Fog Light Install for 3.8s without factory wiring at bumper

LarryJM said:

Update:

Unfortunately my quest to find an easy source of pins for the IGPM connector was for the most part unsuccessful. The pin used by Hyundai is an AMP#2109006-1,2, or 3 depending on wire size with the - 2 AFAIK being for AWG in the 16 to 18 range. This pin is not carried by any U.S. distributor and even if it were a lot of these pins has min qty orders from 100 to 5,000. Thus about the only source you're going to find is from a connector off an existing vehicle.

While the home made pin I showed in an eariler post will work the two real issues are 1) you have to be very careful inserting it so as not to damage the male pin from the IGPM and 2) it's impossible to tell how good of a connection you are making. This second issue can be critical since each fog light draws around 1 to 1.5A so depending if you're going to run one or two wires from the IGPM then the connection needs to support between 1.5 to around 3A. I am currently using one of the pin locations on the IGPM to power a relay coil that then supplies 12V to both fog lights over a single wire. To avoid messing with using a flyback diode(s) the relay I'm using only draws between 30 and 40ma and that requires a much less robust electrical connection from my home made pin that I'm using in the IGPM connector. Personally, I would not recommend using a make shift pin in that IGPM connector even in a 2 wire configuration to power the fog lights directly. I would personally only recommend having this source of fog light power to power a PCB type relay of the type shown below which is a 10A/15A 12V SPST ckt board based relay that you can get from multiple sources on e-bay for under $10:

PCB 12V relay:

After quite a few hours of searching and a lot of luck I identified at least one source for the fog light pins used in our connector and that is from a 2015/16 Sonata in cabin fuse panel. There are two connectors, each using a grey latching mechanism that have the needed pins in them one on the front and one on the back. These are the larger multi sized wire connectors having betwen 38 and 51 pin locations. Below are pics of the front and back connectors for the Sonata showing what connector has the needed pins and how many are actually in that year Sonata connector. It appears these pins are used in other Hyundai connectors mainly on the interior fuseboxes and are specifically of the 060 series ones, but I don't have access to all the different connectors used on the various Hyundai and even Kia model vehicles, but it looks like Hyundai and maybe Kia started using this style/type connector in 2015 and on.

2015/16 Sonata fuse box back:

2015/16 Sonata fuse box front:

I found a listing for a Sonata fuse box on e-bay and while I wasn't going to pay the $100+ for the entire fuse box that included all the connectors I was able to offer and purchase 4 of the connectors which had each of the two pictured above for $20 so now I have around 18 of these pins. With the false starts and wasted $$ in the connector I bought from Mouser I have close to $40 invested in just locating and acquire the pins for the connector on the IGPM for our fog lights.

It would be nice if one could find the pins for the KUM bumper connector, but since there are no distributors for KUM connectors anywhere in the U.S. and the pin size in the connector used seems large I didn't even consider looking to go that route and decided to just wire my foglights up using a common waterproof quality connector similar to other types on our vehicle. This sort of left out the most common one being the Molex type and I decided to use an Amphenol AT series connector shown below . These connectors are not cheap and I paid over $26 for a pair off e-bay and one could definitely use a cheaper 4 pin connector as long as it's waterproof since it's outside the cabin of the vehicle and subject to the elements..

Ampenol AT series 4 pin waterproof connector:

As for wiring, one could obviously use whatever they wanted, but if one wants to do things right I would recommend using actual automotive grade wire that has the higher temp insulation. It looks like around an 18AWG wire is a good size and one warning here is be careful about some of these off shore wires that show the guage with only a "G" after it. 18G foreign wire is often smaller than the good old USA 18AWG wire and IMO the insulation might really be a roll of the dice. I found what I think is a good e-bay source for automotive wire in smaller quantities and that is "acdcelectricparts" who I purchased 25' each of black and orange "AUTOMOTIVE WIRE 18 AWG HIGH TEMP TXL WIRE U.S.A MADE" for $11 total and will use that to run my wires from the fuse box up thru the firewall on the driver's side and then to the front bumper connector and also from that bumper connector to each fog light. I will pick up a ground along that run from one of the factory ones already there in the engine compartment and run individual ground and power wires to each fog light and enclose all wiring in split loom wireways and secure that to the existing wire way that runs from the driver's side firewall up to under the driver's side headlight and then down to the bumper area.

As you have noticed I haven't and don't intend to get into much more specifics on doing this mod since what I intend to do is something unique to my specfic wants/needs and this mod is definitely not a simple plug and play type mod. Thus I have left the details to each person and my thought is that outside of some simple and very specific questions if one needs more than what I have provided they probably should not be attempting this in the first place.

