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159 Xenon projector retrofit - Options

23K views 40 replies 13 participants last post by  epsonix 
#1 ·
Right so I am starting to find that the 159's Headlights leave a little to be desired.. So I am going to embark on the option of Retro fitting Xenon projectors to the 159. Yes I know the self leveling wont actually work, may also fit the WasherJets too so it looks OEM from initial observation. I want to do this as correct as possible.

My question is: What xenon projectors will bolt in without any/ too much cutting? Do the 159 Xenon projectors fit ? If so does anybody have any spare, if so how much. What other projectors will fit from the Retrofit HID companies or other cars?

Alternatively does anybody have much experience with either of these companies or can name any others in europe :
https://www.retrofitlab.com/ Or
The Retrofit Source Inc

The retro fit labs should be the good choice but looking around on the forums their quality seems to be in doubt, their recommendation according to the site are the bosch e46 projectors.

Any input will be well recommended, just to confirm I do not want to just put HID bulbs in and hope for the best....

Thanks in advance BT.
 
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#2 ·
Do you think you will get through an MOT ok if you have Xenon's without self levellers? Its an easy one to spot and I'd doubt they would let it fly. If you have xenon's you are supposed to have a working self levelling system along with working headlight washers.
 
#3 ·
I'd love to retrofit the xenon's but without the self levellers I don't think you will get an MOT. So HID's it is, unless you can fit the full kit.

You can get decent colours off the HID's though if you look hard enough - my personal preference is 5300k, 6000k is too blue and I don't think is really close enough to actual xenons, personally.
 
#4 ·
I fitted H7 replacement type HID bulbs and it *did* pass an MOT with no questions whatsoever. The trick I think is the keep the colours as standard as possible (mine are 4300K, 35W) and make sure it's aimed correctly. They still produce a great deal more light than the regular halogen bulbs, pretty much up to the standard of my old Lexus GS which had OEM xenons.
 
#5 ·
Thanks for the reply's - gives me the confidence to just go ahead with it. If it is really an issue I am sure something could be rigged up to make the adjusters go up and down... Even on the MOT forums they question how they can test HID systems which are self leveling so as long as the power packs are mounted nicely or even hidden away I dont think there is much to worry about. So trying to get some projectors anybody have any 159 Xenon projectors going cheap? Oh Also any idea on the part number for the lamp washer jets?
 
#7 ·
Right so I have been in contact with Retro fit labs - and they have managed to do a bolt in package for 245 Euro. That includes; Bulbs (Higher quality ones than normal), projectors, 159 wiring so that the bi Xenon's work low and hi beam and good quality ballasts (so they say).

What do you guys think? Any reason not to apart from the shaky legal standings...

Finally what part number is the Headlight washer jets? i cant find it on EPER...
Thanks BT.
 
#8 ·
Are you sure you aren't just getting expensive HID's? I'm not sure when you say 'projectors' whether you mean a different housing or if they are just calling their bulb holders projectors to make it seem better VFM?!

If you are retrofitting HID's I don't believe you need self levellers - as has been documented on numerous forums numerous times, plenty of people easily get MOT's with HID's and without self levellers, even if its obvious they have HID's.

It's easy to test if the car has self levellers though- you can see the self leveller system test itself when you first turn the lights on. Park in front of a wall at night in a car with an OEM xenon kit and you will see them at work.
 
#9 ·
Hi James,

Yeah I am pretty sure they are not expensive bulb holders, these are the projectors - Its a set of these : https://www.retrofitlab.com/en/xenon-projectors-1/bosch-e46-bi-xenon-projectors-1.html (the glass globes behind the front lenses) they are meant to be specifically tuned to give the correct cut off when using hid bulbs. Here is a quick video of them doing a conversion. : https://www.youtube.com/watch?v=pgZBtLWRR_s

On the MOT forum above link - If they both move/ self level they take it that they are both working, apparently some cars the lights don't move to calibrate from the looks of what they said...
 
#11 ·
Took the plunge last night - I will post photos when they arrive and once they are fitted 256 Euro delivered... They better be worth it ! Any ideas what the washer jet part number is for the headlights. I know they are not needed but wanted to look into fitting them or some which are similar any ideas?
 
#13 ·
I believe that all 159 bumpers are the same, if you remove the front one you'll see three cut outs on each side where the washer jets need to go. No clue as to part numbers though!

Mine's got the Xenons, no problems with them and you can see the system doing a self level check each time they're turned on at night.

Guy
 
#14 ·
Well lets pretend for now that they don't auto level, as the rear suspension is auto leveling ;) In the future I am sure something can be knocked up to imitate self-leveling on startup if it is a real issue.

So the Package arrived a few days ago.

It came with:
Canbus ballasts ;supposedly quick start ones, god knows if they are any good but the feel heavy and quite well built so I guess that's a start!
5500K d2s bulbs
H7 Main beam splitter (To operate the bi-xenon solenoid when the main beam is triggered
e46 Bi-xenon Projectors
Wiring harness

Going to fit it in a few weeks time I'll report back once it is fitted. The idea is to fit the ballasts on the underside of the headlamp unless anybody else has a better suggestions?? Not had a good look at the headlamps yet so it could be possible to fit the ballast inside the headlamp but it looks a bit too big to achieve this... Going to wrap the whole harness in Tessa tape and the ends in Self Amalgamating Tape to give it that oem, non fettled look, as most of the Xenon retrofits clearly look like they have just been thrown in about 10 mins no offense, but i guess there is only so much you can do without removing the headlights.
 

