Another HID Bi-xenon Retrofit Install *PICS*

Rock Slide · 08-18-2008, 08:40 AM

A big thanks to Pdyebrasil for giving me yet another reason to blow more money on my 4Runner

(He was the first guy I saw do this mod to a 4Runner). Also, a big thanks to Pfdaxe for answering all the emails I sent him every time I ran into a snag. For more information on what they both did, check out this link: Click Me.

Oh and for more information on yet another FX Projector Retrofit I came across, check out WeCool.net: Click Me

For my own install, I followed Pfdaxe’s retrofit very closely. Here’s what I used:

Infiniti FX Bi-xenon Projectors
Acura TSX Lenses
Hella Gen 3 Ballasts
35W 4300K Philip D2S 85122+ Bulbs
H4 Plug-n-Play Wiring Kit -(ebay special)
Malibu Light Covers

Stock Infiniti FX Bi-xenon Projectors:

Note, the yellow wires are not used.

FX Lenses Removed:

The above lenses appear very clear, but looks can be deceiving. So I purchased a set of stock Acura TSX Single Beam Projectors strictly for their truly clear lenses.

I then removed the TSX lenses and installed them into the FX Projectors. Although, the FX lenses I already had were considered the “clear” version by market standards (as seen in the picture above), when compared to that of the TSX lenses, the FX lenses left very little to be desired. The TSX lenses are so incredibly clear, that they make the FX lenses look like crap. Here are a few comparison shots of the FX and TSX lenses:

FX vs. TSX Lenses installed in FX Projectors:

FX vs. TSX Lenses installed in FX Projectors:

1st Comparison Shot:

FX:

TSX:

2nd Comparison Shot:

FX:

TSX:

I obtained both the pair of 35W 4300K Philip D2S 85122+ bulbs and Hella Gen3 Ballasts from YT member Pfdaxe. As for the PnP Wiring Kit, I purchased it directly from Ebay. It came with all the necessary wiring to retain proper function of my high beams with the newly installed FX projectors.

I attempted the Color O-ring Mod, but had mixed results. I simply could not find a large enough gasket to make this mod worth my time. So I scrapped it and moved on. For those interested in this Mod, visit HID Planet: Click Me

For the Malibu Light Covers, I went with Intermatic.com. I found that while they do not sell the entire Malibu light itself, they do offer individual replacement parts for it. (Which was great, considering I only needed the covers anyway.)

Stock Photo of the Entire Malibu Light:

The Product Number for the entire light above is – LZ512SS found here: Click Me

Once you are there, click the "Parts" Tab at the bottom of the page. The first item in the list should be:

Light cover itself: Item # LZ512SSA
Description: SOLAR TOP-WHITE LED-INCLUDES BATTERY
Price per Cover: $6.25

I ordered 4 of these light covers (two extra in case I screwed the other 2 up) and had them at sitting at my front door in 3 days.

Here’s the process I took to convert the Malibu covers into Projector Shrouds:

I also purchased a 2nd pair of oem headlights to use in my 4Runner while I completed this retrofit on my existing headlights. Once I finished the retrofit, I swapped in my newly modified projector headlights and sold the donor lights.

Stock Headlight Housings:

To remove the headlight glass, I baked each light individually in the oven at 350 degrees for 5 minutes. This process permitted the hardened glue to become very soft, which in turn, allowed me to take a flat head screwdriver and pry the glass off of the housing.

Glass & Bulb Cover removed from Driver side Headlight:

In order to fit the FX Projectors in these headlights, the rear opening needed to be enlarged. A 2-inch hole saw made for a quick cut:

Before Rear Opening was cut:

After Cuts were Made:

Projector Mounted with the Malibu Cover On:

To secure the projector itself to the headlight, I drilled 4 small holes into the headlight and ran 4 long screws thru the projector mounting tabs and thru the holes in the headlight. Bolted them down on the backside of the headlight using lock washers, nuts, liquid thread locker and even some JB Weld to further seal them up.

