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Thread: Bi-Xenon Retrofit DIY Guide


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gli_boi
Member Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

Bi-Xenon Retrofit DIY Guide

03-27-2012 03:35 AM

#1

Ok so as I promised a while back that I will make a DIY Guide for the Xenon retrofit. Well that time has come. Keep in mind anything you do is at your own risk, and if you don't think you are up to it you should probably seek professional help in getting this done. I am not responsible for any damage you make cause to: your car, yourself, or others. In this guide i will be using the OEM E-code housings which were obtained from TMTuning as I wanted to keep my stock headlights for spare/scrap parts. You can certainly carry out this project using your OEM headlights. I am using a specific set of projectors, ballasts, bulbs, shrouds, and glue. I will list all these items below. If you have any question do not hesitate to ask, or PM me. As I mentioned before, I have helped another member with providing him direct guidance over the phone in order for him to do his project, so that just shows you I am willing to help you. Parts List / Supplier (and link if available) 1) OEM E-code Housings / TMTuning 2) FX-R Stage IV Retrofit Kit (options below) / The Retrofit Source Ballasts: Denso 35W Bulbs hilips 4300K CCFL Angel Eyes: NO Projectors: LHD Re-sealing Glue: YES Shrouds: Iris Wire Harness: Doesn't matter as I didn't use it 3) Epoxy (i used 4 tubes) / Home Depot 4) Aluminum Tape (used for HVAC) / Home Depot 5) Nuts, bolts, washers (size will depend on your projector) / Home Depot Tools Required: 1) 2) 3) 4) 5) Dremel Tool - I use a Milwuakee with a Dremel Thin Cut wheel Knife Flathead screw driver Torx Drivers (for removing bumper and headlight fastners, T20, T25, T30) Other Misc Tools

---------------------Ok let the fun stuff begin. The pictures all have explanations on there but I will be listing steps here as well. Step 1: (If you are working with new housings that are not on your car, skip this step) If you are using your OEM housings the first step would be to remove the headlights from the vehicle. To do so you need to undo 5 torx screws in each fender well, 8 torx screws under the bumper, 4 torx screws for the grill, and 3 torx screws behind the grill for the bumper support. After removing the bumper assembly you will find more torx screws that are holding the headlight. There is a total of 4 per headlight, make sure to remove all of them, than disconnect the headlight harness and out they come. Step 2: Now its time for when you are going to be clenching your butt cheeks pretty hard, as you will be cutting the lens of the headlight assembly while praying the whole time that you don't mess up. Take your time and don't set the Dremel speed to high as it will cause unnecessary plastic burn, which will make the gap bigger and harder to seal.

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IMG_0033 by dszyda, on Flickr

IMG_0032 by dszyda, on Flickr Step 3: After cutting open the housing and separating the lens away, you will now have to remove all the interior trim pieces before you can take the reflector out. The main trip piece is still attached by the epoxy on the very top, go ahead and use your Demel and cut as close as to the edge of the housing as possible so you can remove the trim.

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IMG_0422 by dszyda, on Flickr Step 4: Now its time for the reflector bowl to be modified. This is another tedious task, and take your time and be very careful as once you start modding the bowl it will loose its stability so it will be a lot more fragile. The pictures provided apply for a general template to this particular projector, so this may change if you are using different projectors. Make sure once you cut out the center of the bowl, to make holes for the bolts that will be used to attach the projector to the bowl.

IMG_0028 by dszyda, on Flickr

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IMG_0030 by dszyda, on Flickr Step 5: Now its time to attach the projector to the bowl using some bolts and nuts that you should have obtained at Home Depot of some other parts store. Remember you are just temporarily mounting the projector in the bowl as this is for you alignment steps. Once the projector is mounted in the bowl, install the bowl back into the housing, and put the housing in the car for alignment process. I aligned mine on the ground, but later repeated the process with the headlights mounted in the car and than marking the reflector bowl and projector for centering reference.

IMG_0425 by dszyda, on Flickr

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IMG_0426 by dszyda, on Flickr

IMG_0431 by dszyda, on Flickr Step 6: After you have successfully aligned the projector in the bowl, now it comes time for the permanent epoxy. Using the bolts attach the projector on the bottom, and than use the HVAC tape to tape the back of the projector to the back of the reflector bowl. Once taped, use the epoxy and fill in from the front to it flows down on the tape and links the projector to the bowl. Let it dry for about 20 minutes.

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IMG_0031 by dszyda, on Flickr Step 7: Once everything is fully cured, now its time to install the bowl back into the headlight assembly. Once installed, reinstall the trim pieces in the proper places. Once everything is back together, it is time for the final piece.. the shroud. The shroud will need some trimming along the top to clear the shape of the housing and the angles. Make sure that it does not interfere with anything. I took a few pictures for using as a reference.

