Help Needed. Replacing burnt bowl from ZKW using theretrofitsource kit

[jonnyd330]

So I went ahead and ordered theretrofitsource e46 kit and much to my dismay and their directions it is not a plug and play kit that is easy. I think I am going to return it because I am in over my head. But now I have my drivers side headlight compeltely dissasembled and don't know what to do. I am hoping y'all have some suggestions.

Ugh I was hoping to have my car back on the road soon but looks like it will be another week.

[az3579]

What are you having trouble with? I believe the minimum modification work is dremeling.

[slater]

What are you having trouble with? I believe the minimum modification work is dremeling.

+1

pics would help us help you.

[jonnyd330]

Thanks fellas. So here are my issues...


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I don't know why but my projector housing is missing one of the things to screw into so the retro fit bracket will only have 3 mounting points.

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The rubber things stick out, the guy at the retro fit store said these might need to be filled down to be flush, I don't know if I need to do that? If so how can I do it?

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Next I don't know how to do the wiring since the plugs are different size, these directions do not talk about this at all. I am guessing the OEM plug is to activate the high beams.

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[jonnyd330]

@az3579 @slater

[az3579]

About the holes:
Three should still be sufficient to mount the projector.

About the 'grommets':
You may have to use a Dremel to cut into them to make them sit flush. I'm not sure if it's calling for you to cut the plastic ears around the grommets as well. I would recommending contacting TRS support to get some guidance from them (assuming you purchased from them).

About the connector:
Yes, the green/red wire connector on the factory harness is for the shutter solenoid that activates the high beam shutter. Does the small black connector in the kit fit the factory harness connector? If so, I imagine those go together, then the large black connector gets connected with the high beam wiring harness outside the housing. That's my best guess based on the pictures you provided. Once again, I would get guidance from TRS on this if you're not sure.

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[jonnyd330]

So I found a guide on here that is very detailed and it looks like it requires a lot more dremel work than I would like to do. I am going to just reassmble my OEM lights and do more research about these kits. If I knew it was going to be so much dremel work I would have just ordered one of the kits off ebay for half the price its the same amount of work.

http://www.zhpmafia.com/forums/showthread.php?19877-Yet-another-projector-retrofit-tutorial-ZKW-gt-Morimoto-Mini-D2S-4-0

I strongly advise against ordering from theretrofitsource if your looking for an easy install.

[holyc0w]

I don't know where you are in Florida, but it looks like they have some installers there.

https://www.theretrofitsource.com/partners/

[slater]

So I found a guide on here that is very detailed and it looks like it requires a lot more dremel work than I would like to do. I am going to just reassmble my OEM lights and do more research about these kits. If I knew it was going to be so much dremel work I would have just ordered one of the kits off ebay for half the price its the same amount of work.

http://www.zhpmafia.com/forums/showthread.php?19877-Yet-another-projector-retrofit-tutorial-ZKW-gt-Morimoto-Mini-D2S-4-0

I strongly advise against ordering from theretrofitsource if your looking for an easy install.

sorry i am chiming in late here, crazy weekend (ice storm here), but BP answered thoroughly. :)

which kit did you order? we should start there. i have had their EvoX-R 'RetroQuik' kit installed for 4 years now, and the install was easy and their instructions were good. i was actually impressed with their customer service and really, the whole ordeal. so which kit did you order? :)

[joeybananaz18]

I have to admit, I was a little nervous about having to do this work myself. So i decided to pick up a pair of AL headlights instead. I have them still in the boxes from the seller. I want to get new covers, gaskets and then put in my gold V2s that have been sitting around for a while. Now I'm thinking of picking up the ZKW-r lenses since they're not on the car yet. It'll be easier to take everything apart and take my time with it since i still have my ZKWs in.

