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How-to HID installation for Astra GTC

13K views 25 replies 11 participants last post by  cornishtaz 
#1 ·
I bought a 9006 5000k HID kit from Hids Direct http://www.ebay.co.uk/itm/CANBUS-HID-CONVERSION-KIT-H1-H3-H7-H8-H9-H11-9005-9006-/220672732805?_trksid=p5197.m1992&_trkparms=aid%3D111000%26algo%3DREC.CURRENT%26ao%3D1%26asc%3D14%26meid%3D3109239107533466727%26pid%3D100015%26prg%3D1006%26rk%3D1%26sd%3D220672732805%26

The first thing to do is remove the bumper to aid the removal of the headlights

Remove 6 T20 screws on top edge of bumper and unclip the clip at each end of top edge


Then remove 4 T20 screws under each wheel arch


Then pull the top edge of the bumper where it meets the rear edge of the wing

It is possible to remove the headlight at this stage but its easier to remove completely to make access to the headlight bolts easier

There are 3 T20 screws on lower front edge of the bumper(for some reason the rear clips for my undertray were broken so it came away with bumper)


There are now 2 E12 bolts that need loosening no need to remove completely




Now disconnect the plug for the foglights/outside temp sensor


The bumper is now ready for removal so with some gentle pulling it'll be off

The next thing to do is remove the headlight bolts the easy ones first these are 7mm




The last bolt is a bit more awkward
First unclip the plastic bracket from the wing end

You'll then be able to see the last bolt


Unclip the headlight electrical plug

There are 2 plastic lugs under the headlight which can be pulled out carefully


The slowly remove the headlight from the car.

Now time to fit the new bulb, wiring and ballast
If you've bought a 9006 bulb then you need to trim the righthand tab to fit the 9012 holder do a small bit at a time until it fits correctly


Now you need to cut a 21mm hole in the twist off bulb cover and thread the wiring though ensuring the grommet is a good fit.(I bought 2 new caps from Vaux for £28) Remove your old bulb and insert the HID bulb and connect up the plug and refit the bulb cover.


I mounted the ballast on the underside of the headlight but you can place it somewhere safe and away from moisture.

If fitting underneath you need to modify the area where the OE ballast would fit


I used some double sided foam tape to hold the ballast in place



Now its time to refit everything the headlight is just a reversal of the removal process.

Now slide the bumper back on ensuring the the lower bracket fits onto the locating bolts


Tighten these bolts and reattach the undertray

Reconnect the foglight connector

Now clip in the bumper at the side


Now its just a matter of screwing the 4 underarch bolts and clipping the upper edge and refit 6 upper bolts.

Now enjoy the greater light output


 
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#6 ·
Great write up Baz :thumbs: Very detailed and informative.

I've linked to this in the bulbs reference thread as well.

Let us know how you get on when you take it for a drive...
 
#11 ·
Sounds the same as the normal GTC - one single-filament bulb provides both high and low beam.
 
#20 ·
Resistors? I should hope not. Resistor @ 20 watts of power are going to run very hot to say the least. As you've seen, the ones on your number plate bulbs already need heatsinks, and we're talking about in excess of 4 times the power output here, in already a much hotter environment.. I'd definitely want a more robust solution than that for my headlights. Last thing you want is those failing on a dark motorway somewhere!
 
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