Need help with Xenon retrofit for ZKWs

[swchang]

Need some help from anyone who's done the Xenon ZKW retrofit...

I recently brought my car to a well-regarded indy shop in my area. The shop owner, who seems to know what he's doing, said he could not install the retrofit kit that people here are recommending. I bought the kit that everyone seemed to recommend (https://www.theretrofitsource.com/complete-retrofit-kits/application-specific/morimoto-retro-quik-system-bmw-e46-zkw-lights-only.html#.V6iqhvkrKM9) and even gave him the link to the DIY thread on this forum (http://www.zhpmafia.com/forums/showthread.php?10787-DIY-The-Retrofit-Source-(TRS)-Retro-Quick-System-Burnt-ZKW-Bowls-Projector-Retrofit-doityourself). Regardless, he said he had a few problems:

1) He could slide the silver plastic covering (not sure of the proper name) over the projector, but it wouldn't latch on or fasten anywhere. It would just slide back off.
2) He said the entire assembly was too long.
3) The wiring pins were incorrect.
4) He said to make things fit he would have had to do a substantial amount of Dremeling.

He thinks I got the wrong parts. Any thoughts or suggestions?

Thanks in advance.

[theothersawyer]

If I remember correctly the shroud (the silver plastic covering) doesn't snap into place, it is JB Welded into place. There was also a minimal amount of dremeling done. I don't remember everything that was done since I had a good friend of mine do the install. He has done quite a few retrofits and said this one was the worst one he has dealt with and it took us like 10 hours to do...

You did buy the correct kit, assuming they sent you the correct stuff. Sorry I can't be of further assistance, but I just watched as my friend did all the hard work!

[slater]

i used that kit on my car. the shroud needs to be glued/RTV'd to the projector assembly - not a big deal. it does not clip on.

otherwise, i don't see why it wouldn't fit (or be too long) - it fit perfectly in my car. what year is your car and what headlights do you have now? (halogen or xenon projector?)

also, reach of to TRS for assistance - they have excellent customer service! i bought a universal kit for my montero from them as well.

[swchang]

I have a 2004 ZHP with ZKW Xenons. I actually did call TRS, but the guy I spoke to didn't seem to know very much. He referred me to the thread on this site for installation instructions...

What about the pin connections? That was also a point of confusion for my shop.

[swchang]

Anyone able to help with respect to the connectors? Is it supposed to just plug right in or is there some soldering or something special that needs to be done? :help

[az3579]

Sorry man, I've got no suggestions... I would have sent my lights to LightWerkz for the retrofit (this is actually what I did). They have all the stuff needed to get the job done and have tons of experience since light retrofits and lighting-related projects is all they do.

It seems to me that the shop you left it with isn't experienced with lighting retrofits, so it's an idea.

[anandoc]

Anyone able to help with respect to the connectors? Is it supposed to just plug right in or is there some soldering or something special that needs to be done? :help

Did you take a look at the following DIY thread?
http://www.zhpmafia.com/forums/showthread.php?10787-DIY-The-Retrofit-Source-%28TRS%29-Retro-Quick-System-Burnt-ZKW-Bowls-Projector-Retrofit-doityourself

All you are really changing are the projector bowls so you just need to splice in the bi-xenon shutter connectors to the factory ones. All the other bulb connectors etc stay the same.

Can you be more specific (with pictures) as to which connectors you are referring to? I did the Morimoto FX-R 3.0 DIY 2 years ago and apart from the dremmeling bits, everything else was pretty straightforward.

[swchang]

Thanks for the suggestions. They actually did have a guy that has a lot of experience with lighting and he said he was baffled... Sigh.

I did look at that DIY and that is the one I gave to the shop. I'll take some pictures tonight or tomorrow and post what I mean. Thanks.

[swchang]

Did you take a look at the following DIY thread?
http://www.zhpmafia.com/forums/showthread.php?10787-DIY-The-Retrofit-Source-%28TRS%29-Retro-Quick-System-Burnt-ZKW-Bowls-Projector-Retrofit-doityourself

All you are really changing are the projector bowls so you just need to splice in the bi-xenon shutter connectors to the factory ones. All the other bulb connectors etc stay the same.

