Morimoto Bi-Xenon retrofit - Installation thread

[RichardCranium]

Long story short, I had a thread from 2018 for a retrofit that I had adjustment issues with.....so I parted it out and went LED. Since that info was no longer relevant, I wanted to clean the thread up and remove all the old stuff, since I just successfully completed the retrofit on the 2 d attempt. In the end, the whole thread got trashed.....so that works too. Below is my current install, with pics and notes, for reference if anyone follows.

Shopped at LightWerkz, and per fellow forum member @Geoffsfas10 recommendation, and got the Mini Stage 3 H1 8.0 kit.

 

[RichardCranium]

First things first, splitting the OEM headlights. This was my 5th pair to split, so I feel like a veteran. Pop the bulbs out, take off the rubber seals around the high/low beams, and place them on a large pan. Throw it in the oven at 200° for 10 minutes (one headlight at a time). I put mine in with the clear lens up, so keep it scratch-free. You'll likely need one oven mit to hold it, while you work a seam to split it.

Using any sort of wide and thin blade prying tool, work a seam in an area of the headlight not seen when installed. Just in case you leave some marks, they'll be hidden from plain site. I always go for this seam.....

 

[RichardCranium]

When you are rotating the headlight around, be really cautious of how you handle it. Those tabs can all bend or break off very easily, since they are warm from the oven.

I always have a towel down, and pivot the headlight on a corner like this.

 

[RichardCranium]

Once split, I always put the clear lens down facing upwards, to keep dust out.

Now you are ready to modify and test fit. First thing you need to do is remove the bolt-in deflector shield on the low beam side. Then you'll have to grind down the knurl the deflector mounted to, so the HID projector can sit flush.

My trusty pneumatic angle grinder with Matco bits.....


The raised part where the deflector was mounted, before......



....and after. It doesn't have to be pretty or perfect, as the HID projector will cover it. You just need for the bump to be completely gone.

 

[RichardCranium]

In order to fit this projector, it took a small amount of filing in the headlight bore (where the low beam bulb protrudes through) to accommodate enough room for the Morimoto projector shaft to fit through. A little patience, and working your way around the inside with a file will get enough clearance worked out. Just file a little, and try to fit the projector through the hole often. All you want is enough room to get it through, no excessive play.

After finally getting the right diameter, I was able to fit the projector with the smaller rubber bushing and only the securing nut on the backside.

At this point, the only modifications I've done are grinding down the perch for the deflector and file the bore to accommodate the diameter of the projector shaft.

@Geoffsfas10 can testify from his own install, no more is really needed to secure the HID, especially if you did minimal filing so the shaft has fairly low clearance. The projector won't be moving.

 

[RichardCranium]

After test fitting the projector in the step above, I was ready to finish up the installation of the projectors so I could start the aiming process.

Before you are ready to proceed from here, you need to modify one more thing. That hole where the deflector was mounted, you should drill that out with about a 1/8" bit. You'll be feeding two 20ga wires through there for the solenoid to activate the armature for "high beam" activation later.

Here is the assembly of the later style projector. Once the projector is set and locked in (not too tight, so it can be rotated to level later), start the assembly. This black plastic ring allows for the newer style dust cap to be threaded on.


The bulb fits in....



This horseshoe clip fits in and sits flush, it keeps the bulb in place. Pretty cool.



Clip installed....

 

[RichardCranium]

And final step, the dust cap installed.



Just realized I don't have a pic of my relay harness or other hardware. I'll grab some over the weekend and add them in, if anyone wants any ideas of where to mount them.

Here is the projector completed, and ready to take out and aim.







High beams, with splitters to retain the halogen high beams as well.

 

[RichardCranium]

The initial journey to a local store, to use a wall out back to aim.



Only had to rotate one side, and it was a small amount. Here it can be seen I need to adjust the drivers side up some, to give a good crossover pattern between both sides.

 

[RichardCranium]

Finished product.

 

[RichardCranium]

Here are the options I chose with the kit:

Bi-Xenon Morimoto Mini Stage III (H1) × 1
Bixenon Projectors: Bi-Xenon: Morimoto H1 8.0 (LHD)
Compatible Ballasts/Igniters: Morimoto XB35 2.0 (35W)
H1 HID Bulbs: H1: 5500K HID Bulbs
Shroud Style: Mini Gatling Gun
Wiring Harness (match stock bulb size): HD Relay: H11/H9/H8
Anti-Flicker Capacitor: No
Shroud Adapters: None