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
Plug-n-Play Wiring Kit
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.

Total Price for this Retrofit after everything was said and done…$285.00. It was definitely worth it IMO.

**

Matthew0404 · 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.

08-18-2008, 08:40 AM	#1 (permalink)
Rock Slide Contributing Member Join Date: May 2006 Location: B'ham, AL... 2002 4Runner Sport 4WD Posts: 1,688	Another HID Bi-xenon Retrofit Install PICS 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 Plug-n-Play Wiring Kit 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. Total Price for this Retrofit after everything was said and done…$285.00. It was definitely worth it IMO. __________________ 2002 4Runner Sport 4WD My 4Runner Profile** Accessories: SS 7.1 Lift Kit, WabFab 1" BL, TJM T15, Stubb Sliders, FX/TSX HID Headlight Retrofit, 1st Gen Rollbar, Tundra Brake Upgrade, Hilux Surf Field Monitor, TRD I.S. Wheels, Nitto TG 265/75s, Hella HID 4000s, Tint, Black Pearl Emblems, Clear Corners, TRD Decals, JBL Door Speakers Mods: Disabled DRLs, Disabled Keyless Entry Chirp, Disabled VTRAC/VSC/ABS, Fog Light Mod, Air Elbow Mod, Ashtray Mod, Mud Flap Mod, Rear Diff Breather Mod Last edited by Rock Slide : 11-20-2008 at 07:13 AM.

08-18-2008, 09:00 AM	#2 (permalink)
Matthew0404 Registered User Join Date: Feb 2007 Location: Central PA Posts: 179	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: 1,403	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: 1,688	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 Headlight Retrofit, 1st Gen Rollbar, Tundra Brake Upgrade, Hilux Surf Field Monitor, TRD I.S. Wheels, Nitto TG 265/75s, Hella HID 4000s, Tint, Black Pearl Emblems, Clear Corners, TRD Decals, JBL Door Speakers Mods: Disabled DRLs, Disabled Keyless Entry Chirp, Disabled VTRAC/VSC/ABS, Fog Light Mod, Air Elbow Mod, Ashtray Mod, Mud Flap Mod, Rear Diff Breather Mod

08-23-2008, 04:38 PM	#7 (permalink)
Fo_SheeZy Registered User Join Date: Feb 2007 Location: East Tennessee Posts: 1,541	Looks good man! __________________ *Check out my 2008 Urban 4Runner on CarDomain!!* http://www.cardomain.com/ride/3108855 http://www.myspace.com/bmplayar *Hella 500's FOR SALE, PM me!*

08-23-2008, 05:13 PM	#9 (permalink)
Whitey13 Registered User Join Date: Jan 2006 Location: MA Posts: 1,033	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?

08-23-2008, 06:41 PM	#10 (permalink)
Ron Helmuth Registered User Join Date: May 2007 Location: Denver metro area-CO Posts: 575	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 Factory Rear Locker/Rear Diff Breather Extension LT265/75/16 Nitto Terra Gs- AR767s Old Man Emu springs- 881 fronts/891 rears Old Man Emu shocks- N91s fronts/ N86 rears All Pro Off Road sliders/ARB "Taco" bumper Redline Tuning hood struts -prop rod now useless! TrueFlow Air Filter fed by airbox deckplate mod Rear wing custom painted in body color (white056)

08-24-2008, 05:22 AM	#12 (permalink)
Elton Contributing Member Join Date: Jul 2005 Location: Toledo,Oregon Posts: 9,093	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 mom 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: 944	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 - Deckplate w/ Trueflow - Hayden Tranny Cooler - Sport Skid - '01 Tails - Clear Corners/Bumper Lights

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* Sponsoring Member Join Date: Jul 2003 Location: Tuscaloosa, AL Posts: 11,485	Wow, Bill does electrical. __________________ WabFab Off-Road, LLC www.myspace.com/wabfab FOR SALE: 1987 4Runner GRAY FOR SALE: 1987 4Runner RED 6th Annual South East 4Runner Jamboree, May 22-25, 2009