Can you be more specific (with pictures) as to which connectors you are referring to? I did the Morimoto FX-R 3.0 DIY 2 years ago and apart from the dremmeling bits, everything else was pretty straightforward.

Wow. I've really slacked off on getting the pics. Can't believe two months has passed already...

Well, if you're still around, here are the pictures of the connectors. Are these the same ones that you used and that were in the DIY?

2772727728

Let me know if you need me to take any other pics. I'll try not to take two months this time... :facepalm

[sillieidiot]

It doesn't matter what the connectors look like on the end. You will be splicing it into the stock bixenon wires anyways. But yeah they are supposed to look like that. You plug those into a plastic connector usually.

Maybe the dude is scared to dremel some stuff?

[swchang]

It doesn't matter what the connectors look like on the end. You will be splicing it into the stock bixenon wires anyways. But yeah they are supposed to look like that. You plug those into a plastic connector usually.

Maybe the dude is scared to dremel some stuff?

I'm not really sure what the deal is. Maybe he didn't realize more extensive modification would be required other than plugging things in? I sent them the link to the DIY that anandoc referenced. Not sure what else I can tell them...

[sillieidiot]

I'm not really sure what the deal is. Maybe he didn't realize more extensive modification would be required other than plugging things in? I sent them the link to the DIY that anandoc referenced. Not sure what else I can tell them...

Yeah I think that's probably it. He's probably thinking more like PnP with no actual retrofitting required. Honestly, if they can't figure it out. It's best if you just go somewhere else. There's no point in making them attempt to do it because it will end up worst than it should be and cost even more to fix (if you can actually fix it). If I still had pictures of Jko's lights, I'd show you what could go wrong lol I couldn't even fix his headlights. Ended up with a totally new retrofit lol

[nextelbuddy]

i just did this myself.. I got my kit from Lightwerkz.net http://www.lightwerkz.net/index.php/complete-retrofit-kits/application-specific-kits/retro-quik-bmw-e46-zkw.html

its pretty much the same procedure as yours.

I had to cut the small plug for the bixenon stepper motor in the headlight housing then use wire crimp connectors to connect to those 2 wires coming from your projector.

I also had to use a dremel and cut a small notch out of the projector housing that holds the projector so that the bixenon stepper motor woudl clear it.

These are the resources I used to help me.

Video showing how to disassemble your light

https://www.youtube.com/watch?v=OA_7vAVA7PY


and this DIY post on this forums

http://www.zhpmafia.com/forums/showthread.php?10787-DIY-The-Retrofit-Source-(TRS)-Retro-Quick-System-Burnt-ZKW-Bowls-Projector-Retrofit-doityourself


sometimes the pictures dont load since they appear to be hosted on photobucket but keep trying if they dont.

[swchang]

Sorry man, I've got no suggestions... I would have sent my lights to LightWerkz for the retrofit (this is actually what I did). They have all the stuff needed to get the job done and have tons of experience since light retrofits and lighting-related projects is all they do.

It seems to me that the shop you left it with isn't experienced with lighting retrofits, so it's an idea.

I think I bought the kit from Lightwerkz. I didn't realize they would be willing to do the retrofitting themselves. So you just sent your whole headlight to them, they did the retrofit, and then sent it back to you for you to just plug back in?


i just did this myself.. I got my kit from Lightwerkz.net http://www.lightwerkz.net/index.php/complete-retrofit-kits/application-specific-kits/retro-quik-bmw-e46-zkw.html

its pretty much the same procedure as yours.

I had to cut the small plug for the bixenon stepper motor in the headlight housing then use wire crimp connectors to connect to those 2 wires coming from your projector.

I also had to use a dremel and cut a small notch out of the projector housing that holds the projector so that the bixenon stepper motor woudl clear it.

These are the resources I used to help me.

Video showing how to disassemble your light

https://www.youtube.com/watch?v=OA_7vAVA7PY


and this DIY post on this forums

http://www.zhpmafia.com/forums/showthread.php?10787-DIY-The-Retrofit-Source-(TRS)-Retro-Quick-System-Burnt-ZKW-Bowls-Projector-Retrofit-doityourself


sometimes the pictures dont load since they appear to be hosted on photobucket but keep trying if they dont.


Thanks. If I ever get a chance to look at doing this myself, I'll use your links.