Backside of Light:

Since I did not get a picture of the back of my finished lights, here is a picture I got from WeCool.net. I used JB Weld to cover my 4 bolts as they did, but instead of using JB Weld to fill in the gap around the back of the projector as this one below, I simply used clear RTV Silicone. Less dry time and easily removable if need be:

The following day, I individually baked each light again for 5 minutes at 350 degrees in order to reseal the glass to the housing. Upon removing each light from the oven, I then firmly pressed the glass back to the housing. After the housings cooled, I placed a thin bead of clear RTV silicone around each light where the glass joins the housing. This was done to further waterproof the housings. I also took the same silicone and placed a good amount of it on the backside of each headlight, where the projector pushed thru the hole, to further seal any small openings.

Finally, ran the wiring and mounted the Ballasts:

Ballasts Mounted in Engine Bay:

Passenger Side:

Driverside:

Bulbs Installed:

Passenger Side:

Driver Side:

Head Lights Mounted:

(Please note, the headlights were not yet properly aimed when I took these photos.)

Aiming the headlights was effortless. I parked on a level surface, 25ft away from a wall and measured the distance from the center of the projector to the ground below. I took that measurement over to the wall and subtracted 2 inches. I marked this new measurement by placing a piece of tape horizontal on to the wall. Finally, I simply aligned the light cutoff on to the wall so it was even with the tape.

For more detailed information on aiming your headlights, check out this site: Click Me

I have not taken any night shots yet, but the light output is a significant improvement over stock. The light cutoff, created by the projectors, is so sharp, it puts aftermarket PnP kits to shame. Although I personally have never been blinded at night by others running PnP kits, I simply prefer the “look and feel” of Projectors instead. IMO, projectors create a more professional appearance in both aesthetics and light intensity.

EDIT:

Here's a couple night shots:

Total Price for this Retrofit after everything was said and done…$285.00.

EDIT:

Figured I might as well add my price list to this post too:

PURCHASED:
Donor Headlight - Driver..........35
Donor Headlight - Passenger....60
H4 Wiring Harness.............. ..30
2 Hella Gen3 Ballasts..............50
2 Phillip D2S H4 4300K Bulbs. ..50
2 Infiniti FX45 Projectors........75
2 Acura TSX Projectors..........150
4 Malibu Light Covers.............30
Total......................................480

SOLD:
Donor Headlight - Driver.........58
Donor Headlight - Passenger...55
Acura TSX Projectors............55
Infiniti FX45 Lenses...............27
Grand Total............................285

There were no misc cost involved b/c I already had plenty of tape, RTV silicone, zip ties, dremel bits and what else just laying around the garage.

It was definitely worth it IMO.

**

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MATT0404 · 08-18-2008, 09:00 AM

Wow, great writeup! Looks really good.

dirtoyboy · 08-18-2008, 09:02 AM

wow thats amazing

pitpatt · 08-18-2008, 09:13 AM

That looks sick man, this has def. been added to my favorites for a future reference!

pfdaxe · 08-18-2008, 10:33 AM

Looks familiar....lol

Great job! It came out very nice and I'm glad I could help. I'm in the process of changing my projectors. I'm retroing a set of TL's with ZKW lens and I'm also adding a CCFL halo angel eyes ring around the projector (BMW style). I'll post pics when complete

http://cgi.ebay.com/ebaymotors/ws/eB...246402536&rd=1

Rock Slide · 08-19-2008, 06:20 AM

pfdaxe, good luck with your own upgrade. Definitely looking forward to seeing the finished product.

Fo_SheeZy · 08-23-2008, 04:38 PM

Looks good man!

pdyebrasil · 08-23-2008, 05:06 PM

Quote:

Originally Posted by pfdaxe

Looks familiar....lol

Great job! It came out very nice and I'm glad I could help. I'm in the process of changing my projectors. I'm retroing a set of TL's with ZKW lens and I'm also adding a CCFL halo angel eyes ring around the projector (BMW style). I'll post pics when complete

http://cgi.ebay.com/ebaymotors/ws/eB...246402536&rd=1

Ooh... You're going to add in the angel eyes?! I definitely want to see that. I was thinking about it but couldn't quite envision it looking good with such a big headlight. BUT I hope that you prove me wrong!

Great job on the retrofit! Looks great. Did either of you use anything to fill in the space around the malibu covers?