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#15 ·
#17 ·
To be fair, fitting HIDs into a car with projector lenses (such as the 159) isn't too bad IMO because they have a sharp cut-off anyway. Fitting them into reflector headlights is a different matter - they spray light everywhere and are indeed very dazzling to oncoming drivers.
 
#18 ·
These style LED's are mounted on either side of a metal bar so while they are extremeley bright and powerful they produce 2 x 170 degree beams oposite eache other like this:

>|<

Normal Bulbs create a 360 degree beam that reflects properly:

When that beam hist your reflector you get a reflection at the same angles so you do not get a true forward facing beam but insteal one in the air and one under your feet!

Interested to see your results though as I have tried many like it and not found a viable solution yet.
 
#19 ·
Hey Jaba, the ones I posted link of (H4, Hi/Low, for my Vespa) are having truly 2 x 180 deg, BUT, one off is for Low, the other is for Hi. meaning that upper LED sends light ONLY to the upper half of the sphere of the reflector. the other side's LED sends only to the lower half of reflector (Hi beam).

unfortunately, was not able to fit that one (general problem with Vespa GTS headlight, too cramped space between the headlight and the instrument). but managed to fit the other LED that I had from before, whose halves project left and right (same for both Hi and Low beams), as you described. That LED is more compact and just about fits in remaining space in front of the Vespa's instrument. BUT, that one has 4 off LEDs and does exactly you've described.

so, unless I sort out the cable problem on new one, I have to go back to halogen or do the HID conversion as some people have done, which means need to buy new headlight and experiment with splitting it :irked:
 
#21 · (Edited)
Any LED's are pointless for ANY light use if the object is to actually see where you are going :)

As mentioned before its not just about how bright they are but the beam pattern whcih is a product of the reflector and the angles at which the light is projected. All LEDs are surface mount so emit light in a 180 degree wide angle. unless they are mounted facing forward, and the beem pushed through a specially designed lens like a modern LED headlight all you do is get a bright glary headlight that doesnt actually help you see.
 
#22 · (Edited)
Right so finished the install last week and have done about 3,000 miles since last week. (Drove out to Germany) The HID's are awesome!! I can see so much better and am no longer dazzled by super bright mer's etc. When I put it on full beam I can see almost forever, it was well worth the time.

The worst part of the install was trying to get undo the torx t30 screws that hold the headlight and bumper on ( snapped 3 torx bits). I installed the ballast on the underside of the headlight, made a nice tidy job and cannot see the ballasts when you open the bonnet. It looks almost OEM as I ended up wrapping all the wires with Tesa loom tape and self amalgamating tape it looks good!

All that is now needed is a rubber dust-cover for the back of the headlight as the D2S fitting sticks out a little bit a D2H setup would of been able to go through the bottom of the headlight and would not of needed now headlight covers.

Attached are some pictures as you can see the cut off is nice and crisp. As I am in Germany atm the alignment I altered to not risk blinding other drivers...

Let me know if you want any pictures of the install or have any questions.

Regards BT
 

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#23 · (Edited)
Ok, so readingf through the thread what makes this interesting is the D2S / D2R conversion that enables the use of athe HID as mainbeam as well.

Standard H7 HID bulbs in a 159 projector headlight are no different to a stock xenon. beam focus is perfect so this alone is a perfectly viable HID conversion.

That said, by using the D2S/R you get decent forward light via teh HID's allowing for the use of a LED in the stock meain beam location.

...interesting
 
#27 ·
Cheers for the update BT!

Surprised they didn't supply rubber grommets with them, bit of a shame! Could be worth a trip to a motor factors and see if they have anything they could give you?

Would be interesting to know what the difference in the reflector is like vs standard
 
#28 ·
Hey guys sorry for the delay its been a busy time ATM working abroad etc. Anyway it looks like their rubber covers only go up to 100 mm ours is 130mm but I think the ones off a defender should fit unless anybody has other suggestions (at least enough to bung up the hole and he held on by the connector.

Attached are some photos of the old projector see the red colour is the burnt projector and inside you can see the surface peeling.. So looks like it was a good time to do the upgrade.

Also attached are some pictures of the install now it's all assembled and complete. Quite tidy I think and almost not visible, just need rubber caps...
 

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#29 ·
Last night added some Philips extreme vision w5w sidelights (6000k) http://www.philips.co.uk/c-p/127996000KX2/x-treme-ultinon-led-led-interior-lighting. These is a slight blue tinge but I think they are OK maybe the 4200k would of been the better bet. Anyway they are 50 lumens each attached are the results - I am happy and much brighter than the original ones.

Got a canbus error with these lights but I didn't expect anything else... I wanted the resistors separate to keep the heat down.
 

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#30 ·
I am abit confused here. HID are Xenon in headlight terms. Xenon is just the gas used. So why are people comparing them?

Tungstan bulb v HID are not as bright at the by a difference if 0.3 lux. at the HV point (Also considering the extra light above the cut off). This is the reason why you need self leveling.

I understand the advantage of changing the project unit because parabolic surfaces are cheaper (lighter) to make but lead to less light control above the cut off. This is due to manufacturing and moulding intoleraces which lead to glare.

I would like to point out that LED's give a more directional light that is why they are used on matrix beams but the angle of light purely comes down to the LED used. This driven by phosphor design mainly. Also you need to consider oem forward facing lens will also use a TIR lens for functional and cosmetic reasons.

Sorry few things were said which i didn't believe were true.
 
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