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Subject: E38 Bi-Xenon! headlight installation in stock headlight assembly!! PIC WARNING! Author: homerraas as Edwin™ : 19427 posts Posted on: 2010-04-16 14:48:50

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







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







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

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• E38 Bi-Xenon! headlight installation in stock headlight assembly!! PIC WARNING! (pic) (vid) (url) - Edwin™ 2010-04-16 14:48:50 (14406 views)
  • OK... I have non factory XENON - darkknight74 2010-04-21 22:14:56 (217 views)
  • I dont know if its been said but.........GROUP-BUY ??? (nt) - audiavant 2010-04-20 17:41:33 (205 views)
    • +1 just a pain he doesn't ship to Canada! #$@#$ hehe (nt) - bmer_D 2010-04-21 19:54:01 (186 views)
  • Very cool, Edwin! This is going on e38.org (nt) - DavidC 2010-04-19 18:36:51 (249 views)
  • Impressive work E! But I have regenerative halide cycle tubular fused quartz! - RobinK 2010-04-19 12:45:48 (174 views)
    • how much better are they? (nt) - bmer_D 2010-04-19 17:24:10 (188 views)
  • Wow! (nt) - beechy 2010-04-19 11:04:39 (151 views)
  • this is MEGA light.. esp. in europe where the fogs stay on with high beams! - ian 2010-04-19 00:33:00 (250 views)
    • Ian, fogs stay on with high beams in the US if you know who to ask..... (nt) - black740ia 2010-04-19 07:22:49 (187 views)
      • I have Fogs and Highs !!!!! I am in Florida,USA (nt) - Carguy63™ 2010-04-20 10:06:54 (173 views)
      • Smart ass (nt) - Edwin™ 2010-04-19 16:04:50 (172 views)
    • I pulled my highbeams as they are useless now highbeam xenon over powers the - Edwin™ 2010-04-19 04:02:15 (225 views)
      • can you not just replace that bulb with an Xenon one? (nt) - bmer_D 2010-04-19 12:20:20 (184 views)
        • yes but they take a while to get up to full strength so for little flashes - Edwin™ 2010-04-19 16:04:25 (155 views)
  • Edwin that's Torx is a security Torx. I had to buy one last week - JoeC 98 740il & 750il 2010-04-18 16:17:44 (173 views)
  • what's the benefit? (nt) - sdmike 2010-04-18 13:54:31 (218 views)
    • MAJOR extra light with the stock 35W bulb and more light distance on the road (nt) - Edwin™ 2010-04-18 19:00:13 (227 views)
      • so it's just a bigger lens? (nt) - sdmike 2010-04-19 00:28:15 (165 views)
        • Yep as seen in the pictures (nt) - Edwin™ 2010-04-19 04:01:03 (186 views)
    • For me (pre-face lift) the projectors were made for xenon where mine were not, - jbkds 2010-04-18 14:10:14 (228 views)
      • Cliff notes.. More light sent out in front of you. Good for safety (nt) - jbkds 2010-04-18 14:15:58 (146 views)
  • This is TOTALLY COOL and just got added to my 'to do' list! - fuzzybear 2010-04-18 12:46:47 (172 views)
  • here is another write up in Russian posted by another member (url) - rrse38 2010-04-18 02:07:11 (244 views)
    • Back in Feb 2007 I was intrigued by member'PKORTUN' (url) - Snitch740i 2010-04-18 23:24:16 (213 views)
      • Feb 2010...I meant ^^^^^^ (nt) - Snitch740i 2010-04-18 23:25:26 (165 views)
    • Is there an english version :S (nt) - bmer_D 2010-04-18 12:27:51 (158 views)
      • Use babelfish.yahoo.com ... pick Russian to English ... it is close enough - aaron00740il 2010-04-18 14:45:55 (192 views)
    • That would have saved me a lot of time (nt) - Edwin™ 2010-04-18 05:42:16 (162 views)
      • Only problem..he cut away too much of the reflector around the projector.. - TxDarth 2010-04-18 11:53:18 (161 views)
