I put the headlight back in. I put ONE screw in the headlight to hold it in place while I was mounting the ballasts. Make SURE when you are putting the headlights back in place that you dont bend or stress the wires coming out of the dustcap. Its a VERY tight squeeze in there so make sure your wires have a good clear path and are not being compressed and bent in funny directions when you put the headlights back in.
 

·
Registered
Joined
·
1,780 Posts
Discussion Starter #2
Step 6: Mounting the Ballasts

Next, you need to choose a mounting place for the ballasts...
For mounting the ballasts, the kit gives you 3m super adhesive tape. I would recommend cleaning ALL surfaces before applying the 3m double adhesive tape. I mounted my ballasts in the same exact place as shown in the installation how-to. The metal wall next to my air filter was extremely dirty and so was the metal wall behind the windshield washer fluid tank. Take a little bit of rubbing alcohol (I used isopropryl) and put it on a paper towel and clean the side of the metal on your car and then clean the surface or the HID ballast. Dont spill any rubbing alcohol on your driveway because it will "stain" your driveway and your retired father will yell at you....... take it from Philter.

Passenger side mounting location:


Drivers side mounting location:


The main difference between our ballasts and the Apexcone ballast is that the Katsuro ballast do NOT have an extra hook on them so you could screw them into the metal....... the ballasts are connected with 3M double sided tape. The tape seems like if you clean all surfaces and get a good connection, it will stick..... however because I am anal, I plan on checking the "connection" between the ballast and the metal the next time I have my car apart.

--------------------------------------------------------------------------------------------------------------------------

Step 7: Re-assemble your car
Once you run the wires and mount your ballasts, re-screw in your headlights and test them one more time to make sure they work. Once you verify again that they are working perfectly, re-install your bumper and screw everything back together.

--------------------------------------------------------------------------------------------------------------------------

Step 8: Now admire your new HID kit:

Pic showing new HIDs compared to stock ugly foglights.... yucky fogs.


Cutoff shots on the old garage door: The lights are perfectly even, I just took a few shots because I was holding the camera up on top of my car and it was slightly crooked.

Cutoff shot, picture taken on top of car:


Cutoff shot, picture taken from inside the car:



Thanks to Rage, Monkeyboydrew, and Skatingzooyork for the previous how-tos and pictures which I incorporated for my how to.

My HID Review
 

·
Registered
Joined
·
2,932 Posts
hmmm i see some glare.... :D

but good job though !!!
 

·
Registered
Joined
·
867 Posts
Great write-up! This should also be pinned though
 

·
Registered
Joined
·
336 Posts
once again, awesome work Philter25!

mods lets pin this up, this is good stuff :yesnod:
 

·
Registered
Joined
·
59 Posts
Way to go Philter ! Like to see that hint of blue showing its face in da pics :)
I'll be getting the Apex 5000Ks too - early January . :D
[/b]
Philter, really wonderful 'how-to'!
One question, where can I get white side marker covers like yours? Mine are yellow and they look ugly on my silver 6. Are they available at the dealer?

Thanks.
 

·
Registered
Joined
·
1,780 Posts
Discussion Starter #12
Philter, really wonderful 'how-to'!
One question, where can I get white side marker covers like yours? Mine are yellow and they look ugly on my silver 6. Are they available at the dealer?

Thanks.
[/b]

As said above me, I believe the only place that sells them is dealers on eBay. Site sponsors no longer carry them so the eBay way I believe is the only way to go.
 

·
Registered
Joined
·
1,780 Posts
Discussion Starter #14
is it really necessary to remove the front bumper?[/b]
You need to take off your headlights, so yes. Without removing the front bumper, you cant access the lower screws to take off your headlight assembly. Its really a piece of cake to take off the bumper and it probably weight about 10 lbs. Its just a giant piece of plastic.
 

·
Registered
Joined
·
349 Posts
Okay...so your saying to install the HID kit, you have to take the headlights off...right? there is no other way?
 

·
Registered
Joined
·
1,212 Posts
Okay...so your saying to install the HID kit, you have to take the headlights off...right? there is no other way?[/b]

you will need to take the headlights off, since you will be performing modifications to them, especially if you do the anti-glare mod. taking off the bumper takes less than 10 minutes and goes on just as quick.
 

·
Registered
Joined
·
2,157 Posts
you will need to take the headlights off, since you will be performing modifications to them, especially if you do the anti-glare mod. taking off the bumper takes less than 10 minutes and goes on just as quick.[/b]
I would have to agree 100%. Also I wouldn't want to mess with touching the new bulbs to my skin or even breaking them trying to fit them in through the engine bay.

Anybody else with this kit have the rubber grommet come out of the head light dust cap? I was just checking my wires today and noticed on of mine had! I am going to take out the housings again tomorrow and through some tape on there to secure them. Just might be some thing to keep an eye on.
 

·
Registered
Joined
·
35 Posts
well I just got done installing my 6000K HIDs with out taking off the bumper. Hardest part for me was getting the metal clip that holds the bulb into the housing back on the new HID Bulb. Mind you I did this at 1:00 AM in my yard with a shop trouble light that kept falling.. Took about 2 hours to do both sides, but WELL worth it. I am going to take the bumper off next week to do the anti glare mod I think, but in the mean time I am LOVIN the HID'S!!!
 

·
Registered
Joined
·
1,780 Posts
Discussion Starter #19
Bump because Ive had some people asking in the past few months about the how-to...... maybe this could be stickified? Kinda funny how we have a hot-to on installing HIDs in the lower fogs but not a how-to on installing HIDs in your driving lights...... im sure a lot more people are installing HIDs in their driving lights vs. lower fogs. :yesnod:
 

·
Registered
Joined
·
1,661 Posts
Pretty helpful guide. Used it to install my Apexcone. Thanks Philter for the How to!
 
1 - 20 of 60 Posts
Top