Whitey13 · 08-23-2008, 05:13 PM

Amazing stuff and I'm sure many with benefit from your thoroughness.
You are quickly becoming the 3rd gen poster child.

P.S. what ever became of your cracked rim situation?

Ron Helmuth · 08-23-2008, 06:41 PM

Stunning. Awesome. Incredible.

Dang you do nice wiring work.

We who like to copycat could not ask for a better tutorial. Very nice.

Rock Slide · 08-23-2008, 09:36 PM

Quote:

Originally Posted by pdyebrasil

Great job on the retrofit! Looks great. Did either of you use anything to fill in the space around the malibu covers?

Thx. Talking about that small space between the cover and housing that causes a shadow? Nah, I just left it as is. I wish the covers had a more "flush" fit, but it doesn't bother me all that much.

Quote:

Originally Posted by Whitey13

Amazing stuff and I'm sure many with benefit from your thoroughness.
You are quickly becoming the 3rd gen poster child.

P.S. what ever became of your cracked rim situation?

Haha, thanks.

As for the cracked rim, it's sitting in my garage as we speak. Got a new rim on the 4Runner now. I learned the hard way what happens when you wheel rocks w/ aluminum wheels

. Granted, that has not stopped me from still doing it, I've just learned to pick my lines better.

Quote:

Originally Posted by Ron Helmuth

Stunning. Awesome. Incredible.

Dang you do nice wiring work.

We who like to copycat could not ask for a better tutorial. Very nice.

The wiring wasn't all that bad. It actually took more time to remove the airbox and battery (to mount the ballasts) than it did to run all the wiring and connect everything together.

Elton · 08-24-2008, 05:22 AM

nice work looks great .... ive always wondered if taking apart the older frosted ones apart painting the housing black add the projectors and install the newer style clear glass part would look like

UNR.Grad · 08-24-2008, 04:09 PM

Looks good, another nice retro. I'm doing another one soon, but going with a different style this time.

berzerkrobot · 08-24-2008, 06:20 PM

Quote:

Originally Posted by pfdaxe

Looks familiar....lol

Great job! It came out very nice and I'm glad I could help. I'm in the process of changing my projectors. I'm retroing a set of TL's with ZKW lens and I'm also adding a CCFL halo angel eyes ring around the projector (BMW style). I'll post pics when complete

http://cgi.ebay.com/ebaymotors/ws/eB...246402536&rd=1

Coming from a BMW owner... every time I see a car that isnt a bimmer with halos, I just shrug and sigh. To me, it is like getting lambo doors on an acura - the only place they belong on a Lamborgini, hence the name

Rockslide: How on earth did you get the projectors and ballasts for only 285, let alone with a set of lights?!?!?! I figured you must have spent over a grando! Nicely done, man.

CASTAIC 4RUNNER · 08-24-2008, 06:33 PM

what did you do to your bumper dude!?!? a winch should a gone there lol

**waskillywabbit** · 08-24-2008, 06:38 PM

Wow, Bill does electrical.

racingcameron66 · 08-24-2008, 07:09 PM

you should def make me sum, and ill pay you 4 sho

**aviator** · 08-24-2008, 07:35 PM

Very sharp looking mod there... How does the plastic of those malibu lights stand up to the heat of the projectors? it looks to be just black styrene plastic... I want to see what the angle eyes looklike when you get there axeman..

berzerkrobot · 08-24-2008, 07:53 PM

aviator the black part was removed. it looks like the hood is metal.

Rock Slide · 08-24-2008, 08:07 PM

Quote:

Originally Posted by Elton

nice work looks great .... ive always wondered if taking apart the older frosted ones apart painting the housing black add the projectors and install the newer style clear glass part would look like

Should look good. However, it would only look good on a black vehicle IMO. I've seen a picture of a newer style black Taco that had a set of projectors retrofitted in and the housings were painted black too. Looked sharp.

Quote:

Originally Posted by berzerkrobot

Rockslide: How on earth did you get the projectors and ballasts for only 285, let alone with a set of lights?!?!?! I figured you must have spent over a grando! Nicely done, man.

What can I say, I got a deal! All my figures are on my computer at work...can't remember them off the top of my head, so I'll post the prices tomorrow so you can see what I spent.

