97-99 MAXIMA HID 97-99 MAXIMA HID PROJECTOR DIYPROJECTOR DIY

Property of: Imports_only1

DISCLAIMERDISCLAIMER

This modification to your headlights is done at your own risk. I will not be This modification to your headlights is done at your own risk. I will not be held responsible for any damage that may occur along the way. held responsible for any damage that may occur along the way.

PARTS NEEDEDPARTS NEEDED

2 Hella bi-xenon projectors (from Audi A6/RS6) 2 Hella bi-xenon projectors (from Audi A6/RS6)

2 Hella/Philips 32 Hella/Philips 3rdrd Generation Ballasts Generation Ballasts

2 Hella OEM bezels from a Mercedes2 Hella OEM bezels from a Mercedes

2 Philips D2S 4100K bulbs2 Philips D2S 4100K bulbs

Dremel tool with various drilling and cutting bitsDremel tool with various drilling and cutting bits

Roll of aluminum foil for shroudsRoll of aluminum foil for shrouds

Tube of JB weldTube of JB weld

Nuts, bolts, washersNuts, bolts, washers

Various tools Various tools

STEP 1STEP 1Take the headlights off the car; this is easy because you don’t need to take Take the headlights off the car; this is easy because you don’t need to take off the bumper to take out the headlights. This can be done by taking out off the bumper to take out the headlights. This can be done by taking out the corner lights first. You’ll see a screw behind the corner lights. The other the corner lights first. You’ll see a screw behind the corner lights. The other 2 bolts are behind the headlights, easily seen from the top.2 bolts are behind the headlights, easily seen from the top.

Once the headlights are off the car, you need to take apart the brackets. Once the headlights are off the car, you need to take apart the brackets.

Once the brackets are off, you need to take apart the plastic lens from the Once the brackets are off, you need to take apart the plastic lens from the rest of the headlight. To do this, you can use the oven method. First, heat rest of the headlight. To do this, you can use the oven method. First, heat the oven up to 400 Fahrenheit; turn oven off; place a piece of cardboard the oven up to 400 Fahrenheit; turn oven off; place a piece of cardboard underneath the headlight and insert it inside the oven. Leave it in there for underneath the headlight and insert it inside the oven. Leave it in there for 10 minutes. After 10 minutes, take it out (use gloves or mittens because it’ll 10 minutes. After 10 minutes, take it out (use gloves or mittens because it’ll be super hot). Use a flat screwdriver or butterknife to pry off the plastic lens be super hot). Use a flat screwdriver or butterknife to pry off the plastic lens slowly and carefully. Don’t let any silicon get onto the reflector because it’ll slowly and carefully. Don’t let any silicon get onto the reflector because it’ll be a pain to try to take it off.be a pain to try to take it off.

STEP 2STEP 2With the headlight apart, you’ll have With the headlight apart, you’ll have the front plastic lens and the rear the front plastic lens and the rear reflector. Look at the back of the reflector. Look at the back of the reflector; you’ll see a round crease reflector; you’ll see a round crease going around the hole where the going around the hole where the bulb socket is. Use your dremel bulb socket is. Use your dremel and cut it along that circle. I and cut it along that circle. I marked it with a black marker for marked it with a black marker for better visibility when cutting. At the better visibility when cutting. At the bottom, you need to cut it at an bottom, you need to cut it at an angle to allow fitment of the bi-angle to allow fitment of the bi-xenon mechanism. Once you’ve xenon mechanism. Once you’ve cut that hole, stick the projector cut that hole, stick the projector from the front and push it backward. from the front and push it backward. You will need to trim the hole a big You will need to trim the hole a big larger for a better fitment. larger for a better fitment. REFER REFER TO PICTURE at Right:TO PICTURE at Right:

Front ViewFront View

STEP 3STEP 3

With a nicely trimmed opening large With a nicely trimmed opening large enough to fit the rear of the projector, it enough to fit the rear of the projector, it should look like this: should look like this: REAR VIEWREAR VIEW

STEP 4STEP 4

This is how it’ll look when properly This is how it’ll look when properly trimmed to fit the rear of the projector:trimmed to fit the rear of the projector:

STEP 5STEP 5

Next, make sure that the projector Next, make sure that the projector is aligned evenly onto the reflector. is aligned evenly onto the reflector. If this is not done correctly, once If this is not done correctly, once you mount the headlight, your cutoff you mount the headlight, your cutoff will be slanted and not straight will be slanted and not straight across. To know if your projector is across. To know if your projector is aligned evenly with the reflector, the aligned evenly with the reflector, the bottom of the bi-xenon mechanism bottom of the bi-xenon mechanism should sit evenly with the bottom of should sit evenly with the bottom of the reflector. Notice the the reflector. Notice the RED LINERED LINE at the bottom. at the bottom.

