Passat (B5) :: 2002 1.8t Sedan - HIDs Blowing Low Beam Fuses


Jan 23, 2013

Car is a 2002 b5.5 1.8t sedan.

Bought the DDM Tuning HIDs, 3500k 35w for the fogs, installed with no problems. Also ordered the 5000k 35w for the low beams. Installed them, they flickered on for a second, then nothing. Let the ballasts charge for a while but still nothing. Called DDM, they said my car needs a error code eliminator kit thing later they were at my doorstep. Plugged one side in, flicked on then nothing. Thought both sides might need the code eliminators plugged in...wrong. both flickered on, and then nothing. Tried again, no flicker, both low beam fuses burned. Plugged the regular bulbs in, changed the fuses, lights working again.

I don't know much about electrical, but DDM said i def don't need a relay kit. Do I need a relay kit? Or would putting higher amperage fuses in the place of the original ones work? if so what amperage?

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I have switched fuses to new ones.

Is there anything else I can check?

Is there relays on this model for the high beams?

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I'm looking for the wiring diagrams or any other users experience in this matter... Where shall I start from?

There was a water leakage behind and under drivers seat. I removed trims etc. to lift the carpet to take the Comfort Module for checking as there were some weird thing in overall car electric systems (central locking, saloon lightnings, electric windows and dropping gauges on instrument panel. I found a small amount of water in container, where the module is placed, but on the electric parts weren't any water marks... Also it's impossible to connect to the CCM via vag-com.

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I have just bought the Passat 2002 TDI AVF engine. When I open the fuse box cover and look at the scheme, I can conclude that some fuses are missing. Probably I don't understand the symbols' meanings. For example the fuse 41 is missing, but my ABS works. But I have the ESP so though that is the same device probably the fuse 42 is for ABS too. Then, the fuse 9 is missing, and my car has the mirror heat function. How can I test do they work? Does the little symbol on the heat switch become yellow when they work? Fuse 10 is missing if I understood the symbol was for CD. My car has Charger in the back and it works.

The last thing is fuse 1. What is this fuse for? Is it for headlight washer, and if is, what is the fuse 3 for? I disregarded the possibility that some cars may have the washing water heater and it is may be for that. My car doesn't have either headlights washer or water heater. The fuse 18 is for long beam and signal lamp, it is obvious.

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I found the issue to be a blown 20 amp fuse in slot 23 (see pic). I replaced it and tried to turn the car on with the HIDs and it blew again. I hooked the stock lights back up and they seem to work fine now with another new fuse. The fuse description says H/LP LO and HID LO LH. Why this fuse is blowing. I am wondering if I just need a higher amperage fuse because of the HID power (in line for harness is 30 amp) or if something else is the culprit. I'm stumped.

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So, last night I go to turn on the high beams on my 2002 Passat (pushing the bar on the left of the steering column forward) ... and nothing happens. The bar clicks into place as it should, but no high beams. The little indicator light on the dashboard does not come on, either.

I try to flash my high beams, and that DOES work. The brights come on, and the little indicator lights up when the beams engage.

So ... I know it's not a fuse, since the lights are actually functioning. What part/switch/relay/whatever needs to be replaced to get this fixed? I feel like this would involve me needing to pull apart the mechanism in the steering column, but I hope not ...

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I have checked all the connections, and they all seem strong. I have used the diagram I found on here from exLEDshop outlining all the connections on the pin array for the headlight harness. I am tapped into the blue wire on the driver's side for + turn and the black for -, and the black w/orange stripe on the passenger side for + turn, and the black for -. If I accidentally have the load resistors connected to the wrong wire, would the turns hyperflash?

I know that it would be better if I used grounding points on the chassis for the load resistors, but could this be causing the short? Or could bad ballasts that are the culprit? The only reason I'm leaning away from it being the ballasts is because they worked fine until I put the load resistors in.

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I took it to a mechanic who could not reproduce the issue after letting it run for four hours. He replaced the fuses and told us to bring him the car when the problem recurred. Reservoir tank is full, no blockage in line from radiator to overflow tank.

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I took it to subaru, who said that the fans are not now under warranty (we have 65k on the car). I decided to have them replace the fans anyway, so I asked them for a diagnosis. However, after two days in the shop, they were unable to reproduce the problem. They ran the car in idle, they tried to recreate the stop-and-go/standstill environment of a carline, but no luck. They said that the fans were drawing the expected amount and that they would need recreate in order to diagnose.

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Where I could look to inspect the wiring for kinks or it's connection run?

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