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Im refitting some phillips D2R globes to another set of headlights I have, the factory ballast to bulb wiring has been cut.

There are the 2 larger gauge wires that I know are + / - for the bulb, there are 2 other smaller wires in the harness that I believe are some sort of safety wires to stop the ballast from firing up without a bulb being attached, can anyone tell me if these should be grounded or do they need some kind of resistance or signal fed to them?

I have some new D2 harness' and plugs to wire in but they are only the 2 wire kind not the OEM 4 wire.

Can anyone help with what to do with the smaller gauge wire?

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Are you looking at the harness socket on the headlight assembly, or on the back of the D2R plug itself? Two of the wires on the socket attached to the headlight assembly go to the auto-levelling motor.

I just had a look around, and found this pic' of a (similarly butchered, by the sounds of it) "complied" stagea headlight - the bottom arrow points to a triangular socket which has been filled with putty; that's the height-adjustment motor, if memory serves. Looking at the ballast at the top though, I see several wires... hmm. There should be some posts on these forums to help you out though. The one I got the picture from for instance is http://www.skylinesaustralia.com/forums/topic/404134-xenon-replacements/

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for anyone that googles this in the future, The 2 larger gauge wires are for positive and negative, dont think it actually matters what way these go around as the stock ballast is AC.

The 2 smaller green wires in the harness are for the safety that does not allow the ballast to fire if there is no bulb connected, what you need to do with these is solder them together and put some heatshrink around them to complete the circuit - just make sure you have a bulb in the socket before you power them up

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