STEP 6STEP 6

This is how much the rear of the This is how much the rear of the projector should protrude out. If it projector should protrude out. If it doesn’t protrude far back enough, doesn’t protrude far back enough, once mounted back onto the bracket, once mounted back onto the bracket, it’ll be too far inward. If it protrudes too it’ll be too far inward. If it protrudes too much, the projector will sit too far back much, the projector will sit too far back and will not look good from the front and will not look good from the front either. either.

STEP 7STEP 7

Next, with the projector evenly aligned Next, with the projector evenly aligned onto the reflector, use a marker to onto the reflector, use a marker to mark the area(s) that will need to be mark the area(s) that will need to be drilled so that you can use the bolts to drilled so that you can use the bolts to hold the projector onto the reflector. If hold the projector onto the reflector. If you look at the projector carefully, you look at the projector carefully, you’ll notice that it have several holes you’ll notice that it have several holes all around it. You can use any holes all around it. You can use any holes you want, whichever is easiest. I chose you want, whichever is easiest. I chose to use only 2…..one on top and one on to use only 2…..one on top and one on the bottom but diagonally. the bottom but diagonally.

After you drilled the holes, mount the After you drilled the holes, mount the projector onto it and use the nuts and projector onto it and use the nuts and bolts to tighten them; be sure to use bolts to tighten them; be sure to use washers also because you won’t want washers also because you won’t want to crack the reflector with the nuts. to crack the reflector with the nuts.

STEP 8STEP 8

To make sure that the projector is To make sure that the projector is pointing straight forward like the pointing straight forward like the original halogen bulb and not too much original halogen bulb and not too much inward or outward, I used a crease on inward or outward, I used a crease on top of the headlight as a marker. Look top of the headlight as a marker. Look at the picture to see what I mean: The at the picture to see what I mean: The RED ARROWRED ARROW designates the correct designates the correct angle of the projector. You may need angle of the projector. You may need to loosen the bolts so that it’ll allow you to loosen the bolts so that it’ll allow you to move the projector to be aligned to move the projector to be aligned with the with the RED ARROWRED ARROW..

You’ll notice that the 2 bolts are too You’ll notice that the 2 bolts are too long. I used the dremel to cut the long. I used the dremel to cut the remaining length that is not needed.remaining length that is not needed.

STEP 9STEP 9

Once the projector is tighten onto the Once the projector is tighten onto the reflector, you can test-fit it with the reflector, you can test-fit it with the Hella bezel. The bezel will be a bit big Hella bezel. The bezel will be a bit big so you’ll need to squeeze the top and so you’ll need to squeeze the top and bottom to fit onto the projector. Don’t bottom to fit onto the projector. Don’t worry, it’s flexible so it won’t break or worry, it’s flexible so it won’t break or crack.crack.

Here’s a look with the bezel mounted Here’s a look with the bezel mounted onto the projector.onto the projector.

STEP 10STEP 10

Here’s how it should look with the Here’s how it should look with the bezel on. It’ll stick out a bit but don’t bezel on. It’ll stick out a bit but don’t worry about it. Once you mount the worry about it. Once you mount the plastic lens back on, it’ll fit nicely.plastic lens back on, it’ll fit nicely.

STEP 11STEP 11

Once you have test-fitted everything Once you have test-fitted everything and that all is well, you’ll need to make and that all is well, you’ll need to make a shroud to cover the rest of the a shroud to cover the rest of the projector. I’ve seen many people not projector. I’ve seen many people not using shrouds to cover the projectors. using shrouds to cover the projectors. This is okay too but the problem is that This is okay too but the problem is that this will create unwanted glares this will create unwanted glares because light is escaping through the because light is escaping through the sides of the projectors, bouncing sides of the projectors, bouncing around the reflector and scattering it around the reflector and scattering it everywhere. everywhere.

