Enough has been discussed about the poor headlights of the Ecosport. The stock reflectors are extremely poor and the OE bulbs are like candles. I decided to try out various options at improving the lighting of the Ecosport. Have documented the journey to En
lightenment for benefit of other forum members. You could say below is my tryst with LED's. The purpose of this thread is not just to help others upgrading to LED but to break some myths especially the one that says LED bulbs are "plug n play".
I had replaced the stock halogen bulbs with Philips X-treme vision bulbs. While they were a good upgrade form the hopeless stock bulbs they were still far from acceptable for our roads.
I had a couple of options to explore. One was to change the fogs to LED's. I found Morimoto Fog light assemblies that directly fit into Ford vehicles. This was completely plug and play and hardly any work needed. But they were expensive for what was essentially fog light illumination and not true headlights.
Morimoto 3" Fog lights for Ford:
https://www.theretrofitsource.com/as...to-xb-led.html Experiment #1 Hikari H4 LED's:
I thought I'll try out LEd headlights which were supposedly plug and play and would offer a bigger jump in lighting. After doing some research I realised it was important to look at LED bulbs that had the LED's in the exact same matching location as halogen bulbs. The filaments should match perfectly. There were far too many bulbs that did not have matching design vs the halogen.
I narrowed down to these 2:
1.
https://www.amazon.com/HIKARI-Headli.../dp/B01LCE19PW
2.
https://www.amazon.com/Auxbeam-Headl.../dp/B074GZ3S4P
I found better reviews of the Hikari and figured CREE LED's would be better than CSP. Went ahead and bought them through a friend who was in USA and carried them down to Bangalore for me.
As you can see the top half of the bulb is similar but the bottom part has a cooling fan and then a cable that goes till the LED driver.
A close look at the LED light source themselves. The low beam is a CREE XHP50 2x2 array:
High beam is a CREE XML2:
In comparison with a halogen H4 bulb:
Now lesson #1 in installing any type of LED's. When manufacturers say Plug n play, don't take them seriously. The only part that is plug and play is the wiring connector. You don't have to cut any wiring and the connectors are compatible. In my case I had picked up H4 Hikari LED's and they had a cooling fan on the bottom, a LED driver small box like a ballast you get in HID's and the H4 connector matching what you get in halogen bulbs.
So what exactly is the challenge? Getting that huge LED with the cooling fan and LED driver to actually fit inside the headlight assembly.
The first problem is once you place the LED into the slot of the headlight you need to clamp them down using the retainer. Now this is easy with the halogen bulb as the retainer just goes over the 3 pin plugs. But with the LED's the retainer doesn't fit since the fan is too big for the retainer to go over it.
I didn't have a pic of the retainer as I was too frustrated when trying to fit it in. But here's a reference pic of a retainer with H4 bulb from google. Now imagine with the H4 LED above to go over this metal retainer.
The retainer has 3 mounting points. 1 is removable whereas the other 2 are fixed as hinges. Now the only way to get the retainer to go over the LED assembly is to remove all 3 points. By removing all 3 the entire wire clip retainer comes off. Then you can guide it over the base of the bulb. After that depending on your dexterity and patience getting all 3 points back into their slots while holding the bulb in place with 1 hand is a royal pain in the back side. After more than an hour of trying, I would either get 2 points or the bulb would fall off. After some struggle I manage to get the clips on all 3 but now I don't know how and I am sure its going to be a struggle when I remove them.
After the bulb is in place, comes the second problem. The wiring maybe plug and play but the LED has an additional driver which can't be placed inside the assembly. The H4 female connector from the car is inside the headlight assembly in the Ford. Not so for other brands. And this connector is not water proof. So the only option was to have the wire from the bulb come out of the assembly so that the driver is outside the assembly, then the wire goes back inside the assembly to plug into the socket.
But then we have a problem. The dust cover. If a wire has to come out and then back in, you need to cut the dust cover and then it won't be sealed. The Hikari kit did not have any parts for sealing the dust cover.
In the end, I had to do a jugaad. I got the wire out but the dust cover was fit over the wire which meant there was a small gap. Wasn't top happy with this but since it was only an experiment, I went with it till I could figure out a way.
Finally had the bulb in place and working. Turned it On and it was crazy bright. In terms of illumination I could clearly see an improvement over the X-treme vision halogens. But my excitement was short lived. Parked the car against the wall and observed the beam pattern. It was sad. The cut off had disappeared with too much scatter. No bright hot spot and overall beam height had shifted too high causing massive glare to oncoming vehicles.
Low beam Xtreme vision halogen on left and hikari h4 LED on right:
Halogen bulb has sharp cut off and a decent hot spot as well:
Sadly the LED is all over the place. Note the lack of cut off and scatter. There's a lot more light but pointless since it's scattered:
After some adjustments I realized the problem was not just the bulbs but the headlight reflector design mostly. The CREE LED's were Array type LED's which meant 4 LED in a 2x2 pattern was the light source. This meant the light source was a more square source then a straight line seen on halogen filament. Moreover the narrow slim reflector design in the ford created a wider beam than focussed beam. I tried these LED's on a round reflector of Etios and they were far far better. So while these Hikari LED's would have worked on a different car, for the Ford they were useless.
It was back to the drawing board. One lesson learnt was don't go by Amazon reviews. These Hikari LED's have Japanese name with designed in America and made in Japan. In reality they are nothing but chinese LED's sold on aliexpress popularly known as V18 turbo LED:
https://www.aliexpress.com/wholesale...=v18+turbo+led