IMG_0423 by dszyda, on Flickr

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IMG_0424 by dszyda, on Flickr Step 7: Now its time to glue everything back together. Make sure that your lens and inside of the housing is all clean and dust free, as if it's not you will be taking everything apart yet again (except easier this time). With the provided rubbery glue that you received with your retro kit you can follow the directions from TRS below, however I did not use this method. "apply the strip into the channel on your headlight housing, press on the front lens, heat (265F for 7 minutes) and press the two halves back together. After cooling, slice off the excess with a razor blade for a clean, OEM-perfect seal." What I did, is applied a strip just like they suggest, than i used a heat-gun at 500F setting to heat up the rubber for about 3 minutes, than pressed the lens back on and held it for a couple minutes. I trimmed the excess glue off from the top only. And then you have your finished product.

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IMG_0429 by dszyda, on Flickr

IMG_0430 by dszyda, on Flickr Light Output Photos of my setup:

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IMG_0019 by dszyda, on Flickr

IMG_0020 by dszyda, on Flickr

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IMG_0021 by dszyda, on Flickr

IMG_0023 by dszyda, on Flickr

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IMG_0022 by dszyda, on Flickr

IMG_0025 by dszyda, on Flickr

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IMG_0026 by dszyda, on Flickr

IMG_0027 by dszyda, on Flickr Hope this helps to all of you that are looking to complete this project!

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22/10/13 00:10

CapeGLS
Senior Member

03-27-2012 03:49 AM
Great write up. :thumbsup:

#2

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Vehicles: 01 Golf GLS 1.8T, 02 Jetta WGN 2.0, 11 JSW 2.5SE (Wifes)

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asusc
Member

03-27-2012 04:52 AM
Well done.

#3

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Oct 22nd, 2004 Scottsdale, AZ 609 2012 GLI

Matt / 2012 Candy GLI / AWE / APR official mk6 Jetta/GLI DIY guide Hit me up if you need a VAGCOM in Phoenix. Reply With Quote

fasttt600
Member Join Date: Location: Posts: Vehicles: 12 GLI Apr 12th, 2007 Phoenixville PA 3,021 07 baggedwagon, now

03-27-2012 05:48 AM
awesome write up. did you have any vagcom work to get them to work? Since these are bi-xenon, do they also do the high beam?

#4

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tankisarockstar
Member Join Date: Location: Posts: Jan 11th, 2006 908 NJ 200

03-27-2012 08:35 AM
wanna make some money? lol

#5

Vehicles: 07 Rabbit. 11 Jetta SE with Convience and roof. .

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alscrx
Junior Member Join Date: Location: Posts: Vehicles: Mar 9th, 2005 CT 58 2012 GLI Autobahn/Nav

03-27-2012 09:12 AM
So what was the total cost of this project??

#6

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fasttt600
Member Join Date: Location: Posts: Vehicles: 12 GLI Apr 12th, 2007 Phoenixville PA 3,021 07 baggedwagon, now

03-27-2012 10:13 AM Originally Posted by alscrx


So what was the total cost of this project??

#7

I guess it would depend if your buying an extra set of headlights or using your own. Reply With Quote

gli_boi
Member

03-27-2012 11:48 AM

#8

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Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

22/10/13 00:10

Originally Posted by fasttt600


awesome write up. beam? did you have any vagcom work to get them to work? Since these are bi-xenon, do they also do the high

No vag-com work required.. might be diff for the GLI since they got a different cluster.. As far as the highbeams, it was a simple wiring inside the headlight

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gli_boi
Member Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

03-27-2012 11:49 AM Originally Posted by alscrx


So what was the total cost of this project??

#9

Total about $700

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ajz9415
Member

03-27-2012 11:59 AM
nice work very tempting. I have a set of euro headlights waiting to be installed.

#10

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fasttt600
Member Join Date: Location: Posts: Vehicles: 12 GLI Apr 12th, 2007 Phoenixville PA 3,021 07 baggedwagon, now

03-27-2012 12:05 PM
sorry for asking so many questions. I can pm if you'd like, I just figured others might want to know. as fas as the high beam, could you elaborate on the wiring. which light actually lights up when the high beams are engaged. Looking at the pic of the rear view. does the projector stick out of the housing? are you able to put the factory rubber cap back on? Thanks in advance.

#11

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gli_boi
Member Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

03-27-2012 12:22 PM Originally Posted by fasttt600


sorry for asking so many questions. I can pm if you'd like, I just figured others might want to know. as fas as the high beam, could you elaborate on the wiring. which light actually lights up when the high beams are engaged. Looking at the pic of the rear view. does the projector stick out of the housing? are you able to put the factory rubber cap back on? Thanks in advance.

#12

Not a problem, as far as the back cap yes it still seals normally. The projector sticks out of the reflector bowl but not out of the actual housing. As far as the high beams, the projector has 2 wires coming of the hibeam shutter motor which need to be snaked over by the high beam bulb and tapped to the highbeamb wires. The way it works in my setup, if my headlights are off only the halogen beams go on, if the headlights are on than both the bixenon and reflector beams go on. This could however be altered by using a relay to shut the circuit off if you didn't want the reflectors to go on with the xenons, but that's something I haven't done yet, but if I do I will add the information in here.

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fasttt600
Member Join Date: Location: Apr 12th, 2007 Phoenixville PA

03-27-2012 12:25 PM
that must be super bright if you get the shutters to open and the actual high beams to work. I like that.