Quote:

Originally Posted by waskillywabbit

Wow, Bill does electrical.

crazy aint it. Even installed a new ceiling fan in the guest bedroom 2wks ago too

Quote:

Originally Posted by UNR.Grad

Looks good, another nice retro. I'm doing another one soon, but going with a different style this time.

Awesome. Looking forward to the pics.

Quote:

Originally Posted by CASTAIC 4RUNNER

what did you do to your bumper dude!?!? a winch should a gone there lol

Good eyes! I photoshopped my tag out. Trying to direct everyone's attention to my lights instead of the tag.

Quote:

Originally Posted by racingcameron66

you should def make me sum, and ill pay you 4 sho

That's tempting, but I'd have to charge you an arm and a leg. I put more time in this retro than I ever planned too. I could have done them much quicker, but with as busy as I stay, I was doing good just to get an hour's worth of work in on a Saturday! Might be a while, before I get around to doing another retro...

Quote:

Originally Posted by aviator

Very sharp looking mod there... How does the plastic of those malibu lights stand up to the heat of the projectors? it looks to be just black styrene plastic...

Thanks. Oh and there is no plastic involved in this retro. The covers themselves are a thin metal. That black plastic piece I removed from the inside of the cover is discarded.

**rocket** · 08-24-2008, 08:30 PM

By far the best retro that i've seen. Your attention to detail is good as it gets. Very nice job!

Rock Slide · 08-25-2008, 07:08 AM

Quote:

Originally Posted by berzerkrobot

Rockslide: How on earth did you get the projectors and ballasts for only 285, let alone with a set of lights?!?!?! I figured you must have spent over a grando! Nicely done, man.

As promised, here's what I spent:

PURCHASED:
Donor Headlight - Driver..........35
Donor Headlight - Passenger....60
H4 Wiring Harness.............. ..30
2 Hella Gen3 Ballasts..............50
2 Phillip D2S H4 4300K Bulbs. ..50
2 Infiniti FX45 Projectors........75
2 Acura TSX Projectors..........150
4 Malibu Light Covers.............30
Total......................................480

SOLD:
Donor Headlight - Driver.........-58
Donor Headlight - Passenger...-55
Acura TSX Projectors............-55
Infiniti FX45 Lenses...............-27
Grand Total............................285

There were no misc cost involved b/c I already had plenty of tape, RTV silicone, zip ties, dremel bits and what else just laying around the garage.

Quote:

Originally Posted by rocket

By far the best retro that i've seen. Your attention to detail is good as it gets. Very nice job!

Thanks. This was the first one I had ever done before, so I really did not know what to expect going into it. Seemed like it took for ever though, but it was a good experience nonetheless.

racingcameron66 · 08-26-2008, 09:50 AM

That's tempting, but I'd have to charge you an arm and a leg. I put more time in this retro than I ever planned too. I could have done them much quicker, but with as busy as I stay, I was doing good just to get an hour's worth of work in on a Saturday! Might be a while, before I get around to doing another retro...

just let me know

pfdaxe · 08-26-2008, 10:00 AM

Quote:

Originally Posted by racingcameron66

That's tempting, but I'd have to charge you an arm and a leg. I put more time in this retro than I ever planned too. I could have done them much quicker, but with as busy as I stay, I was doing good just to get an hour's worth of work in on a Saturday! Might be a while, before I get around to doing another retro...

just let me know

I'll be starting my second retro in a couple of weeks. I think this one will go a bit smoother and quicker. If I can get it down to a relatively good time frame for turn-around, I may start doing some for people....

UNR.Grad · 08-27-2008, 07:45 AM

2 Hella Gen3 Ballasts..............50

Wow, great deal!!!

