My cossie headlight decided to fill up with water when I was trailering my XR and without noticing this I turned the car on+headlights and about 3 minutes later I turned the car off due to me seeing smoke rising from the hood. A wire going from the battery to the cossie headlamp was melted as was a section of the fuse box that contained the fuse connecting to the headlights.
Do I need to replace the fuse box as well as the entire harness for the car or can I replace the fusebox and just the damaged wire going to the headlight?
Also, has anyone swapped their fusebox before? What am I looking to get into?
dhraakoxr wrote: ↑Fri Mar 17, 2023 10:05 am
Hey all need your opinion please.
My cossie headlight decided to fill up with water when I was trailering my XR and without noticing this I turned the car on+headlights and about 3 minutes later I turned the car off due to me seeing smoke rising from the hood. A wire going from the battery to the cossie headlamp was melted as was a section of the fuse box that contained the fuse connecting to the headlights.
Do I need to replace the fuse box as well as the entire harness for the car or can I replace the fusebox and just the damaged wire going to the headlight?
Also, has anyone swapped their fusebox before? What am I looking to get into?
I took one out partially. The fuse box under the hood with all the relays. It seems like they dropped the wire bundle downward from the top to inside the cabin on the assembly line. The box has plastic tabs that click into place. So if you get under it from inside the car and pull inward on those plastic tabs the box will lift up a little. You want to install relays to run the euro lights complete with fuses.
The best way to keep your Kia from being stolen is to not have a Kia.
dhraakoxr wrote: ↑Fri Mar 17, 2023 10:05 am
Hey all need your opinion please.
My cossie headlight decided to fill up with water when I was trailering my XR and without noticing this I turned the car on+headlights and about 3 minutes later I turned the car off due to me seeing smoke rising from the hood. A wire going from the battery to the cossie headlamp was melted as was a section of the fuse box that contained the fuse connecting to the headlights.
Do I need to replace the fuse box as well as the entire harness for the car or can I replace the fusebox and just the damaged wire going to the headlight?
Also, has anyone swapped their fusebox before? What am I looking to get into?
I took one out partially. The fuse box under the hood with all the relays. It seems like they dropped the wire bundle downward from the top to inside the cabin on the assembly line. The box has plastic tabs that click into place. So if you get under it from inside the car and pull inward on those plastic tabs the box will lift up a little. You want to install relays to run the euro lights complete with fuses.
Thanks and good point on the relay! I know somewhere there is a "how to wire cossie headlights". I think whoever wired these 15+ years ago didn't do it right.
The build quality seems good on the one i bought. Perhaps it's an option...
Cheers
Thanks for this. What about the relays though?
Honestly I would use a relay for each side...You could use the original headlight wire to trigger the new pair. Basically make your own headlight harness, but they should definitely have relays. Lights pull way too much current not to, hence why so many have melted fuseboxes and wiring.
The build quality seems good on the one i bought. Perhaps it's an option...
Cheers
Thanks for this. What about the relays though?
Honestly I would use a relay for each side...You could use the original headlight wire to trigger the new pair. Basically make your own headlight harness, but they should definitely have relays. Lights pull way too much current not to, hence why so many have melted fuseboxes and wiring.
Ok sounds great, this is a good call.
First step is to source a new fuse box or some sort of replacement.
Standard make many small parts for fuses, relays, connectors, etc.. for mechanics and relay socket mounts with short output wires are part of that. SMP are the folks who make Blue Streak ignition parts. If OEM is not available, Blue Streak is my next choice. For some Coil on Plug items they are perhaps superior to the OEM coils for Ford. The little stuff is not online, I don't think, but an older parts store will possibly have them or a catalog you can order from for these. Very much worth seeking out as they have been very useful to me.
Honestly I would use a relay for each side...You could use the original headlight wire to trigger the new pair. Basically make your own headlight harness, but they should definitely have relays. Lights pull way too much current not to, hence why so many have melted fuseboxes and wiring.
Ok sounds great, this is a good call.
First step is to source a new fuse box or some sort of replacement.
Check painless wiring systems, they have many options to install new harness.
We have used these in many customer vehicles and they are very easy to install.
Hey Ed can you put a direct link to headlight shell retainers and melting fuse box? When I go to the page you linked I can't clink on any of that stuff. It just has the standard list of resources I always see there. Like the Rapido intercooler instructions, Rapido SVO plus uprade instructions etc. Is that screen pic you posted above the old imon email list?
The best way to keep your Kia from being stolen is to not have a Kia.
A wire going from the battery to the cossie headlamp was melted as was a section of the fuse box that contained the fuse connecting to the headlights. 
