[ankurbhageria]

Hi

I am using Philips genuine 35W HID kit on Grand i10 petrol. The lights have been working fine for four years.

Recently, the lights turn off randomly; when I check, the ground wire connecting the harness to the car body is extremely hot.

Please suggest how to rectify this problem.

Thanks

[graaja]

Originally Posted by ankurbhageria

Hi

I am using Philips genuine 35W HID kit on Grand i10 petrol. The lights have been working fine for four years.

Recently, the lights turn off randomly; when I check, the ground wire connecting the harness to the car body is extremely hot.

Please suggest how to rectify this problem.

Thanks

Is the wire hot throughout its length, or at the place where it is connected to the chassis?

If the former, this could mean that there is an overload (faulty bulb or relay). You will have to change the faulty component.

If the later, it could be a loose connection in the connection between the wire and the chassis. Check for any loose connection in the crimping between the wire and the terminal, or a loose nut or screw that fastens the terminal to the chassis. You could also remove the terminal from the chassis, sand off the contact area to expose the chassis and fasten the terminal again.

[gthang]

Originally Posted by ankurbhageria

Hi

I am using Philips genuine 35W HID kit

Please suggest how to rectify this problem.

Thanks

Check the inline fuse holder. Fuse seating gets loose with time leading to intermittent power.

Cheers

[ankurbhageria]

I checked the fuse and holder. They seem fine.

Thanks

[R2D2]

Originally Posted by ankurbhageria

Recently, the lights turn off randomly; when I check, the ground wire connecting the harness to the car body is extremely hot.

It looks like a short or an overload (that's what causes the wire to heat up) somewhere in the HID wiring harness. I would strongly recommend getting this looked into and resolved before it becomes a fire hazard. You really don't want to take a risk.

[ankurbhageria]

Originally Posted by graaja

Is the wire hot throughout its length, or at the place where it is connected to the chassis?

If the former, this could mean that there is an overload (faulty bulb or relay). You will have to change the faulty component.

If the later, it could be a loose connection in the connection between the wire and the chassis. Check for any loose connection in the crimping between the wire and the terminal, or a loose nut or screw that fastens the terminal to the chassis. You could also remove the terminal from the chassis, sand off the contact area to expose the chassis and fasten the terminal again.

It's hot throughout, burning hot. The terminal connecting the chassis is normal.

I also heard continuous clicking ("krrrrrrrrr") for 2-3 seconds. That could be the relay.

Thanks for the reply, I'll update this post with the fix.

[ankurbhageria]

Originally Posted by R2D2

It looks like a short or an overload (that's what causes the wire to heat up) somewhere in the HID wiring harness. I would strongly recommend getting this looked into and resolved before it becomes a fire hazard. You really don't want to take a risk.

Yes, that's my concern. I'll get it checked soon.

[gthang]

Originally Posted by ankurbhageria

I checked the fuse and holder. They seem fine.

Thanks

Did you try powering up the lights and wiggle the holder? If the lights don't flicker, it's fine. It took a while for me to isolate similar problem because visually everything looked fine.

Cheers

[ankurbhageria]

Originally Posted by gthang

Did you try powering up the lights and wiggle the holder? If the lights don't flicker, it's fine. It took a while for me to isolate similar problem because visually everything looked fine.

Cheers

Hi

I did try wiggling the wires to check for loose or damaged connections.

The light flickers when I move the ground wire, especially when it gets hot. Additionally, the fuse on the harness is also getting very hot.

[ankurbhageria]

I got the system fixed a week after posting, apologies for not updating the forum

The positive wire was the culprit. It's battery terminal and fuse socket connectors were corroded, leading to excessive current draw.

That wire, being much thicker than ground, wasn't getting as hot as the latter.

Got a new positive connector crimped to the wire and had the series fuse holder replaced. The system is in order now.

Thank you all.