I currently have a fully functional fog light system meeting my wants/needs that uses the full functionality of the Multi-function stalk switch with the fog light switch on it. While it is not what I envision as my final configuration, I might wait till sometime in the next year or so to wire up what will be my final configuration. This is mainly driven by the weather since it's getting too hot to be crawling around and working outside on my Genesis. Until I actually install they pins into the connector on the IGPM I can't say for absolute certainty that they are the correct ones, but I feel 99% confident that they are. Since I have almost 20 of these pins now I would consider possibly letting a few sets go (approx about 5) to members that want to wire up their fog lights using a replacement stalk switch. About the only thing I might want to do is to somehow offset some of the $40 or so I have invested in obtaining these pins and anyone interested can PM me and we can work out any details there.

With this update this about closes out what I have to say in regards to this mod unless someone has a specific question that I might provide here that would benefit the general readership

Larry

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John B said:

LarryJM: I recently bought a new 2G 2016 Genesis sedan base model. I would love to add the LED fog lights but after reading your excellent post on the modifications, know this is beyond my capabilities. My question: Is it possible my car could be pre-wired for these fog lamps and only need the switch added, and if so, how can I tell this? Thanks very much.

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LarryJM said:

If you have the extra two wires coming out of the connector pictured above where I inserted that single wire then you probably have the wiring from the junction box up to the bumper area. HOWEVER, you will still need to either wire up the fog lights and tap into the car side of that bumper connector or buy a wiring harness for the front bumper side that replaces the one you now have which requires you probably removing the bumper cover. There really is not what you could really call a simple plug and play and just adding the stalk switch requires careful installation especially when working with the air bag. Air bags can be deadly if mis handled and are nothing to mess with.

Larry

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LarryJM said:

Several folks recently have reported that they are missing the orange and black wires at the bumper for the fog light install using the 5.0 multi-function switch with the fog light option on the switch. I was in the same boat and while I have a current install that gives me even more options I wanted to eventually have an option for a complete factory type configuration system. I did not have the orange and black wiring at the bumper for the fog lights and was unsure what I could do wrt installing the multi-function swtich and wiring it up so it would operate just like the factory OEM system including the dash indicator light.

I paid for a weeks worth of access to the manuals on the Hyundai service site and downloaded the entire ETM for both my vehicle along with the 2015 5.0 and 2016 3.8 sections concering lighting. I thought I had identified where the fog lights originated from which then go directly to that bumper connector on the driver's side. However, w/o the switch I was unsure if it would provide the power for the fog lights when installed.

I just received my switch from rpmtrade via e-bay and have confirmed with a multimeter where the fog light power originates and that it seems to work just like the OEM systems in the 5.0 and those on the 2016's. So this is good news for those not having the orange/black factory wiring at that bumper connector. The bad news is that is a little more complicated to wire things up and get them as close to factory as possible. First one needs to install the proper contacts into the spots on the connector that powers the foglights. Next one has to find an alternative to using that bumper connector on the driver's side since that is a KUM connector and as best as I can determine there are no U.S. sources for pins to add wires to that connector. I believe I have found a source (Mouser) for the missing pins in the fog light connector that is the source of the power for the fog lights. For the bumper connection I plan to use a 4 conductor AMP weather proof one and run two orange wires back to the fog light power source and two black wires to ground somewhere. This will mimic the OEM orange and black wires on the bumper connector. From there I will run separate orange and black wires to each fog light since I think you need this to allow for the tell tail light out fault function to work correctly. I already have the fog lights wired up, but the run from the bumper up the passenger side of the engine compartment and then into the cabin to my fog light relay control box. I haven't finalized ultimate wiring configuration since I would like to retain the existing reduced brightness Fog Light DRL function along with the ability to turn on my fog lights regardless of what other lights are on. The OEM system only allows the fog lights to be on with the low beams. The purpose of going to this extra work in my case is that I have to pass an annual Va state safety inspection and want my system to look 100% OEM to the Inspector and to operate as such for at least inspection purposes.

FWIT the connector that appears to supply the fog light power is the one on the IGPM co-located with the fuse block under the fuse panel located behind the driver's crash pad. The connector is the 16 pin connector at the upper right with double rows of 3 each on each side of 4 larger wires in the middle. The larger wires in the middle should be from the left to the right looking at the connector from the wire side are White, Yellow, Red, BLANK.
The fog light connector pins are the two blank locations on the bottom row to the right of the larger wires and has a single grey wire in the row in the position closest to the interior of the vehicle.

I still have some work to do mainly to confirm what I have targeted for the new pins in the connector on the IGPM are the correct ones and that has to wait for the donor pin connector currently on order from Mouser.

It' going to be a while (weeks not months), but I plan to document with pics what I did that is new from what has already been documented along with sources and part numbers of things like the correct connector pins so the fog light wires can be added to the existing connector on the IGPM.

I will be happy to answer some of the simpler question in this thread, but want to wait on the nitty gritty until I have confirmed 100% that what I'm doing will really work.

So it appears the good news is there is hope for those wanting to add a very OEM type fog light system to their 3.8 on vehicles w/o the orange/black wires in the bumper connector. The bad news is that is not a real simple plug and play, but should be something for those with moderate ability to do.