[jonnyd330]

Good point I didn't add which kit i got.

https://www.theretrofitsource.com/complete-retrofit-kits/morimoto-retroquik-bmw-e46-zkw-repair.html

PROJECTORS: 2x Morimoto D2S 4.0

RQ BRACKETS / HARDWARE: 2x G10 Fiberglass / Stainless

[slater]

Good point I didn't add which kit i got.

https://www.theretrofitsource.com/complete-retrofit-kits/morimoto-retroquik-bmw-e46-zkw-repair.html

PROJECTORS: 2x Morimoto D2S 4.0

RQ BRACKETS / HARDWARE: 2x G10 Fiberglass / Stainless

i just read through the instructions - it's very simple. it looks like the only modification required is trimming the stock headlight bracket to allow the new project to sit flush against the RetroQuik bracket - 5min or less, with a dremel or a utility knife. otherwise it looks pretty darned plug and play... sorry to say, but i don't see how they could've made it any easier!

[jonnyd330]

If you are looking at the directions they provide on their page, those are miss leading. I called and they said there were a number of items not included such as the need to dremel out some for the solenoid and then doing the wiring. I found this guide which uses the same Morimoto projectors but not the prefabricated mount included with my kit.

http://www.zhpmafia.com/forums/showthread.php?19877-Yet-another-projector-retrofit-tutorial-ZKW-gt-Morimoto-Mini-D2S-4-0

His directions are far more complete and make me think this is over my head, worring about the position of everything and if its going to bump when trying to auto level. I'm worried about screwing these things up to where they are completely unusable.

[slater]

If you are looking at the directions they provide on their page, those are miss leading. I called and they said there were a number of items not included such as the need to dremel out some for the solenoid and then doing the wiring. I found this guide which uses the same Morimoto projectors but not the prefabricated mount included with my kit.

http://www.zhpmafia.com/forums/showthread.php?19877-Yet-another-projector-retrofit-tutorial-ZKW-gt-Morimoto-Mini-D2S-4-0

His directions are far more complete and make me think this is over my head, worring about the position of everything and if its going to bump when trying to auto level. I'm worried about screwing these things up to where they are completely unusable.

OK, did they send you updated instructions for the solenoid? the wiring is not a surprise. i guess TRS is assuming that folks buying their RetroQuik kits are aware of what is required before buying the kit.

that thread you linked is for installation without the TRS RetroQuick bracket, which really takes the guesswork out. most of his trimming is related to that. nothing in the thread was surprising, to me.

if you've got a dremel - or can borrow one, and know how to use it, you can do this.

[jonnyd330]

OK, did they send you updated instructions for the solenoid? the wiring is not a surprise. i guess TRS is assuming that folks buying their RetroQuik kits are aware of what is required before buying the kit.

that thread you linked is for installation without the TRS RetroQuick bracket, which really takes the guesswork out. most of his trimming is related to that. nothing in the thread was surprising, to me.

if you've got a dremel - or can borrow one, and know how to use it, you can do this.

Thanks for the vote of confidence. ;)

I guess reading all these treads has scared me from doing it. I found this one that made it look awful and he had the bracket but now after reviewing it I don't think he installed them correctly. It looks like he mounted the projector from the rear and it should be on the front.

[jonnyd330]

So after procrastinating for a while I finally decieded to jump in. I got the driver side headlight done today and I am shocked at what a difference the light output is. The kit is no where near plug and play as they elude to in their directions so buyer beware but with that said its a great upgrade.

[JohnnyGraphic]

So after procrastinating for a while I finally decieded to jump in. I got the driver side headlight done today and I am shocked at what a difference the light output is. The kit is no where near plug and play as they elude to in their directions so buyer beware but with that said its a great upgrade.

Thanks for the update! Glad it worked out for you. Did you use JohnD’s DIY posted above?

[jonnyd330]

I used a mix of directions and figuring things out on my own since there was not a set of directions specifically that worked for what I was doing.

Here is a pic of the light output difference between the new drivers side and old passanger side. Its crazy how much more light there is, id say 90% of the light is from the new projector.

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[BMWCurves]

Wow. That’s...impressively bad on the passenger side.


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[JohnnyGraphic]

I used a mix of directions and figuring things out on my own since there was not a set of directions specifically that worked for what I was doing.

Here is a pic of the light output difference between the new drivers side and old passanger side. Its crazy how much more light there is, id say 90% of the light is from the new projector.

32771

Nice!! Like night and day difference!!!!

[johnrando]

#iseewhatyoudidthere :)

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