        • I agree ... only trim where needed ... he also left off the outter lens part - aaron00740il 2010-04-18 12:03:37 (172 views)
  • Jeez, you could write your own Bentley Manual. Great job! (nt) - Steve R 2010-04-18 00:51:58 (200 views)
  • Awesome Big E..where can i go to buy this???? (nt) - Snitch740i 2010-04-17 18:10:33 (174 views)
    • Read the post buddy (nt) - Edwin™ 2010-04-17 18:11:08 (167 views)
      • U didnt mention where u bought them but NVM Geoff posted an Ebay linky (nt) - Snitch740i 2010-04-17 19:45:02 (167 views)
        • 19 posts down in capital SELLER INFO (nt) - Edwin™ 2010-04-18 01:42:37 (180 views)
        • He did in the post that says 'SELLER INFO' ... might be gone now. Search - aaron00740il 2010-04-17 21:36:08 (175 views)
  • Impressive, I knew you more tricks up your sleeve. Nice work. (nt) - rg0115 2010-04-17 17:40:08 (150 views)
  • BANG (nt) - black740ia 2010-04-17 17:17:15 (195 views)
    • LOL also got them from Mike? (nt) - Edwin™ 2010-04-17 17:26:55 (148 views)
      • Yes sir (nt) - black740ia 2010-04-17 17:36:11 (143 views)
  • Nice job. I have essentially the same system on my 03 745i. It is a 'night - chuckc 2010-04-17 16:25:03 (173 views)
    • Is this Bi-xenon for low and hi beam in the same lenses ¿I am still on halogen - bmw635 2010-04-18 00:49:31 (178 views)
      • The high beams still operate normal (in the way I set mine up) the difference is - jbkds 2010-04-18 00:59:54 (213 views)
  • E, that is one hell of a mod. Now I want projectors in.. - dj37027 2010-04-17 12:52:23 (153 views)
    • fly me over (nt) - Edwin™ 2010-04-17 13:31:47 (136 views)
      • Group buy (nt) - bmer_D 2010-04-17 14:09:47 (147 views)
  • Do you have check high beam message or will the solenoid be enough resistance (url) - aaron00740il 2010-04-17 11:10:03 (217 views)
    • It's you choice to leave the high beam connected or not, but no messages! (nt) - Edwin™ 2010-04-17 11:42:11 (148 views)
    • Does this work with the self leveling of the light assembly? (nt) - aaron00740il 2010-04-17 11:30:18 (214 views)
      • Yes. (nt) - Shled℠ 2010-04-17 11:44:34 (170 views)
      • Watch the video (nt) - Edwin™ 2010-04-17 11:42:38 (176 views)
  • Awesome mod !! It looks like the BZ's are on hi-beam all the time..... - audiavant 2010-04-17 09:53:22 (172 views)
    • Yes it cuts the high beam, when you flip the switch it drops (high beam on) (nt) - Edwin™ 2010-04-17 11:43:41 (157 views)
  • SELLER INFO: Factory_xenon , His name is Mike, he reponds quick and ships (url) - Edwin™ 2010-04-17 02:01:38 (362 views)
    • come to papa! ... I just picked up a set (nt) - aaron00740il 2010-04-17 14:12:16 (155 views)
    • what setup did you buy...he has several bi-xenon - Carguy63™ 2010-04-17 10:24:16 (169 views)
      • is this the correct set up?? (url) - Carguy63™ 2010-04-17 10:25:54 (237 views)
        • Yes D2S E55 or E60 lenses work (nt) - Edwin™ 2010-04-17 11:44:38 (224 views)
          • so if you go with this and leave the original - Carguy63™ 2010-04-17 11:55:34 (172 views)
            • uhuh, cool huh! (nt) - Edwin™ 2010-04-17 13:32:48 (153 views)
              • Sorry just bought them about 10 minutes ago....... (nt) - TxDarth 2010-04-17 14:22:04 (151 views)
                • He has another new listing ... check his store! (nt) - aaron00740il 2010-04-17 14:50:44 (148 views)
                • Damn, that was quick, already recieved email from Mike shipping today. (nt) - TxDarth 2010-04-17 14:33:25 (160 views)