08-18-2008, 09:00 AM	#2 (permalink)
MATT0404 Registered User Join Date: Feb 2007 Location: NW PA Posts: 170	Wow, great writeup! Looks really good. __________________ 99 4Runner 4x4 3.4 5 speed E-Locker SAW 2.0 Coilovers LC coils and shocks 1" 4 Crawler Body Lift 1" Diff drop SS adjustable trac bar Addco front/rear sway bars 285/75/16 Maxxis Bighorns

08-18-2008, 10:33 AM	#5 (permalink)
pfdaxe Registered User Join Date: Aug 2002 Location: Phoenix, AZ Posts: 1,443	Looks familiar....lol Great job! It came out very nice and I'm glad I could help. I'm in the process of changing my projectors. I'm retroing a set of TL's with ZKW lens and I'm also adding a CCFL halo angel eyes ring around the projector (BMW style). I'll post pics when complete http://cgi.ebay.com/ebaymotors/ws/eB...246402536&rd=1 __________________ My 2000 TRD 4 Runner My email

08-19-2008, 06:20 AM	#6 (permalink)
Rock Slide Contributing Member Join Date: May 2006 Location: B'ham, AL... 2002 4Runner Sport 4WD Posts: 2,046	pfdaxe, good luck with your own upgrade. Definitely looking forward to seeing the finished product. __________________ 2002 4Runner Sport 4WD My 4Runner Profile Accessories: SS 7.1 Lift Kit, WabFab 1" BL, TJM T15, Stubb Sliders, FX/TSX HID Projector Retrofit, 1st Gen Rollbar, Tundra Brake Upgrade, Hilux Surf Field Monitor, TRD Ivan Stewart Wheels, Nitto TG 265/75s, WeatherTechs, Hella HID 4000s, LED Tail Lights, JBL Speakers Mods: Disabled DRLs, Disabled Keyless Entry Chirp, Disabled VTRAC/VSC/ABS, Fog Light Mod, Air Elbow Mod & Rear Diff Breather Mod *"Why fix a Jeep, when you can drive a Toyota?"*

08-23-2008, 04:38 PM	#7 (permalink)
Fo_SheeZy Registered User Join Date: Feb 2007 Location: East Tennessee Posts: 1,598	Looks good man! __________________ *Check out my 2008 Urban 4Runner on CarDomain!!* http://www.cardomain.com/ride/3108855 http://www.myspace.com/bmplayar

08-23-2008, 06:41 PM	#10 (permalink)
Ron Helmuth Registered User Join Date: May 2007 Location: Denver metro area-CO Posts: 1,339	Stunning. Awesome. Incredible. Dang you do nice wiring work. We who like to copycat could not ask for a better tutorial. Very nice. __________________ 99 4Runner SR5 4wd 3.4/5 spd- Fact. Rr. Locker/Diff Breather Ext. Old Man Emu lift springs- 881 fronts/890 rears O/M/E shocks- N91s fr./N86 rr. All Pro Off Road welded sliders-prevent body damage! ARB"Taco"bumper/Gamiviti clear lenses/Hella 500s Redline Tuning hood struts/Bushwacker Extend a Fenders all my photos are over on Facebook now-I gave up on photo hosting sorry.... http://www.facebook.com/album.php?ai...5&l=5795132731

08-23-2008, 05:13 PM	#9 (permalink)
Whitey13 Registered User Join Date: Jan 2006 Location: MA Posts: 1,115	Amazing stuff and I'm sure many with benefit from your thoroughness. You are quickly becoming the 3rd gen poster child. P.S. what ever became of your cracked rim situation?

08-24-2008, 05:22 AM	#12 (permalink)
Elton Contributing Member Join Date: Jul 2005 Location: Siletz,Oregon Posts: 10,647	nice work looks great .... ive always wondered if taking apart the older frosted ones apart painting the housing black add the projectors and install the newer style clear glass part would look like __________________ My Truck 98 4runner SR5 3.4L 5spd 4x4 E-Locker Mods Mom 07 Tundra d-cab limited 5.7L 4x4 auto sister 92 pickup SR5 X-cab 3.0L 5spd 4x4 Papa 89 Pickup SR5 X-cab 4x4 3.0L 5spd/98 4runner SR5 4x4 auto 3.4L R.I.P 91 4runner SR5 4x4 3.0L 5spd Totaled 5/13/06 My Wreck

