General Bi Xenon Projector Installation

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INSTALLATION INSTRUCTIONS FOR DIY BIXENON RETROFIT KIT

Tools Required:#2 Phillips Head Scewdriver#1 Phillips Head Screwdriver

Large flat blade screwdriver

Pliers, needle nose

Rubber Band

Reccomended:

Compressed or canned air

Cotton terry cloth, soft and

clean

2 Cotton terry towels, soft and

clean

Kit Contents:2x Bixenon Projector assemblies

2x NightVision brand 35w HID

ballasts

2x Bixenon projector bulbs

2x Fully integrated wiring

harnesses

4x-12x wire taps

1x tubes sealent

Propreitary concerns:

Some people and businesses feel they can steal whatever they want

for their own use regardless of who owns the property. All images

and text included in these instructions are the sole property of Retro-

Solutions, LLC and and under no circumstance is anyone allowed to

copy or distibute any of the following contents of this guide in any

way. Any violation will of copyright will be pursued to the fullestextent of the law.

Copyright Retro-Solutions LLC 2009 All rights reserved.

NEVER:

Never use any alcohol or other solvents on any part of the lamps

unless otherwise instructed.


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Remove the headlamps from the car following previously available instructions.

Remove any screws on the back of the housings, remove all bulbs and sockets.



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Place headlamps in a 200-220F oven for 15-20 minutes. Use a baking pan with a soft clean terry

towel and the lamp lens placed face down. Be extremely careful to not blocking the

temperature sensor for the oven or it will overheat!



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The headlamp will be warm, mildly hot to touch when removed from the oven. If using bare

hands just be careful not to touch metal pieces. Place the lamp lens down on a soft clean terry

towel.

Starting at the inside (smaller) corner of the lamp, insert a large flat head screwdriver blade into

the seam and gently twist to push the halves apart making the gap larger. Move along and do

the same every -1every once and a while going back to the corner and starting over to

make the gap larger and larger. You may want to place a piece of masking or duct tape over

the end of the screwdriver as the sealant can become messy and stick to an otherwise good

screwdriver.



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Finally you should have enough gap formed to be able and use your fingers to get a grip and

pull the halves apart by hand. Go slowly, and watch the tabs ahead as you will have to free

them as you move along or it will hinder progress. Also watch the sealant as it will create strings,

use the screwdriver to break these as you go, you do not want to ruin the lamps because a

string of sealant gets on the chrome.



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Now you have the two separated halves, place the lens half in a safe place, free of dust.



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Next take the projectors out and remove the bulb retainer screw from rear of assembly. And

carefully remove the bulb out the back. (small version shown here).



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Next twist off the wing nut and slide the lock washer, alignment ring. Pry off the rubber isolator

only if absolutely needed for fitment (this is rarely required).

For 9005/9006 verson lamps, yoiyu may find loosening the three screws on the bulb retaining ring

will allow for easier alignment. Here we have removed it for viewing purposes.



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Place the projector alignment ring into the bulb recepticle. Make sure to install it the correct side

up, the tab inside the ring should be at the very top when veiwing the lamps right side up.

Replace the the bulb retainer if removed in 9005/9006 applications. Be sure to check the ring

alignment before tightening up fully.



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Before inserting the projector, route the wires alongside the projector along the projector body,

through the bulb hole, through the alignment ring, locking ring and wing nut. There is a groove

on the projector neck in which these wires are to sit when installed.

Alternatively, wires can also be routed through other existing cittylight or parking light holes in

reflectors (shown).



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Insert the projector with the marked up position corresponding to the tab on the alignment ring.



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Insert the locking ring over the back of the projector, and screw on the wing nut. Remember to

make sure the wires follow down the existing groove as needed.



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Using a rubber band wrapped around the handles of pliers, clip onto the bulb retainer to hold it

in place easily while using using a screwdriver in the other hand to screw the clip into place.



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Snap together the connections for the wires on the projector to the corresponding wiring

attached to the bulbs.

At this time the lamps can be placed onto the vehicle to check and tweak alignment for the

two lower steps of each cutoff to align level across both sides.

Once aiming is completed, Be sure the wing nut is fully secrured down while holdng the

projector from moving from the front.

Clean off any fingerprints and dust from inside the lamps before replacing the lens.

Place the front lens back on the rear of the housing. After the lens is resting in place, place the

lamp back in the oven for 200-220F for 10 minutes.

Remove the lamp and place it lens side down on a cotton terry towel. Squeeze the two halves

together by hand first. Then replace the two screws on the outside edge. Then using clamps or

vice grips, start squeezing the halves together starting at the outside edge and working to the

pointed end.



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Let the lamps cool 1-2 hours before replacing all the bulbs and sockets.

Next fold the interior of the OEM rubber bulb cover inside out, and slip it over the wires and and

rubber seal from the projector.



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Next slip the rubber cover from the projector over the lip made in the OE rubber cover.



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Then place the two rubber covers onto the rear of the headlamps.



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Take the supplied sealent and apply it on the seam between the two rubber seals and let it dry

fully.



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The only steps that remain are placing the headlamps back to the vehicle and routing the

wiring. All connections are labeled. Polarity on all connections is not specific with exception of

the wires to power the angel eyes, these are Red and Black. These can be connected to any

12v source on the vehicle, however black must connect to black or other corresponding ground

connection. There are included wire taps. For best operation do not turn on vehicle lamps until

the vehicle engine is started.

As the provided wiring will generally offer a great deal of flexibility in operation, please contact

us directly for any assitance.

General Bi Xenon Projector Installation

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