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DIY Bi-Xenon Retrofit into a 99 323i

5K views 22 replies 14 participants last post by  TheJustAssassin 
#1 ·
Hello everyone,

I thought that I would try to contribute to the community here and share my recent retrofit of OEM Bi-Xenons into a 99 323i.

This guide will cover the dismantling of the Xenon light assemblies and re-assembly into the OEM Halogen assemblies.

There are only 3 reasons why anyone would really want to do it this way...

1) Bi-Xenon assemblies purchased have broken tabs (like mine)
2) You dont want to have to find a way to bolt your clip in Corners onto
the new assemblies (like me)
3) You're bored (like me)

If you fall into any of these above categories then read on....

Tools needed:
- Ratchet, Sockets, Extension (To remove the lights)
you will need at least a 6" extension to get to one of the bolts
holding the assemblies in place. Socket Size I used was an 8mm.
- Long magnetic stick (in case you drop the screws)
- Screwdrivers
Long Flat Head
Short Flat Head
Phillips
- Torx bits or drivers if you are lucky enough to have these
- Drill
- Dremel

Step 1: Remove the headlight
There are 4 bolts holding the headlight in place.
Start by removing the corner light then the screws.

I will not post any pictures of this step since it is very simple and there are many other DIY's out there with this information.

Step 2: Begin Disassembly

This is what we will be starting with. Go ahead and take off the rubber gasket along the top. This is what the hood rests on when shut.


Step 3: Remove Lens

There are several clips like this around the headlight. Un-clip these and pull the lens free.


Step 4: Remove the inner trim.

On my lights the trim is black, but yours may be silver. This just clips in, so a good pull should make it come free.


Step 5: Remove Bulbs and Ballast





Step 6: Remove Projectors

This is what you should have now. We will need to remove everything that is chrome.


Step 7: Unfasten retaining clips that hold the chrome pieces in.

1. Start by using a small screwdriver to unfasten this circular clip.



2. On the inside of the housing you will see a pin with a ball on it holding
the bottom of the projectors in. Use the long screwdriver to pry it up
and out of the retaining clip.



3. Lastly you need to compress one of the sides of the this grey clip
that holds the top piece in.

 
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9
#2 ·
Part 2

Step 8: Disconnect Xenon Wires

Now that the projectors are coming out in one piece you will notice several wires which need to be disconected.



1. Start by removing this blue plug.



2. Now remove the black plug with blue wires.



3. Use a torx bit (or small screwdriver) to remove the Xenon ignitor



4. Unplug the 3 pin connector on the ignitor.



5. Use a torx bit (or small screwdriver) to remove the black piece with the ball on it that held the projectors in.



6. Use a screwdriver and push on the black rubber plug where the wires enter the Xenon housing. It will pop out and you can fish the wires through.



You should now have these items to transplant into your Halogen assemblies.



Step 9: Prep the Halogen Housing.

Use the above steps (minus the wires portion) to gut your halogen assemblies. You should end up with something like this.



Notice how there is no hole for the Xenon wires to come in. We will fix this.

Step 10: Create a hole.

You will be drilling a hole here.

 
#3 ·
Part 3

1. Get your trusty drill and begin drilling. You should get something like this.



2. Use the Dremel to make the hole bigger.



3. Fish your wiring back through.



4. If your hole is the right size you should be able to snugly fit the
rubber portion into place. If its too big you may need to seal it up with some silicon.



Step 11: Re-assembly

Install the piece with the ball on it that holds the bottom of the projectors
in place. Fish the wiring around it and lets put the projectors into our new housing.



Once you get everything snapped back into place you should have this.



Go ahead and put the inner trim, lens etc.. back on.

Step 12: Protect your lights.

Too bad the Halogen assebly doesnt have the clips to hold the protective
cap around the Xenon bulb. We will just re-use the old Halogen rubber boots.



Once everything is back in place, go ahead and put it back on the car.




Tomorrow I will make the high-beams work. But as a little teaser....

(Paraklas told me this trick)

On the Bi-Xenon ballast there is an extra 3 Pin plug.



Take a wire tap (obtainable at your local hardware store) and tap into the
Halogen High Beams Positive Wire.

Take some extra electrical wire and add a small connector on the end that
will fit securely over one of those pins on the 3 pin connector.

Connect this to the Middle of the 3 pins.

Now when you turn your High Beams on, it will send the extra juice required
to make the shutter open to allow the Xenon Highs to show.

Once I get pictures of this, I will post for you to see how it was done.
 
#8 ·
---zxcvbnm--- said:
Can i just buy the projector (all the chrome) and transplant it into mine?
I plan on keeping the halogen bulbs a while longer, but i want the look of the projector on the road. Great job btw
Yes you should be able to do this without a problem. I believe some of the newer e46s come with projectors but no xenons. Sam concept.
 
#13 ·
mister wiggles said:
im a bit confused as to what you're doing. from my POV. you took the projector housing from 1 headlight and retrofitted it into another. please help me understand. i feel noobish.

Yes that is what I did. But I took Bi-Xenons (low and high beam Xenons) and fitted them to a car that is not supposed to have them.

Technically I could have used the housing from the Bi-Xenons but they also had the screw in corners which I couldnt find for a pre-facelifted sedan. Plus the clips on the housing I had were busted.



As for if I worry about the wiring?... No, not at this time. I probably will not keep these headlights that much longer as i really want to figure out how umnitza makes their quad xenons.....

Plus even if it burned out the center high beams are still functional. I dont really use the highs anyways.
 
#22 ·
Posts can only be edited for approximately 20-30 minutes after they're first created. If you would like, I can edit your post to include the pictures. I recommend using E46F to host the pics as they are far less likely to go missing again.

Send me a PM if you'd like me to add your pictures back into your post. :)
 
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