DIY: Lexus IS200 BiXenon projector retrofit

JapCarForum Car Manufacturers Lexus/Toyota DIY: Lexus IS200 BiXenon projector retrofit

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P.Lindblom
Posting Freak

821

22-03-2022, 05:58 PM

Here's the kit I bought: http://www.ebay.co.uk/itm/181344042858 - As far as I understand it's pretty much an exact copy of the Morimoto Mini H1 kit from TRS.

It comes with everything you need, plus a bunch of things you won't need... and two metal brackets that I have no idea what they are for.

[Image: DSC_5524_fix2.jpg]

The first thing you need to do is disassemble your headlights. There are plenty of guides on how to bake and open headlights, so I won't go into details on that.

[Image: DSC_5531_fix.jpg]

Here's what the lens looks like when separated from the rest of the headlight.

[Image: DSC_5536_fix.jpg]

Here's an insert. If you want them black or any other color now would be a perfect time to paint them since you won't need them until you're reassembling your headlight.

[Image: DSC_5537_fix.jpg]

The amber piece just pops out of the insert, so there's no need for masking. I would, however, sand down the chrome a bit to make the paint stick better.

[Image: DSC_5542_fix.jpg]

Here's a painted insert with the amper piece reattached. You could also leave them off and use orange indicator bulbs instead.

[Image: DSC_5540_fix.jpg]

Anyway, this is the part of the headlights you need to concentrate on. The next step is to remove the little caps in the low beam reflectors. You might be able to do so without removing the reflectors, but it's certainly easier if you do.

[Image: DSC_5546_fix.jpg]

The reflectors are held in place by the two adjusting screws in these two pictures.

[Image: DSC_5549_fix.jpg]

Unscrew them from the back of the housings, using an 8mm socket.

[Image: DSC_5553_fix.jpg]

Now there's only one thing holding the reflectors in place. It's hard to explain how, but it's easily detached with a bit of wiggling.

[Image: DSC_5563_fix.jpg]

It's also a good idea to remove the rubber sealings on the back of the housings.

[Image: DSC_5565_fix.jpg]

Here's a very naked housing.

[Image: DSC_5566_fix.jpg]

And the reflectors.

[Image: DSC_5568_fix.jpg]

This is the cap you need to remove.

[Image: DSC_5570_fix.jpg]

Do so by unfolding its tabs on the back of the low beam reflector

[Image: DSC_5571_fix.jpg]

Edited 27-04-2016, 11:01 PM by Sparkystav.

P.Lindblom

22-03-2022, 05:58 PM #1

This is a mod I've been wanting to do for years, but since it doesn't comply with MOT rules I haven't found it worth doing. However, when I discovered there are really cheap, complete kits available on Ebay I couldn't resist. I bought a kit to make this DIY. I won't install it permanently on my IS200 since I don't use it anymore and I'm thinking about selling it. Fortunately I had an old spare headlight lying around, collecting dust.

After a bit of wet sanding and polishing it looked decent enough.

[Image: DSC_5503_fix.jpg]

Here's the kit I bought: http://www.ebay.co.uk/itm/181344042858 - As far as I understand it's pretty much an exact copy of the Morimoto Mini H1 kit from TRS.

It comes with everything you need, plus a bunch of things you won't need... and two metal brackets that I have no idea what they are for.

[Image: DSC_5524_fix2.jpg]

The first thing you need to do is disassemble your headlights. There are plenty of guides on how to bake and open headlights, so I won't go into details on that.

[Image: DSC_5531_fix.jpg]

Here's what the lens looks like when separated from the rest of the headlight.

[Image: DSC_5536_fix.jpg]

Here's an insert. If you want them black or any other color now would be a perfect time to paint them since you won't need them until you're reassembling your headlight.

[Image: DSC_5537_fix.jpg]

The amber piece just pops out of the insert, so there's no need for masking. I would, however, sand down the chrome a bit to make the paint stick better.

[Image: DSC_5542_fix.jpg]

Here's a painted insert with the amper piece reattached. You could also leave them off and use orange indicator bulbs instead.

[Image: DSC_5540_fix.jpg]

Anyway, this is the part of the headlights you need to concentrate on. The next step is to remove the little caps in the low beam reflectors. You might be able to do so without removing the reflectors, but it's certainly easier if you do.

[Image: DSC_5546_fix.jpg]

The reflectors are held in place by the two adjusting screws in these two pictures.

[Image: DSC_5549_fix.jpg]

[Image: DSC_5550_fix.jpg]

Unscrew them from the back of the housings, using an 8mm socket.

[Image: DSC_5553_fix.jpg]

[Image: DSC_5558_fix.jpg]

[Image: DSC_5562_fix.jpg]

Now there's only one thing holding the reflectors in place. It's hard to explain how, but it's easily detached with a bit of wiggling.