08-24-2008, 04:09 PM	#13 (permalink)
UNR.Grad Contributing Member Join Date: Apr 2004 Location: Reno, NV / S. Tahoe, CA Posts: 927	Looks good, another nice retro. I'm doing another one soon, but going with a different style this time. __________________ 2000 Silver 4runner :Highlander Edition: - Tundra TRD Coils/Blue Tokico Struts w/spacer- Downey Coils/N86 Shocks - Front Dif. Drop - Rear Dif. Breather - E-Brake Extension - Tundra Calipers/Rotors - Akebono Ceramic Pads - Goodrich SS Brake Lines - LX450 Wheels w/ 265/75/16 BFG A/T KO's and Full Size Spare - TRD Exhaust - Deckplate w/ Trueflow - Hayden Tranny Cooler - JAOS Rear Spoiler - Sport Skid - '01 Tails - Clear Corners/Bumper Lights - Leather Seats - Alpine CD player

08-24-2008, 06:33 PM	#15 (permalink)
CASTAIC 4RUNNER Registered User Join Date: Feb 2007 Location: Castaic, California Posts: 181	what did you do to your bumper dude!?!? a winch should a gone there lol __________________ 1999 Toyota 4runner SR5 4WD V6 5speed

08-24-2008, 06:38 PM	#16 (permalink)
waskillywabbit Super Moderator-Sponsoring Member Staff Join Date: Jul 2003 Location: Tuscaloosa, AL Posts: 14,548	Wow, Bill does electrical. __________________ WabFab Off-Road, LLC MySpace Twitter Facebook 7th Annual South East 4Runner Jamboree, 2010 The toughest part of a Jeep is the chick driving it. WabFab Off-Road 4th Anniversary Sale

08-24-2008, 07:35 PM	#18 (permalink)
aviator Super Moderator Staff Join Date: Mar 2003 Location: COTKU,Ontario,Canada Posts: 7,469	Very sharp looking mod there... How does the plastic of those malibu lights stand up to the heat of the projectors? it looks to be just black styrene plastic... I want to see what the angle eyes looklike when you get there axeman.. __________________ Silver 1994 Hilux Xtra cab 4x4 3.0 K&N cone filter, ported MAF, advanced timing, oversize exhaust, free flow cat, "rumble" muffler custom covered SR5 seats, map lights, factory AC tv4184 style black interior conversion started mods to come... header, custom centre console, stereo upgrade tinted windows Founding member 1972TLC fan club - Get well soon Mary Toyota Hilux... Get in or Get out of the way.

08-24-2008, 07:53 PM	#19 (permalink)
berzerkrobot Registered User Join Date: Aug 2008 Location: Moon Base Posts: 105	aviator the black part was removed. it looks like the hood is metal. __________________ '97 T4R SR5 4x4 \| Detroit Lock'd Rear Diff \| Toytec lift w/OME shocks \| Diff Drop \| 33" Cooper STTs on 15x8s \| Glasswerks Unlimited 4.5" prerunner flares \| Rear control arm skids \|10lb co2 onboard air tank w/regulator \| Hella FF1000s \| Custom steel front and rear bumpers, Line-X'd \| Custom steel rock sliders \| Air Intake Mod

08-24-2008, 08:30 PM	#21 (permalink)
rocket Super Moderator Staff Join Date: Apr 2005 Location: Colorado Posts: 4,527	By far the best retro that i've seen. Your attention to detail is good as it gets. Very nice job! __________________ '96-'02 gone: '92

08-27-2008, 07:45 AM	#25 (permalink)
UNR.Grad Contributing Member Join Date: Apr 2004 Location: Reno, NV / S. Tahoe, CA Posts: 927	2 Hella Gen3 Ballasts..............50 Wow, great deal!!! __________________ 2000 Silver 4runner :Highlander Edition: - Tundra TRD Coils/Blue Tokico Struts w/spacer- Downey Coils/N86 Shocks - Front Dif. Drop - Rear Dif. Breather - E-Brake Extension - Tundra Calipers/Rotors - Akebono Ceramic Pads - Goodrich SS Brake Lines - LX450 Wheels w/ 265/75/16 BFG A/T KO's and Full Size Spare - TRD Exhaust - Deckplate w/ Trueflow - Hayden Tranny Cooler - JAOS Rear Spoiler - Sport Skid - '01 Tails - Clear Corners/Bumper Lights - Leather Seats - Alpine CD player

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