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Nice write up, lots of good pics
only a couple of minor problems with the install. Some of the wiring techniques are not conducive to long term reliability.
The purple wire going to the 7.5 amp fuse in the underhood fuse box is not a reliable connection. Vibration or other kinds of movement will eventually loosen the connection. Also when you force a wire into the spade connection of the box along with the fuse blade it spreads out the connector. This connector is spring loaded, when you spread it too far it opens up. If the purple wire is ever removed the connector will be looser than normal causing increased resistance in the circuit.
the best way to connect in this case is go behind the fuse box to the same wire as this connector and splice in with a crimp connector that comes with shrink tube insulation. They do make little connectors that go into a fuse connection but they also spread out the connector.
The connection at the bulb is not sealed to the elements. Note the factory connection, it has a rubber seal. This is a problem area, there's some heat generated at the bulb, combined with moisture this will cause corrosion which causes more heat and eventual meltdown and failure. A quick fix would be to pack the connectors with dielectric grease and check it periodically. A more permanent fix would be to get some factory connectors and splice into them with heat shrink crimp connectors or solder connections and heat shrink.
The yellow scotch-lock by the steering column is an interior only type connector also in that it's not sealed. You have to be really careful with these type connectors even on the interior, they are one of the more problematic of AM connectors. A more bulletproof way is shrink tube crimp connector or solder/shrink tube.
Have you looked at your wire gauges and amperage requirements? All copper wire alloys are not created equal. Japanese manufactures generally use the highest grade copper wires commonly available. Off the shelf AM wire is generally medium or low grade. If unsure it's better to increase the gauge size by at least one step. There's also the factor of length, the longer the run, the more the amperage drop. When you are not getting enough amperage to the bulbs due to these factors they will not be at their full brightness.
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Mitsubishi dealer tech
Pacific Northwest
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the funniest thing about this message is that by the time you realize it doesn't say anything it's too late to stop reading it.
Last edited by NWM_Tech; Jul 4, 2009 at 09:07 AM.
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