BMW 330i ZHP - My ZKW to AL headlight swap to include ZKW lenses doityourself

[danewilson77]

Just some notes I think will help someone trying to tackle this. I would like to thank Jon publicly for his help on this, and answering my several texts and emails.

This build replaces the normal ZKW headlights with AL headlights (SAT bowls) and ZKW lenses.

"Nice to have" tool list, above and beyond normal sockets and screwdrivers.

- Telescoping magnet pickup. Perfect for "getting started" the inner/lower headlight Torx screws.
- Torx sockets. You will need a tiny Torx bit to remove one screw on the ZKW lense housings. In addition you will need regular Torx set.
- Six inch extensions.
- Glass cleaner. Ensure you use on inside/outside of ZKW lenses and on outer headlight lenses just prior to final install.
- Electronic parts cleaner.
- One set of used AL headlights
- Your set of ZKW's, or ZKW lenses from the http://www.theretrofitsource.com/product_info.php?products_id=136

1. Drain windshield fluid reservoir > I used a Motive Power extractor to do this. This is only necessary if you plan to fully remove the headlight washers. This headlight swap can be done without removing the headlight washers though. Be advised.

2. Remove interference > I removed my intake to facilitate room on the drivers side. Nothing needs to be removed on the passenger side.

3. Go ahead and unplug all lighting connections. There will be 4 connections on each headlight, and a couple of more, if you have angel eyes installed.

4. Remove 4 screws on each headlight. 2 above, and two below. The two below are Torx and the two above are normal bolts. You can use the below video to facilitate removal. Like I said though.....the headlight washers need not be fully removed to remove the headlights.


http://www.youtube.com/watch?v=N_xmWuqyQ1Y


http://www.youtube.com/watch?v=RxbRFtiDeUQ

5. Now that you have the headlights out of the car.....go to a somewhat clean area....with a lot of room to facilitate breakdown and removal of your ZKW lenses for install into your AL headlights with SAT bowls. I used the below video, and I thank Jon for providing it. Now remember....in the below video he is disassembling AL headlights. NOT ZKW's. The ZKW's are different in three regards.

1. The upper center socket needs to additionally be jarred loose, and...
2. The inner hinge will have to be disconnected to facilitate removal, VA and...
3. Actual lense removal differs on the ZKW's.

I will post pictures of the three items mentioned above when time permits.


http://www.youtube.com/watch?v=SaQfWLe528U

The above steps should get the ZKW headlights out of the car and get the AL headlights rebuilt with ZKW lenses.

6. Modification of ZKW headlight brackets to receive AL headlights > The picture below will describe exactly what you need to do to facilitate install of your newly rebuilt AL headlights with ZKW lenses.

But DW.....why do I need to modify my headlight brackets? The box on the bottom of the AL headlights interfere with the headlight bracket. That is the major reason.

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWALHeadlighthousingundersidecomparison.jpg

Drivers side before

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketdriversidebefore1.jpg

Drivers side after bracket modification

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketdriversideafter.jpg

Passenger side before

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketpassengersidebefore.jpg

Passenger side bracket modification

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/ZKWlightbracketpassengersideafter.jpg

7. After you get the headlight assemblies to seat properly, you're golden. Snug them down with your 4 hold down bolts, re-install intake, lower trim, and re-fill washer reservoir (if drained)

8. The last thing you'll want to do is perform the headlight aiming procedure. I used the below procedure as I could not find Trevors pic.

http://www.m3forum.net/m3forum//showthread.php?t=176238

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/hellainstructions.jpg

[JupiterBMW]

Excellent write up Dane. I believe that a culmination of ALL the DIYs out there will eventually make this whole process much better. Your DIY helps immensely. Great photos and writeup.

And thanks for the kudos. I'm just glad I was able to help. If anything, thank my wife. We were having Mexican at a little place near home my last night before coming to the ship when you called. I got the 'roll eyes' look when I said I had to answer... :rofl

[danewilson77]

Welcome to the "Eye roll" club. Apologize that I interrupted your dinner.

In retrospect, for the fella's that have ZKW's, I wonder if a guy could just buy a set of P46's (only for the bowls), and retrofit the bowls into his ZKW's?

I guess the question is, are P46 bowls better than ZKW's bowls. I've heard of "build quality" issues (with P46's), but if your just using the bowls and retaining all other ZKW parts, I wonder if it would be ok? So the real question is, are the bowls any good?

Kinda sucks to spend $600 on lights then take them apart, but unfortunately, that's the life we live in. Or....you spend $1500.00 on Magnetti Marelli's.

http://i1015.photobucket.com/albums/af278/nicee46/Maintenance%20and%20Misc/P46.jpg

http://www.ecstuning.com/BMW-E46-330i-M54_3.0L/Lighting/Headlights/ES2500715/

[johnrando]

If you are married, you are clearly NOT doing enough mafia/car stuff until you get the eye roll. If you haven't gotten it, you either married an angel (male or female) or you are just not true mafia yet. The eye roll puts you one step closer to being "made". :biggrin

[echo46]

Very good write up. Very cool.

