MOD -> Bi-Xenon headlight in stock housing

[Edwin NL]

OK here we go!

First off tnx to Pavel for the push to just do it!

The projector lens





Old vs NEW





Take the headlight out of the car (see E38.org)

Remove the weather strip



Flip over and undo the 3 T20 screws



Slide out



Use a screwdriver to remove the clips



Remove the cover of the xenon





Back view



Use a screwdriver to pry both headlight adjusters off







Remove the headlight cover



Remove the screw in the corner



Remove cover and you see this





Use a pair of pliers to pinch the center so it pops (headlight adjuster)



Unplug the highbeam



Remove the ground wire



Remove the tabs (front and rear) yo remove the center piece









Now you see the back screws



Not sure what you call these (inverted torx?)



Undo all 3

[Edwin NL]

Pull the lens straight out



Empty housing



The major difference in lens size!



But just as long!



Only one is marked RIGHT!





Nice and full!



When test fitting you can encounter the motor to hit the housing





I removed a little



The holes in the lens



The screw size



Drilled the holes a little bigger





Nice a tight fit!



Made them a little bigger for better adjustment









Align it correct!!!







Headlight without cover



With cover



The cover does not fit so we need to grind a little to make room



After I'm done



Nice and tight and does not touch

[Edwin NL]

In place



Reconnect the ground wire



Gently slide it back in!!!



My projector was hitting the inside of the housing





So removed a little extra metal



Installed







Solder the wires (extend them)





And connect them to the brown (ground wire) and the white from the high beam light

But it back together and install in the car!

Here a new and old headlight!

New




Old


All done



And the AWESOME video

[ame]http://www.youtube.com/watch?v=WGadPVW3UWk[/ame]

And a Night video with both lenses in place

[ame]http://www.youtube.com/watch?v=lyP1rHoHnN0[/ame]