How to Install a Mini H1 HID Projectors
How to retrofit a MINI H1 Projector into your stock Headlight
This guide was created by myself and was first posted in www.ozvr4.com the guide below was cut and pasted, but was also slightly modified to suit LHD drive cars..
with the USDM headlights (single reflector) same procedure still applies, but with the addition of the bi-xenon wires hooked up to your hi beam wire.. also you will need to purchase a relay kit for your car.. like the kit in the link shown below
http://cgi.ebay.com/ebaymotors/HID-H...ht_3540wt_1165
Pre-Installation Check
Check if your Oven is big enough to fit 1 headlight assembly
Check if your headlight is suitable enough for the install - eg.. cracks, scratches & etc..
Check if your projector modules are both LHD or specifically configured for your road use (guide was originally created for RHD setup)
http://i54.photobucket.com/albums/g9...785-Edited.jpg
Check if you have all the necessary tools and accessories to complete the project.
http://i54.photobucket.com/albums/g9...784-Edited.jpg
http://i54.photobucket.com/albums/g9...786-Edited.jpg
Tools needed..
1x long nose pliers
1x + screw driver
1x - screw driver (preferably one with a wide head - for prying)
2x Big 'C' Clamps
1x egg timer or timer app from your mobile phone :)
Pair of Leather Gloves - TIG Welding Gloves are preferred as its thick but soft enough so you can move your fingers easily..
Accessories included with the Projector Modules
2x H7 Adaptor (not needed)
2x H4 Adaptors
2x Big Silicon Washer
2x Thin Silicon Washer
2x Aluminum Nut
2x Bulb Holder Clip (Installed in the Module)
2x Bulb Holder (Installed in the Module)
6x Bulb Holder's Screws (Installed in the Module)
Extra Accessories needed for the USDM Single Reflector Headlights
1x bi-xenon Relay kit -assuming that this also comes with a guide for your ease of installation..
If you have all the stuff listed above, then you ready to proceed with this project
1. remove your headlights from your car..
2. remove all the bulbs and connectors currently installed (dont worry about the park bulb wire as its there permanently)
3. put the headlight assembly in the oven.. BUT BEFORE YOU DO.. Do these following check ups..
4. after pre-heat, put your headlight in the oven for approximately 3-5 minutes @ approximately 140* Celcius - this way the headlight assembly wont melt or lose its shape..
5. Keeping in mind the tabs on the lens cover and assembly.. lift this up slightly, enough so that it wont be in any way damage while you're performing step 6.
http://i54.photobucket.com/albums/g9...781-Edited.jpg
http://i54.photobucket.com/albums/g9...782-Edited.jpg
6. after heating the headlight, remove it and put it on your work bench and start to pull the lens cover way from the assembly..
http://i54.photobucket.com/albums/g9...778-Edited.jpg
*NOTE* try to make sure that the sealant don't touch the good part of the lens cover as well as the reflectors otherwise it'll be a PITA to remove..
7. Once you have removed the lens cover, start to pull out the rear facing reflector, so you can insert the projector module in place.. you can do this by removing the screws holding the park light's bulb holder, then once you've removed it you can secure the park light's bulb holder back
http://i54.photobucket.com/albums/g9...791-Edited.jpg
these are what you need to remove so you can install the module into the housing..
http://i54.photobucket.com/albums/g9...790-Edited.jpg
At this stage you are now ready to install the projector module into your headlight's factory housing..
8. Insert the silicon washer (included in the kit) onto the back of the projector module, then insert the module into the factory housing.. keep in mind of the bi-xenon's solenoid cable, insert that first if you wish to use it or otherwise cut it off..
http://i54.photobucket.com/albums/g9...794-Edited.jpg
9. Secure the projector module by using the adaptor washer and the ring nut provided.. use whichever adaptor that you need - either H4 or H7
http://i54.photobucket.com/albums/g9...793-Edited.jpg
10. Before fully locking the nut, make sure that your projector is aligned properly, rotate to either direction if needed.. then fully lock it - you need a bit of force but not too much otherwise you will break the reflector..
11. Mount the bulb holder by using 3 screws provided, then insert the H1 hid bulb that you have selected or included in the kit. After this you can secure the bulb by using the clip provided.. should be installed like in the picture below
http://i54.photobucket.com/albums/g9...788-Edited.jpg
12. plug in the hid bulb with your hid ballast and test..
13. Insert the Shroud that came with the Projector Modules - as pictured below
http://i54.photobucket.com/albums/g9...797-Edited.jpg
14. Once happy put the lens cover back on (clean it first if you need to) and put it back in the oven for another 3-5 minutes @ 140*C
15. After heating it, remove the headlight from the oven and further push in the lens on to the assembly and secure it by using couple of 'C' Clamps and let it cool down for about 10-30 minutes.. again keep in mind of the tabs so they don't break/snap *note* I used rags to dampen the clamps as well as to not scratch the lens..
http://i54.photobucket.com/albums/g9...802-Edited.jpg
16. Re-check your work in case you have missed something.. then install it back..
17. Enjoy!
Any Questions?! feel free to pm me or add to this thread..
