First and foremost you're attempting this at your own risk. I'm going to gather the info I used to do the retrofit on my own truck. I will try and be as detailed as possible and use as many pictures of the steps I have. Big thanks to SIGep4Runner(1st one to do use these projectors) and RitzyRunner(DIY headlight removal) over on YT. Hope you don't mind I'm going to use your pics and copy part of your DIY.
Things you will need:
Bi-xenon projector lens: Found on ebay from sellers in china for around $100. The kit consist of 2 projector lens, 2 HID bulbs and a harness for each projector.
HID Ballast: THE KIT DOES NOT COME WITH BALLAST. The seller where I bought mine sells ballast separately if you don't already have them. If it were me I would just buy a HID plug and play kit from DDM Tuning - HID Kits, DEPO Lights, BMW Bumpers & Lighting for $30-$50. The kits come with bulbs and ballast so for about the same amount of money you can have an extra set of bulbs as spares.
Tool:
Friend or an extra set of hand for a few minutes
Oven (Yes tell your wife her oven has now become our tool lol..)
Utility knife (IMO it was the most important tool)
Various screwdrivers (big head flat and a good phillips)
3/8 drive ratchet handle
6”-8” 3/8 drive extension
10mm deep socket
Needle nose pliers
#2 Philips screw driver
Oven mittens
Cook sheet or foil paper
Silicone (if your lucky this is optional)
Ok lets remove the headlights.....
'99 headlight Install on '98 - YotaTech Forums
Ok now that you have your headlights out you're half way there. Clean them off and go into your kitchen.
1. Preheat oven to 275 Temp. Remove upper grill/rack and leave one on the bottom.
2. You need to remove everything from the back of the headlight. There is a spring on there I didn't bother to take it off.
Everything on
The black bracket is being held on by 3 clips and a spring. Unhook the spring and unclip the 3 clips. In order to remove clips you need to push in the two tabs on the clip simultaneously and pull the bracket. This is where you need the friend or an extra set of hands. Here is a pic of the clip. This is one of three clips the other two are have to be reached from the inside of bracket.
Now everything off
3. Once you have everything off it is now ready to go into the oven. Put it on a cookie sheet with some foil paper and put it in the oven for 7 mins.
When 7 mins are up, take it out of the oven and place it somewhere where you can start to work on opening up the headlight. With your mitten or what ever you have to prevent from burning yourself hold the headlight, take the utility knife and make a couple of passes on the top of the headlight. For me, that barely broke the seal. Instead of making more passes I pressed down hard with the utility knife until I felt it break through the seal. I kept doing that every couple of inches until I had done the top and one side. By now the adhesive cooled off and I put it back in oven for 3 more minutes. Take it out of the oven and carefully try to separate the lens and backing with your screw driver. Be careful as I did chip one of my lens a bit because the seal wasn't open enough and I was trying to pry it open with the screwdriver. If that happens start off with knife until you have enough room to fit the screw driver in between the crevice
4. Take your projector and slide it into the headlight. You will get instructions with your kit as to how to mount it. It's self explanatory and I didn't take pictures of this.
5. Once you have it in there correctly(on the threaded part it will be marked top), held on nice and tight from the back with it's 3 prong spacer/aligner and nut you're ready to close it up. Press the lens and the backing together as much as possible. Put it back in the oven for 6 to 7 mins. Take it out and again immediately press it together again with your mittens until you feel you've sealed it up as much as possible. Here is where I say to apply a thin bead of silicone to ensure the seal is 100%.
6 Do the same to the other headlight, put everything back on the back of the headlight and you're done with your retro job.
Go back outside with the two supplied harness. One is longer than the other so make sure you use the right one for the right side. I personally didn't want the angel eyes so I decided to no hook that part up. You have a grnd, power with inline fuse that goes directly to the battery, two connectors that go the HID bulb, one that goes to the projector, one to the ballast and then small power and ground that belongs to the angel eyes(I cut the ends and taped them up).
7. Once you've hooked everything up tuck it away with a zip tie, double sided stick tape or just tuck it and hope it doesn't move around in there for you guys who off-road. Put your headlights and everything back on like it was before and congrats you're pretty much done.