Larry

Click to expand...

LarryJM said:

Several folks recently have reported that they are missing the orange and black wires at the bumper for the fog light install using the 5.0 multi-function switch with the fog light option on the switch. I was in the same boat and while I have a current install that gives me even more options I wanted to eventually have an option for a complete factory type configuration system. I did not have the orange and black wiring at the bumper for the fog lights and was unsure what I could do wrt installing the multi-function swtich and wiring it up so it would operate just like the factory OEM system including the dash indicator light.

I paid for a weeks worth of access to the manuals on the Hyundai service site and downloaded the entire ETM for both my vehicle along with the 2015 5.0 and 2016 3.8 sections concering lighting. I thought I had identified where the fog lights originated from which then go directly to that bumper connector on the driver's side. However, w/o the switch I was unsure if it would provide the power for the fog lights when installed.

I just received my switch from rpmtrade via e-bay and have confirmed with a multimeter where the fog light power originates and that it seems to work just like the OEM systems in the 5.0 and those on the 2016's. So this is good news for those not having the orange/black factory wiring at that bumper connector. The bad news is that is a little more complicated to wire things up and get them as close to factory as possible. First one needs to install the proper contacts into the spots on the connector that powers the foglights. Next one has to find an alternative to using that bumper connector on the driver's side since that is a KUM connector and as best as I can determine there are no U.S. sources for pins to add wires to that connector. I believe I have found a source (Mouser) for the missing pins in the fog light connector that is the source of the power for the fog lights. For the bumper connection I plan to use a 4 conductor AMP weather proof one and run two orange wires back to the fog light power source and two black wires to ground somewhere. This will mimic the OEM orange and black wires on the bumper connector. From there I will run separate orange and black wires to each fog light since I think you need this to allow for the tell tail light out fault function to work correctly. I already have the fog lights wired up, but the run from the bumper up the passenger side of the engine compartment and then into the cabin to my fog light relay control box. I haven't finalized ultimate wiring configuration since I would like to retain the existing reduced brightness Fog Light DRL function along with the ability to turn on my fog lights regardless of what other lights are on. The OEM system only allows the fog lights to be on with the low beams. The purpose of going to this extra work in my case is that I have to pass an annual Va state safety inspection and want my system to look 100% OEM to the Inspector and to operate as such for at least inspection purposes.

FWIT the connector that appears to supply the fog light power is the one on the IGPM co-located with the fuse block under the fuse panel located behind the driver's crash pad. The connector is the 16 pin connector at the upper right with double rows of 3 each on each side of 4 larger wires in the middle. The larger wires in the middle should be from the left to the right looking at the connector from the wire side are White, Yellow, Red, BLANK.
The fog light connector pins are the two blank locations on the bottom row to the right of the larger wires and has a single grey wire in the row in the position closest to the interior of the vehicle.

I still have some work to do mainly to confirm what I have targeted for the new pins in the connector on the IGPM are the correct ones and that has to wait for the donor pin connector currently on order from Mouser.

It' going to be a while (weeks not months), but I plan to document with pics what I did that is new from what has already been documented along with sources and part numbers of things like the correct connector pins so the fog light wires can be added to the existing connector on the IGPM.

I will be happy to answer some of the simpler question in this thread, but want to wait on the nitty gritty until I have confirmed 100% that what I'm doing will really work.

So it appears the good news is there is hope for those wanting to add a very OEM type fog light system to their 3.8 on vehicles w/o the orange/black wires in the bumper connector. The bad news is that is not a real simple plug and play, but should be something for those with moderate ability to do.

Larry

Click to expand...

John B said:

LarryJM: I recently bought a new 2G 2016 Genesis sedan base model. I would love to add the LED fog lights but after reading your excellent post on the modifications, know this is beyond my capabilities. My question: Is it possible my car could be pre-wired for these fog lamps and only need the switch added, and if so, how can I tell this? Thanks very much.

Click to expand...

fishdetector said:

Time to patch up wounds and forget the fog lights.

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surprisinguy said:

You can get the fog light wiring harness on eBay that plugs into the light. You can probably find a local trim shop that will install the foglights (I did). You might want to check that out

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fishdetector said:

I learned that the bumper cover on my 2015 3.8L Sedan is not equipped with the necessary mounting studs to mate with the fog light assembly. Apparently the necessary information can be found in the VIN. I have not learned how to decipher the info from the VIN yet. Also, the location of the build may have an impact on compatibility of the OEM foglight assembly. Long story short...purchased pair of salvage lamps for a shop to install (my first rodeo; not shops). The assemblies could not be mounted so thought they for different year. Purchased new assemblies only to find out bumper incompatible. If VIN does not identify the fog option then there will be no supporting wire harness either. I'm sure install would void warranty. Time to patch up wounds and forget the fog lights.

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