[JupiterBMW]

If you are married, you are clearly NOT doing enough mafia/car stuff until you get the eye roll. If you haven't gotten it, you either married an angel (male or female) or you are just not true mafia yet. The eye roll puts you one step closer to being "made". :biggrin

Oh trust me, this is so NOT my first eye roll. :rofl

[ChristopherL]

Hi Dane/Group -

Sorry to bump this old thread, but it's the most concise swap thread I've found.

A few months ago I replaced my burnt ZKW bowls with refurbed ones from ClemsonE46. This was done in tandem with brand new ZKW headlight covers (plastic), seals, etc. I'm afraid that they are already starting to burn - I've got a brown/yellow hue coming from one side. I need to check bulbs first before jumping the gun, but I've begun planning on removing the ZKW assemblies entirely.

I have a low mileage set of E46M AL headlights.
I understand the fitment/bracket issues outlined above when installing AL's into a ZKW equipped car.

However, I'm unclear on your mention of the lens swap above?
Are you indicating I should be swapping the ZKW clear projector lens over and replace the Bosch/AL "foggy" projector lens?
Is there any functional purpose to this or just the aesthetic aspect?

If I install the proper AL brackets, are the AL headlight assemblies a plug and play install without projector lens swaps?

Thank you!
-Chris

[danewilson77]

Hi Dane/Group -

Sorry to bump this old thread, but it's the most concise swap thread I've found.

A few months ago I replaced my burnt ZKW bowls with refurbed ones from ClemsonE46. This was done in tandem with brand new ZKW headlight covers (plastic), seals, etc. I'm afraid that they are already starting to burn - I've got a brown/yellow hue coming from one side. I need to check bulbs first before jumping the gun, but I've begun planning on removing the ZKW assemblies entirely.

I have a low mileage set of E46M AL headlights.
I understand the fitment/bracket issues outlined above when installing AL's into a ZKW equipped car.

However, I'm unclear on your mention of the lens swap above?
Are you indicating I should be swapping the ZKW clear projector lens over and replace the Bosch/AL "foggy" projector lens?
Is there any functional purpose to this or just the aesthetic aspect?

If I install the proper AL brackets, are the AL headlight assemblies a plug and play install without projector lens swaps?

Thank you!
-Chris
Hi Chris,

Have you contacted ClemsonE46 to discuss premature bowl burnout?

S7 Edge, out

[GreatFrog]

Since the dimming headlight is a safety concern, is it possible for BMW to issue a recall on these headlights? or was there any attempt to force BMW to recognize this problem?

[Aeternalis]

Since the dimming headlight is a safety concern, is it possible for BMW to issue a recall on these headlights? or was there any attempt to force BMW to recognize this problem?
From what I understand, BMW was not compelled to issue a recall for the ZKW lamps. Thus we're on our own fixing the problem.

[ChristopherL]

Hi Chris,

Have you contacted ClemsonE46 to discuss premature bowl burnout?

S7 Edge, out

I have not, as I knew it was a low-cost solution to the deplorable lighting condition of the burnt OE bowls.
The lighting pattern is not the best, with strong hot spots and dim areas. I suspect it is a result of the repair to the bowls from previous burning. Clemson46 does a great job, but it's just not feasible to get a perfectly repaired bowl to OE contours, and as such it affects the beam pattern/throw.

Do you have insight into the lens swap as indicated into your original post? Was that just for the cleaner cut off and clear lens appearance?

Thanks,
-Chris

[danewilson77]

Bump

Sent from my SM-G955U using Tapatalk

[trancenation]

Does anyone know if the ZKW D2S bulbs are compatible for use in the AL Assembly? I purchased some AL assemblies (From a coupe) and they didn't come with any D2S Bulbs. I do see that there are two different PN's on Realoem for AL vs ZKW D2S.

Any input is appreciated.

Thanks

[holyc0w]

I believe all D2S bulbs should work.

[Vas]

Does anyone know if the ZKW D2S bulbs are compatible for use in the AL Assembly? I purchased some AL assemblies (From a coupe) and they didn't come with any D2S Bulbs. I do see that there are two different PN's on Realoem for AL vs ZKW D2S.

Any input is appreciated.

Thanks

They are since both use D2S HID bulbs.

FYI coupe headlights wont work on the sedan. And internals from them wont work into zkw headlights.

[trancenation]

They are since both use D2S HID bulbs.

FYI coupe headlights wont work on the sedan. And internals from them wont work into zkw headlights.

Thanks.

Actually you can use pre-facelift coupe headlight or E46 M3 headlight assemblies in sedans. One just needs to swap over the black/silver sedan insert and lens cover. It's just the facelifted coupe's headlights (sealed) that can't fit.