                  • Yeah ... I bought the other set he had ... he is fast (nt) - aaron00740il 2010-04-17 14:45:56 (144 views)
                    • Told you guys!! (nt) - Edwin™ 2010-04-17 15:43:37 (142 views)
              • great for rally racing (nt) - bmer_D 2010-04-17 14:11:06 (141 views)
  • That is a really cool mod. Those BX's were cool as hell on the 3er loaner I once - Ed 2010-04-16 20:56:29 (191 views)
  • Fantastic Mod, The best mod ever !!! (nt) - CarlT 2010-04-16 17:47:32 (185 views)
  • Updated video! Some night shots with both headlights in place (vid) - Edwin™ 2010-04-16 17:15:08 (250 views)
    • Awesome! Now make 'em move left and right with steering wheel!!! Great write up (nt) - _wolf 2010-04-26 09:57:32 (154 views)
  • Awsome work from E... but I have a question - Carguy63™ 2010-04-16 16:45:52 (160 views)
    • I could not see the video before...now I do...got it (nt) - Carguy63™ 2010-04-16 16:55:17 (156 views)
  • Great job Edwin! Way better write then I had started! (nt) - jbkds 2010-04-16 16:07:17 (163 views)
  • Incredible... but can they be too bright now and end up getting pulled over?? (nt) - bmer_D 2010-04-16 16:06:41 (171 views)
    • Nope it's all stock same 35W bulb! (nt) - Edwin™ 2010-04-16 16:26:44 (166 views)
      • damn! Just wonder if it blinds the guy coming the other way - bmer_D 2010-04-16 17:24:41 (165 views)
        • Had the lights adjusted to spec and inspection proof!! so if it does I don't - Edwin™ 2010-04-16 17:36:12 (190 views)
          • how long did it take you?? hehe, I'm glad I don't live near you - bmer_D 2010-04-16 18:29:56 (195 views)
            • First one took me 6 hours and the 2nd a little 3 hours, i wanted it perfect (nt) - Edwin™ 2010-04-17 11:46:05 (156 views)
              • of course anything below that would be an insult (nt) - bmer_D 2010-04-17 14:14:08 (144 views)
            • I have the same projector but with the 55W bulb and don't blind anyone with the - jbkds 2010-04-16 19:09:31 (207 views)
              • Hey Chief...have you had any problems running the larger bulbs??? - TxDarth 2010-04-17 22:23:32 (186 views)
                • Re: Hey Roger...I have the retrofit HID system from DDM. My lights were never (url) - jbkds 2010-04-17 23:01:55 (224 views)
              • Hey Chief...have you had ay problems running the larger bulbs??? - TxDarth 2010-04-17 22:20:00 (171 views)
              • Simple D2S bulb swap Master Chief? No codes? (nt) - Shled℠ 2010-04-17 12:09:28 (184 views)
                • Re: I get the check low beam bulb so for now I have two bulbs wired in to stop - jbkds 2010-04-17 23:20:12 (184 views)
                  • Did you promote again and I didn't hear about it? - 740isport 2010-04-19 11:54:57 (153 views)
                    • Oh No.. Still a Senior Chief, Not up for Master till March 2012. (nt) - jbkds 2010-04-19 14:09:24 (151 views)
              • lol, nice (nt) - bmer_D 2010-04-16 19:34:29 (151 views)
  • Very nice FedEd!!!! Where, what from and how much for the projectors... - TxDarth 2010-04-16 15:20:06 (178 views)
    • Got my projectors from ebay, search for M5, E55 Bi-Xenon.. Mine where 75 shipped - jbkds 2010-04-16 19:33:26 (241 views)
      • Be sure you get 100% clean lenses, not with burn marks or scratches, mine were - Edwin™ 2010-04-17 11:47:10 (172 views)
        • Also if you are putting these in a pre-facelift housing you will also need - jbkds 2010-04-17 23:15:34 (190 views)
  • Awesome upgrade as usual! (nt) - Moose 2010-04-16 15:13:41 (168 views)