To make a shroud, use a piece of To make a shroud, use a piece of aluminum that is durable but yet aluminum that is durable but yet flexible. Cut it to the size that will fit flexible. Cut it to the size that will fit around the projector.around the projector.

STEP 12STEP 12

Once you’ve made the shroud, fit it around the projector. Make sure it Once you’ve made the shroud, fit it around the projector. Make sure it doesn’t get in the way of the bi-xenon mechanism when it goes up and doesn’t get in the way of the bi-xenon mechanism when it goes up and down. Put the bezel back onto the projector to secure the shroud in place.down. Put the bezel back onto the projector to secure the shroud in place.

STEP 13STEP 13

Once you know that everything fits nicely, it’s time to take it all apart again. Once you know that everything fits nicely, it’s time to take it all apart again. Why?....you might ask! Well, you don’t want a dirty headlight, do you? Why?....you might ask! Well, you don’t want a dirty headlight, do you? Take everything apart and clean the headlight reflector thoroughly with Take everything apart and clean the headlight reflector thoroughly with water and soap, and wipe it dry with a soft piece of cloth. Try not to scratch water and soap, and wipe it dry with a soft piece of cloth. Try not to scratch the reflector. While you’re at it, also clean the projector, bezel, and shroud the reflector. While you’re at it, also clean the projector, bezel, and shroud so no finger print or grease is visible. so no finger print or grease is visible.

One important note while cleaning the reflector of the projector and One important note while cleaning the reflector of the projector and headlight -----headlight -----NEVER, NEVER, NEVERNEVER, NEVER, NEVER use rubbing alcohol or paint thinner use rubbing alcohol or paint thinner to do it. They will scrape away the chrome and leave an ugly smear. to do it. They will scrape away the chrome and leave an ugly smear. Instead, just use a nice clean piece of cloth. (My white cotton undershirt Instead, just use a nice clean piece of cloth. (My white cotton undershirt was what I used)was what I used)

Once you’ve clean everything, put it back together again. Once you’ve clean everything, put it back together again.

STEP 14STEP 14Once everything is back together again, it’s Once everything is back together again, it’s time to use the JB welding stuff. Cover the time to use the JB welding stuff. Cover the gaps at the rear of the reflector with several gaps at the rear of the reflector with several layers of JB weld. Let it dry overnight. Use layers of JB weld. Let it dry overnight. Use more layers if need to, but make sure more layers if need to, but make sure there’s no open gaps left or moisture will there’s no open gaps left or moisture will leak in. Once it’s all dried, you can spray leak in. Once it’s all dried, you can spray paint it to whatever color you like. I spray paint it to whatever color you like. I spray mine black. mine black.

Next, heat up the oven again to 400 Next, heat up the oven again to 400 degrees Fahrenheit and turn it off. Putting degrees Fahrenheit and turn it off. Putting the headlight back together is the reverse of the headlight back together is the reverse of taking it apart. taking it apart.

Place the bracket back onto the headlight. Place the bracket back onto the headlight. You may need to cut a piece of the lower You may need to cut a piece of the lower part of the bracket to fit the bi-xenon part of the bracket to fit the bi-xenon mechanism. My 2 bolts were a big long so I mechanism. My 2 bolts were a big long so I had to cut a small part of the bracket off had to cut a small part of the bracket off also.also.

Another shot:Another shot:

STEP 15STEP 15

The other headlight is done exactly the same as described. Once both The other headlight is done exactly the same as described. Once both sides are finished, sit back, relax, have a beer (if you haven’t had one or two sides are finished, sit back, relax, have a beer (if you haven’t had one or two throughout the whole process), and give yourself a pack on the back. The throughout the whole process), and give yourself a pack on the back. The hard part is over.hard part is over.

Finally, go mount those headlights back onto your car. Finally, go mount those headlights back onto your car.

Wait until nighttime to adjust the beam. Wait until nighttime to adjust the beam.

ENJOY!!!!!!ENJOY!!!!!!

FINISHEDFINISHED