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Bi-Xenon Retrofit DIY Guide

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 notresponsible for any damage you make cause to: your car, yourself, or others. In this guide i will be using the OEM E-code housings whichwere obtained from TMTuning as I wanted to keep my stock headlights for spare/scrap parts. You can certainly carry out this project usingyour OEM headlights. I am using a specific set of projectors, ballasts, bulbs, shrouds, and glue. I will list all these items below. If you haveany question do not hesitate to ask, or PM me. As I mentioned before, I have helped another member with providing him direct guidanceover 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 / TMTuning2) FX-R Stage IV Retrofit Kit (options below) / The Retrofit Source

Ballasts: Denso 35W

Bulbs hi lips 4300KCCFL Angel Eyes: NOProjectors: LHDRe-sealing Glue: YESShrouds: IrisWire Harness: Doesn't matter as I didn't use it

3) Epoxy (i used 4 tubes) / Home Depot4) Aluminum Tape (used for HVAC) / Home Depot

5) Nuts, bolts, washers (size will depend on your projector) / Home Depot

Tools Required:

1) Dremel Tool - I use a Milwuakee with a Dremel Thin Cut wheel2) Knife3) Flathead screw driver4) Torx Drivers (for removing bumper and headlight fastners, T20, T25, T30)5) 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 torxscrews 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 bumpersupport. After removing the bumper assembly you will find more torx screws that are holding the headlight. There is a total of 4 perheadlight, 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 assemblywhile praying the whole time that you don't mess up. Take your time and don't set the Dremel speed to high as i t will cause unnecessaryplastic burn, which will make the gap bigger and harder to seal.

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03-27-2012 03:35 AM #1

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IMG_0033 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 thereflector 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 theedge of the housing as possible so you can remove the trim.
http://www.flickr.com/people/dszyda/http://www.flickr.com/photos/dszyda/6874042132/http://www.flickr.com/photos/dszyda/6874042132/http://www.flickr.com/people/dszyda/http://www.flickr.com/photos/dszyda/6874042282/http://www.flickr.com/photos/dszyda/6874042282/


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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 startmodding 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 particularprojector, so this may change i f you are using different projectors. Make sure once you cut out the center of the bowl, to make holes for thebolts that will be used to attach the projector to the bowl.



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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 otherparts store. Remember you are just temporarily mounting the projector in the bowl as this is for you alignment steps. Once the projector ismounted in the bowl, install the bowl back into the housing, and put the housing in the car for alignment process. I aligned mine on theground, but later repeated the process with the headlights mounted in the car and than marking the reflector bowl and projector forcentering reference.



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Step 6:

After you have successfully aligned the projector in the bowl, now it comes time for the permanent epoxy. Using the bolts attach theprojector 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 theepoxy 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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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 inthe proper places. Once everything is back together, it is time for the final piece.. the shroud. The shroud will need some trimming along thetop 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 areference.



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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 youwill be taking everything apart yet again (except easier this time). With the provided rubbery glue that you received wi th your retro kit youcan 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 backtogether. After cooling, slice off the excess with a razor blade for a clean, OEM-perfect seal."

What I did, is appl ied a strip just l ike they suggest, than i used a heat-gun at 500F setting to heat up the rubber for about 3 minutes, thanpressed 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 finishedproduct.
http://www.flickr.com/people/dszyda/http://www.flickr.com/photos/dszyda/6874038796/http://www.flickr.com/photos/dszyda/6874038796/


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Light Output Photos of my setup:


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12/18





Hope this helps to all of you that are looking to complete this project!

2012 VW Jetta GLI Autobahn | 6 speed | Frost Silver | Unitronic K04

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Great write up. :thumbsup:

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03-27-2012 03:49 AM #2

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Well done.

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03-27-2012 04:52 AM #3

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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?Join Date:

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03-27-2012 05:48 AM #4

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wanna make some money? lolJoin Date:

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So what was the total cost of this project??Join Date:

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03-27-2012 09:12 AM #6

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

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03-27-2012 10:13 AM #7

Originally Posted by alscrx

So what was the total cost of this project??

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14/18



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 wiringinside the headlight

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Originally Posted by fasttt600

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



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Total about $700

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03-27-2012 11:49 AM #9

Originally Posted by alscrx

So what was the total cost of this project??



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nice work very tempting. I have a set of euro headlights waiting to be installed.

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03-27-2012 11:59 AM #10

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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 youelaborate on the wiring. which light actually lights up when the high beams are engaged. Looking at the pic of the rear view. does theprojector stick out of the housing? are you able to put the factory rubber cap back on? Thanks in advance.

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03-27-2012 12:05 PM #11

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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 actualhousing.

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 beambulb 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 theheadlights 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 ifyou 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 inhere.

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03-27-2012 12:22 PM #12

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 therear view. does the projector stick out of the housing? are you able to put the factory rubber cap back on? Thanks in advance.



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that must be super bright if you get the shutters to open and the actual high beams to work. I like that.Join Date:

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03-27-2012 12:25 PM #13
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wow

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03-27-2012 01:50 PM #14

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

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03-27-2012 04:49 PM #15

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

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03-27-2012 05:39 PM #16

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

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03-27-2012 05:47 PM #17

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?



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

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03-27-2012 05:47 PM #18

Originally Posted by WakingTh3Fall3n

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



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xHoldenMcNeilx 03-27-2012 06:00 PM #19
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looks great man good workJoin Date:

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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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03-27-2012 06:02 PM #20

Originally Posted by gli_boi

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

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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 goingon, but with time they will be on there. You can always email them to order as well.

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03-27-2012 07:02 PM #21

Originally Posted by azthegame

Yeah I know they provided the housings, you had said in your other thread that they had them but j ust 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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Also looks like this guide has been added to the Official DIY list, I feel honored heheJoin Date:

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03-27-2012 07:03 PM #22



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Great job bro! thanks a lotJoin Date:

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03-27-2012 11:50 PM #23

Check out ---->PEPE


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Forum VW Model-Specific Forums Jetta/GLI VI Bi-Xenon Retrofit DIY Guide

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

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06-01-2012 04:37 PM #25

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

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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 toreseal once we finish our Retrofit

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06-01-2012 04:58 PM #26

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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

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06-01-2012 05:12 PM #27

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

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HAHA... I would love to help someone make their own. Wouldn't want to have the full responsibility of someone's lights

Let me know Jason

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06-01-2012 05:15 PM #28

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Nice write up!Join Date:

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