[Image: DSC_5563_fix.jpg]

It's also a good idea to remove the rubber sealings on the back of the housings.

[Image: DSC_5565_fix.jpg]

Here's a very naked housing.

[Image: DSC_5566_fix.jpg]

And the reflectors.

[Image: DSC_5568_fix.jpg]

This is the cap you need to remove.

[Image: DSC_5570_fix.jpg]

Do so by unfolding its tabs on the back of the low beam reflector

[Image: DSC_5571_fix.jpg]

[Image: DSC_5572_fix.jpg]

P.Lindblom
Posting Freak

821

22-03-2022, 05:58 PM

Now the fun part begins. It's time to unpack your shiny projectors.

[Image: DSC_5573_fix.jpg]

Remove the three screws holding the bulb holder in place.

[Image: DSC_5574_fix.jpg]

I also removed the four screws for the shroud. That was, however, mostly out of curiosity. You're better of leaving the shroud on.

[Image: DSC_5575_fix.jpg]

If you're not afraid of splicing wires, cut off the connector for the high beam actuator. This way you can run the wires through one of the holes for the low beam cap you removed earlier.

[Image: DSC_5582_fix.jpg]

The threaded part of the projector fits nicely through the hole in the low beam reflector. Secure it using the strange looking nut.

[Image: DSC_5584_fix.jpg]

Make a tiny hole in the rubber sealing, for the wires, and replace it. Reattach the bulb holder.

[Image: DSC_5586_fix.jpg]

Fit the xenon bulb

[Image: DSC_5587_fix.jpg]

Here's the projector, nicely secured in the headlight housing.

[Image: DSC_5588_fix.jpg]

There are several different ways of aligning retrofitted projectors. One way is to simply reinstall the lensless headlights on the car and twist the projectors by hand until the cutoff is horizontal. Then, of course, tighten the nuts some more to make sure the projectors won't move. Another way is to make a simple bracket for the headlights, point them against a white wall and mark the cutoff before fitting the projectors. Then use the markings to align them again just before fitting the headlight lenses again.

Since I don't plan on using my projectors I didn't put a lot of energy into aligning them. When you feel like you're done just remove the xenon bulb, reattach the headlight insert and lens and bake the headlight again. This is what you'll end up with.

[Image: DSC_5509_fix.jpg]

Or this.

Before fitting the headlight to my car I just connected it to make sure it worked. Connect the HID ballasts to your low beam connectors and the actuator wires to the high beam connector.

[Image: DSC_5514_fix2.jpg]

Then I couldn't resist fitting the headlight.

[Image: DSC_5637_fix.jpg]

I made a video showing the end result. As you can see the leveling motor works just like before.

[youtube]fGUZ9Co1VEw[/youtube]

There are a few advantages with these BiXenon projectors.

First of all you get both low and high beam from the same bulb. This means there won't be a delay when you switch to high beam. The actuator is even faster than the standard halogen bulb.
The main beam reflector isn't needed anymore. You can paint it black, you can fit some sort of a DRL light in it or you can keep the 65W halogen bulb if you want even more light from the high beam.
The best thing is, of course, the beam pattern. It so much better than the lousy IS200 reflectors.

Unfortunately I don't have a large white wall to show you the cutoff on. The closest thing I've got is a white car. Not ideal, but you'll get an idea.

Here's a picture I took with the projector headlight off. This is the amount of light you get from the standard halogen low beam.

[Image: DSC_5632_fix.jpg]

This picture was taken using the same shutter speed and aperture, but with only the projector light on. As you can see it's a lot brighter and the cutoff is really sharp.

[Image: DSC_5630_fix.jpg]

There you have it. Feel free to ask anything about the install and let me know if you want pictures of specific parts. Tomorrow afternoon I will remove the projector and return my converted headlight to stock. That's another good thing about this kit. You don't make any permanent changes to your headlights by converting them.

Edited 27-04-2016, 11:02 PM by Sparkystav.

P.Lindblom

22-03-2022, 05:58 PM #2

Now the fun part begins. It's time to unpack your shiny projectors.

[Image: DSC_5573_fix.jpg]

Remove the three screws holding the bulb holder in place.

[Image: DSC_5574_fix.jpg]

I also removed the four screws for the shroud. That was, however, mostly out of curiosity. You're better of leaving the shroud on.

[Image: DSC_5575_fix.jpg]

[Image: DSC_5578_fix.jpg]

If you're not afraid of splicing wires, cut off the connector for the high beam actuator. This way you can run the wires through one of the holes for the low beam cap you removed earlier.