8. Now you need to align your projector so they line up horizontally and your headlights so they line up vertically. Mine aren't aligned perfectly, but you get the point.
Things you will need:
Bi-xenon projector lens: Found on ebay from sellers in china for around $100. The kit consist of 2 projector lens, 2 HID bulbs and a harness for each projector.
HID Ballast: THE KIT DOES NOT COME WITH BALLAST. The seller where I bought mine sells ballast separately if you don't already have them. If it were me I would just buy a HID plug and play kit from DDM Tuning - HID Kits, DEPO Lights, BMW Bumpers & Lighting for $30-$50. The kits come with bulbs and ballast so for about the same amount of money you can have an extra set of bulbs as spares.
Tool:
Friend or an extra set of hand for a few minutes
Oven (Yes tell your wife her oven has now become our tool lol..)
Utility knife (IMO it was the most important tool)
Various screwdrivers (big head flat and a good phillips)
3/8 drive ratchet handle
6”-8” 3/8 drive extension
10mm deep socket
Needle nose pliers
#2 Philips screw driver
Oven mittens
Cook sheet or foil paper
Silicone (if your lucky this is optional)
Ok lets remove the headlights.....
'99 headlight Install on '98 - YotaTech Forums
Ok now that you have your headlights out you're half way there. Clean them off and go into your kitchen.
1. Preheat oven to 275 Temp. Remove upper grill/rack and leave one on the bottom.
2. You need to remove everything from the back of the headlight. There is a spring on there I didn't bother to take it off.
Everything on
The black bracket is being held on by 3 clips and a spring. Unhook the spring and unclip the 3 clips. In order to remove clips you need to push in the two tabs on the clip simultaneously and pull the bracket. This is where you need the friend or an extra set of hands. Here is a pic of the clip. This is one of three clips the other two are have to be reached from the inside of bracket.
Now everything off
3. Once you have everything off it is now ready to go into the oven. Put it on a cookie sheet with some foil paper and put it in the oven for 7 mins.
When 7 mins are up, take it out of the oven and place it somewhere where you can start to work on opening up the headlight. With your mitten or what ever you have to prevent from burning yourself hold the headlight, take the utility knife and make a couple of passes on the top of the headlight. For me, that barely broke the seal. Instead of making more passes I pressed down hard with the utility knife until I felt it break through the seal. I kept doing that every couple of inches until I had done the top and one side. By now the adhesive cooled off and I put it back in oven for 3 more minutes. Take it out of the oven and carefully try to separate the lens and backing with your screw driver. Be careful as I did chip one of my lens a bit because the seal wasn't open enough and I was trying to pry it open with the screwdriver. If that happens start off with knife until you have enough room to fit the screw driver in between the crevice
4. Take your projector and slide it into the headlight. You will get instructions with your kit as to how to mount it. It's self explanatory and I didn't take pictures of this.
5. Once you have it in there correctly(on the threaded part it will be marked top), held on nice and tight from the back with it's 3 prong spacer/aligner and nut you're ready to close it up. Press the lens and the backing together as much as possible. Put it back in the oven for 6 to 7 mins. Take it out and again immediately press it together again with your mittens until you feel you've sealed it up as much as possible. Here is where I say to apply a thin bead of silicone to ensure the seal is 100%.
6 Do the same to the other headlight, put everything back on the back of the headlight and you're done with your retro job.
Go back outside with the two supplied harness. One is longer than the other so make sure you use the right one for the right side. I personally didn't want the angel eyes so I decided to no hook that part up. You have a grnd, power with inline fuse that goes directly to the battery, two connectors that go the HID bulb, one that goes to the projector, one to the ballast and then small power and ground that belongs to the angel eyes(I cut the ends and taped them up).
7. Once you've hooked everything up tuck it away with a zip tie, double sided stick tape or just tuck it and hope it doesn't move around in there for you guys who off-road. Put your headlights and everything back on like it was before and congrats you're pretty much done.
8. Now you need to align your projector so they line up horizontally and your headlights so they line up vertically. Mine aren't aligned perfectly, but you get the point.
arty::fro:
