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Discussion Starter · #1 ·
Hello community. Originally posted on zhpmafia. I've had my 2004 ZHP sedan for over a year, typical ZKW burnt bowls. After lots of research, last December, I finally decided to tackle this project. I went with Morimoto Mini D2S 4.0 projectors based on a few pictures I saw online. What drew me to this projector was the definition and width of the cutoff.



http://www.youtube.com/watch?v=mSJQ9XpqaaY

The project is definitely not plug and play but if you have the tools it's another option to consider. I finally got through sorting over 150 pictures and instead of doing the step by step here, I annotated the images. Sorry for the few grammar errors, busy schedule so I was working at night.

I'm making this tutorial newbie friendly so if you've never tinkered with your headlights you'll find useful pictures. However, by the time I was ready to install these things I kind of stopped taking pictures, too excited to see the lights in action. I did take pictures of the final result and a little driving clip included in the end.


Components

Morimoto Mini D2S 4.0 from Lightwerkz
http://www.lightwerkz.net/index.php...i-xenon-morimoto-mini-d2s-4-0-projectors.html

E46-R shrouds also from Lightwerkz
http://www.lightwerkz.net/index.php/components/projector-shrouds/e46-r-projector-shrouds.html

Morimoto XB D2S 5500K bulbs
http://www.lightwerkz.net/index.php/components/hid-bulbs/morimoto-xb35-d2s-bulbs.html


Tools

- flat blade screwdriver
- pocket size flat blade screwdriver
- phillips screwdriver
- interchangeable bit screwdriver
- 6" magnetic hex bit extension
- T25 driver
- T15 driver
- 8mm socket
- ratchet, 3/8" or 1/4" doesn't matter
- ratchet extension (optional)
- magnetic parts holder (optional)
- locking clamp pliers or needle nose pliers
- Dremel 3000 kit
- drill
- 1/16" drill bit
- 3/32" drill bit
- soldering iron w/ solder
- 18-22 gauge heat shrink wrap
- pick tools, various angles
- Sharpie
- pen
- painters/masking tape
- JB Weld
- Blue Magic polishing cream
- #6 x 1/2" phillips sheet metal screws
- #6 - 32 x 3/4" machine screws with matching nuts
- #6 flat washers
- 1 1/2 flat corner braces

Part 1

Headlight removal

step001 by fatherlemmisty, on Flickr

step002 by fatherlemmisty, on Flickr

step003 by fatherlemmisty, on Flickr

step004 by fatherlemmisty, on Flickr

step005 by fatherlemmisty, on Flickr

step006 by fatherlemmisty, on Flickr

step007 by fatherlemmisty, on Flickr

step009 by fatherlemmisty, on Flickr

Now use your ratchet and 8mm socket to loosen the front screws
step010 by fatherlemmisty, on Flickr

For the rear screws you'll use your screwdriver with magnetic extension and T25 driver. (Not pictured.)
step011 by fatherlemmisty, on Flickr

step012 by fatherlemmisty, on Flickr

step013 by fatherlemmisty, on Flickr


Headlight disassembly

Take your headlights inside the house, I recommend working on a table. Here's the Morimoto unit.
step015 by fatherlemmisty, on Flickr

step017 by fatherlemmisty, on Flickr

This trim comes off pretty easy.
step018 by fatherlemmisty, on Flickr

step019 by fatherlemmisty, on Flickr

step020 by fatherlemmisty, on Flickr

step021 by fatherlemmisty, on Flickr

step022 by fatherlemmisty, on Flickr

step023 by fatherlemmisty, on Flickr

step025 by fatherlemmisty, on Flickr

step026 by fatherlemmisty, on Flickr

step027 by fatherlemmisty, on Flickr

step028 by fatherlemmisty, on Flickr

step029 by fatherlemmisty, on Flickr

step030 by fatherlemmisty, on Flickr

step031 by fatherlemmisty, on Flickr

I believe this was a Torx 15 driver, sorry for the grammar.
step032 by fatherlemmisty, on Flickr

While this one Torx 25, but don't quote me on this haha
step033 by fatherlemmisty, on Flickr

step034 by fatherlemmisty, on Flickr

step035 by fatherlemmisty, on Flickr

step036 by fatherlemmisty, on Flickr

step038 by fatherlemmisty, on Flickr

step039 by fatherlemmisty, on Flickr

I meant the burnt projector bowl
step040 by fatherlemmisty, on Flickr

step041 by fatherlemmisty, on Flickr

step042 by fatherlemmisty, on Flickr

The heat also burned the driver's side shroud. Bummer. I would've reused the OEM shrouds.
step045 by fatherlemmisty, on Flickr

For comparison, the ZKW lens is frosty while the Morimoto is all clear.
step047 by fatherlemmisty, on Flickr_a_
 
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