[Image: DSC_5582_fix.jpg]

The threaded part of the projector fits nicely through the hole in the low beam reflector. Secure it using the strange looking nut.

[Image: DSC_5584_fix.jpg]

Make a tiny hole in the rubber sealing, for the wires, and replace it. Reattach the bulb holder.

[Image: DSC_5586_fix.jpg]

Fit the xenon bulb

[Image: DSC_5587_fix.jpg]

Here's the projector, nicely secured in the headlight housing.

[Image: DSC_5588_fix.jpg]

[Image: DSC_5589_fix.jpg]

There are several different ways of aligning retrofitted projectors. One way is to simply reinstall the lensless headlights on the car and twist the projectors by hand until the cutoff is horizontal. Then, of course, tighten the nuts some more to make sure the projectors won't move. Another way is to make a simple bracket for the headlights, point them against a white wall and mark the cutoff before fitting the projectors. Then use the markings to align them again just before fitting the headlight lenses again.

Since I don't plan on using my projectors I didn't put a lot of energy into aligning them. When you feel like you're done just remove the xenon bulb, reattach the headlight insert and lens and bake the headlight again. This is what you'll end up with.

[Image: DSC_5509_fix.jpg]

Or this.

[Image: DSC_5511_fix.jpg]

Before fitting the headlight to my car I just connected it to make sure it worked. Connect the HID ballasts to your low beam connectors and the actuator wires to the high beam connector.

[Image: DSC_5514_fix2.jpg]

[Image: DSC_5518_fix.jpg]

Then I couldn't resist fitting the headlight.

[Image: DSC_5637_fix.jpg]

I made a video showing the end result. As you can see the leveling motor works just like before.

[youtube]fGUZ9Co1VEw[/youtube]

There are a few advantages with these BiXenon projectors.

First of all you get both low and high beam from the same bulb. This means there won't be a delay when you switch to high beam. The actuator is even faster than the standard halogen bulb.
The main beam reflector isn't needed anymore. You can paint it black, you can fit some sort of a DRL light in it or you can keep the 65W halogen bulb if you want even more light from the high beam.
The best thing is, of course, the beam pattern. It so much better than the lousy IS200 reflectors.

This picture was taken using the same shutter speed and aperture, but with only the projector light on. As you can see it's a lot brighter and the cutoff is really sharp.

[Image: DSC_5630_fix.jpg]

Lexuspat
Administrator

6,827

22-03-2022, 06:15 PM

Wow great build. And great mod

Sent from my GT-I9505 using Tapatalk

[Image: FB_IMG_1474048273787_zpsnbfq6a3s.jpg]

[SIZE="2"]Click to visit my Project Thread or my Flickr Account[/SIZE]

OutlawJapClub Admin Team

Lexuspat

22-03-2022, 06:15 PM #3

Wow great build. And great mod

Sent from my GT-I9505 using Tapatalk

[SIZE="2"]Click to visit my Project Thread or my Flickr Account[/SIZE]

OutlawJapClub Admin Team

Moley
Posting Freak

6,230

22-03-2022, 06:54 PM

Fantastic walk through. Well done. And the lights look ace

Lexus IS200 Mods--TTE Supercharger, Tein Superstreet Coilovers & EDFC, 6000K HID Lights, HKS Silent High Power Exhaust, DBA Front Discs, Kenwood DNX9240 Head Unit, 19" Rims, TRD Kit, FIGS Bonnet Struts, Greddy Pillar Pod & Defi Gauges, TTE Red ARBS . And Been To WIM twice

Moley

22-03-2022, 06:54 PM #4

Fantastic walk through. Well done. And the lights look ace

el_bandido
Account not Activated

2,757

22-03-2022, 08:15 PM

Will these comply with UK mot rules?

el_bandido

22-03-2022, 08:15 PM #5

Will these comply with UK mot rules?

Sparkystav
Administrator

14,683

22-03-2022, 08:43 PM

Awesome! I want!

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

Sparkystav

22-03-2022, 08:43 PM #6

Awesome! I want!

Read my thread here: The Evolution of my Turbo Lexus from NA-Supercharged-Twin Turbo-Massive Single
Please leave your comments.

OutlawJapClub Admin Team

P.Lindblom
Posting Freak

821

22-03-2022, 08:51 PM

el_bandido Will these comply with UK mot rules?

Unfortunately not. In order for them to be road legal your car must be fitted with auto leveling headlights and high pressure washers. There are auto leveling kits available, but I've never tried one. If I were to keep my IS200 and convert the headlights I would either get an extra set of halogen headlights to swap to before the MOTs or I would try to fit a halogen bulb in the projector, but retrofitting BiXenon projectors is just as illegal as fitting a simple HID kit to your standard headlights, even though projectors are a lot better.