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Next stage is to prepare the wiring on the car to accept the new lights. The Discovery II old headlights have a double filament bulb and are wired in such a way that when you switch from dip beam to main beam, the dip beam is switched off (except when briefly ‘flashing’ the lights). The new lights are different in 2 ways, firstly because they have separate light units for dip and main beam and secondly because when you switch from dip to main beam, the dip beam must stay on.
There is one other small difference which is that the old style indicator housing also contained a sidelight marker bulb - this is no longer required so the plug connector for these side markers should be taped up and stowed out of the way of the new lights.
First thing to do is, using one of the spot weld holes, prepare this to become an earthing point - the old headlight dip/main beam shared an earth cable but as the new lights are on together it is sensible to provide a separate main beam earth to prevent an overload on the wiring.
Use a small nut/bolt and washers to secure ring connectors to the car body through the spot weld hole - I used the same mount point as is required for the relay - see further on in text.
Locate the previously labeled headlamp connector plug, side light connector plug and indicator connector plug and cut off the plugs as close to the plug as you can - to provide maximum length of wires. The indicator earth wire is not required and can be taped up.
The following colouring of wiring is what was found on my car and in the light units I purchased, ensure you check your wiring with a test meter to ensure it is the same. Fit female spade connectors to the cut ends of the wiring loom of the car.
DRIVER SIDE WIRING
HEADLIGHT CONNECTOR PLUG
BLACK...............................................................CONNECT TO NEW LIGHT UNIT BROWN WIRE
BLUE/BLACK.........................................................CONNECT TO NEW LIGHT UNIT GREY WIRE
BLUE/ORANGE................................................CONNECT TO NEW LIGHT UNIT ORANGE WIRE
SIDE (PARKING) LIGHT CONNECTOR PLUG
BLACK.........................................................CONNECT TO NEW LIGHT UNIT THIN BLACK WIRE
RED/ORANGE..........................................................CONNECT TO NEW LIGHT UNIT RED WIRE
INDICATOR PLUG
GREEN/WHITE.......................................................CONNECT TO NEW LIGHT UNIT BLUE WIRE
NEW EARTH (GROUND) CABLE YOU HAVE INSTALLED
...................................................................CONNECT TO NEW LIGHT UNIT THICK BLACK WIRE
Next job is to install a relay which will allow the dipped beam lights to remain on, once you switch to main beam. This has only to be installed at one side as it controls both lights. Follow the wiring diagram below to connect the relay which is available from car accessory shops such as Halfords.
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