Facelift Projector Lens Swap?

[relentlessone]

Does anyone know if it is possible to swap out the projector lens on facelift headlights? Is the projector removable through the back of the headlight? It seems to be pretty wide open with the panel removed:



Photo credit to AlpineMsix.

On my E46 I was able to swap out the factory lens with a ZKW-R lens, and the cutoff/output was amazing compared to stock. The output and cutoff on the stock xenons is pretty sad in comparison, so I'm looking to do the same.

[relentlessone]

OK how about what brand/model projector is in the facelift xenons? Or at least the lens diameter?

[MINIz guy]

Not 100% but I'm betting you're using a Hella projector with a 3" lens.

Crack open your headlights to see if you can remove the projector. That opening looks big enough to be able to unscrew the projectors, if you are able to do so.

[relentlessone]

Originally Posted by MINIz guy

Not 100% but I'm betting you're using a Hella projector with a 3" lens.

Crack open your headlights to see if you can remove the projector. That opening looks big enough to be able to unscrew the projectors, if you are able to do so.

I'm hoping it is a 3" lens, that way I can swap in the ZKW-R!

That is what I am going to have to do. I was trying to get a quick answer without having to take the headlights out. That way I could just order the lenses, and only take the bumper/headlights off the one time to install them. No big deal though, thanks for your help.

[MINIz guy]

You should be able to get a ZKW-R lens on easily. If I recall, you should be using a projector found of E39's too and that fits ZKW lenses fine.

[relentlessone]

I emailed The Retrofit Source and they confirmed the ZKW-Rs will fit. Now I just need to remove the headlights to see if I can access the lens from the backside.

[relentlessone]

Last night I took the headlights out and examined the projector from the back opening. It does not appear to be removable. There are two screws toward the bottom of the projector, but removing them doesn't loosen it. The two vertical pieces of metal behind the projector are secured from the front, so there is no way to get to them. Those pieces of metal meet up at a central axis in front of the projector which I assume is for the Active Xenon swiveling. I didn't try anything else considering how expensive these are to replace if I broke something, but if anyone finds another way please let me know!

[MINIz guy]

Pictures?

I would say break the mounts as cleanly as you can and reinstall with nuts and bolts.

I guess these lights are much more complicated than pre-facelift models. Those things are a breeze to modify compared to yours, it sounds.

[relentlessone]

Originally Posted by MINIz guy

Pictures?

I would say break the mounts as cleanly as you can and reinstall with nuts and bolts.

I guess these lights are much more complicated than pre-facelift models. Those things are a breeze to modify compared to yours, it sounds.

I didn't take any pictures, but there isn't too much to see from the back. I pulled this picture from TwinsPoppa's front bumper DIY:

ImageBam

It shows a slightly better view of what's there than what I posted above.

I was able to find this photo of E60 projector out of the housing that shows the metal bracket and central axis. From what I could see this is the same projector on the facelift E53.



That image was pulled from this thread which shows several other angles:
Complete 2006 BMW E60/61 Dynamic HID Kit

I don't think I am going to purposely break anything, I'd be sick if I messed up my headlights and had to buy a whole new unit. One thing I did consider was to drill two holes in the top of the headlight to remove the two screws that are holding in that metal plate. From there I might be able to get the projector out, and I could always pop some rubber plugs in the holes and silicone them to seal them up. Getting the chrome bezel on and off inside the headlight without scratching the front of it might be difficult. I remember from my E46 bezels that they scratched very easily.

One thing the E46 designers got right though was having the ability to remove the headlight lens with a couple tabs. I used to have those headlights apart monthly swapping painted shrounds and different angel eyes in and out. Oh the good-old days, haha.

[Clockwork]

can I ask what the advantage is to replacing your projectors (assuming they are not broken)?