#13

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x13atma17x
Member

03-27-2012 01:50 PM
wow

#14

Join Date: Location: Posts: Vehicles: 323i

Apr 1st, 2011 SoCal 103 MK6 Jetta SE / E46

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WakingTh3Fall3n
Member

03-27-2012 04:49 PM
Awesome write up.... Now I will e broke thanks LOL What wheels are those btw?

#15

Join Date: Location: Wiscompton Posts: Vehicles:

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azthegame
Member

03-27-2012 05:39 PM

#16

Looks good Derrick. Thanks again for the phone instructions! When is TMTuning going to publicly release those headlights? And how much they charge for them?

Join Date: Location: Posts: Vehicles: 4DR Golf TDi

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gli_boi
Member Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

03-27-2012 05:47 PM Originally Posted by azthegame


Looks good Derrick. Thanks again for the phone instructions! When is TMTuning going to publicly release those headlights? And how much they charge for them?

#17

They are not being a released product. This is just a guide with instructions showing what can be done. But you never know lol.. TMTuning provided the housing to me for doing the retro.

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gli_boi
Member Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

03-27-2012 05:47 PM Originally Posted by WakingTh3Fall3n


Awesome write up.... Now I will e broke thanks LOL What wheels are those btw?

#18

OEM r32 from a MKv.. These are my winters..

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xHoldenMcNeilx

03-27-2012 06:00 PM

#19

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Member Join Date: Location: Posts: Mar 13th, 2008 Northern VA 2,884

22/10/13 00:10

looks great man good work

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azthegame
Member

03-27-2012 06:02 PM Originally Posted by gli_boi


They are not being a released product. This is just a guide with instructions showing what can be done. But you never know lol.. TMTuning provided the housing to me for doing the retro.

#20

Join Date: Location: Posts: Vehicles: 4DR Golf TDi

Oct 27th, 2011 Arlington, TX 985 2012 Jetta SEL, 2012

Yeah I know they provided the housings, you had said in your other thread that they had them but just didn't list them on their website yet, I meant the housings being for sale on their site, not complete retrofitted housings

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gli_boi
Member Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

03-27-2012 07:02 PM Originally Posted by azthegame


Yeah I know they provided the housings, you had said in your other thread that they had them but just didn't list them on their website yet, I meant the housings being for sale on their site, not complete retrofitted housings

#21

Ahh gotcha.. Yeah they are working on updating the site last i checked but they have a bunch of other things that are also currently going on, but with time they will be on there. You can always email them to order as well.

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gli_boi
Member Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

03-27-2012 07:03 PM
Also looks like this guide has been added to the Official DIY list, I feel honored hehe

#22

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elppe
Member Join Date: Posts: Vehicles: Apr 15th, 2011 274 2011 Jetta SE.

03-27-2012 11:50 PM
Great job bro! thanks a lot

#23

Check out ---->PEPE<---Reply With Quote

gli_boi
Member Join Date: Location: Posts: Vehicles: Jun 2nd, 2009 LITH, IL 1,035 06 VW GLI

03-28-2012 02:26 AM Originally Posted by elppe


Great job bro! thanks a lot

#24

No problem! Thanks

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magrider
Member Join Date: Posts: Jun 1st, 2012 161

06-01-2012 04:37 PM

#25

Vehicles: 2011 Touareg VR6 Sport. 2012 Passat TDI SEL

Excellent write-up. Just one quick question: having done HID projector retrofit on my Civic, instead of cutting into the headlight, why didn't you just heat the sealant in the oven and pry the headlight open once the sealant is soft? Does the baking method not work for this headlight?

Last edited by magrider; 06-01-2012 at 04:40 PM. Reply With Quote

azthegame
Member

06-01-2012 04:58 PM

#26

VW uses a super tough epoxy to seal the lights. Japanese auto makers use the rubber butyl sealing glue, which is what we need to use to reseal once we finish our Retrofit

Join Date: Location: Posts: Vehicles: 4DR Golf TDi

Oct 27th, 2011 Arlington, TX 985 2012 Jetta SEL, 2012

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DFWSKATE
Member

06-01-2012 05:12 PM
mk4 headlights were able to open up in oven so they've recently switched adhesives. I would absolutely love a set of dual projector retrofits. Maybe someone local would make me some if I had the money cough cough

#27

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Floss Filthy x Watercooled Society @jason_watercooledsociety

Originally Posted by justrave


i wish calvin and jason would move so i could officially say that texas sucks.

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azthegame
Member

06-01-2012 05:15 PM
HAHA... I would love to help someone make their own. Wouldn't want to have the full responsibility of someone's lights

#28

Let me know Jason


Join Date: Location: Posts: Vehicles: 4DR Golf TDi Oct 27th, 2011 Arlington, TX 985 2012 Jetta SEL, 2012

Going to be at the meet next Thursday? I am hoping to attend my first.

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NYC_S
Member Join Date: Posts: Mar 10th, 2005 294

03-21-2013 02:18 PM
Nice write up!

#29

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