MacV and I install Hella Euro Smiley/HIDs

[Denton]

Written by MacV

So Denton and I met up this Friday to throw a few parts together. Although we didn't get them all done in time, we DID get the Hella Euro Ellipsoids and 6000k HID kit in. We threw some Euro trim on his 5er (great touch), and we installed an auto dimming rearview mirror which was, IMO, the coolest and easiest mod I've ever done.

As for the purpose of this thread. I'm going to try and give a little guidance to the people that are wanting to swap in Euro Ellipsoids and add HID.

Terms: Do everything at your own risk, this is no where near a perfect or professional tutorial. Just another source to study before doing the job.

Denton is replacing his US Hella Lamps with the Euro Hella Lamps and installing a Genesis 6000k HID system. Genesis is made by McCulloch which has a decent reputation. (I say decent because I'm sure people will disagree just to disagree) I've purchased Genesis kits before and have always been satisfied. I introduced them to Denton and he grabbed a set.

Here we go...

Step 1

You'll need to start by taking off the bumper. THIS IS NOT REQUIRED!! IF YOU CAN START AT STEP TWO YOU'LL DO GREAT. I REMOVE THE BUMPER BECAUSE I CAN PERFORM STEP 2 EASIER. Remove the side trim by pulling from the wheel towards the front of the car. The front parts of the trim just snap out, so pull hard. On either side of the bumper you have two black 1/4 turn screws. You know what to do. Then take off the four 17mm bolts hold the bumper on. Make sure to disconnect your fogs and exterior temperature reader. Rip that sucker off. Note: You can't be scared to use force. If you are, don't even start this project.
http://img148.imageshack.us/img148/5518/dsc0677il1.jpg

Step 2

Now our favorite part of the car is ready to come off. The Kidney assembly. Read the Bentley before reading my explanation of this. Basically there are two clips on the far sides of this the panel and they're tough to get. The Bentley says use a screwdriver through a hole, but reaching my hand under when the bumper is off seems easier to me. You've just got to use some force and rip each side out, careful not to use too much force and bend the metal. Stick your fingers in the middle of each kidney and push down on the two obvious clips, then release the two clips on the top of the kidney's. Remove. HINT: The Bentley will describe all of this much better.
http://img187.imageshack.us/img187/8610/dsc0677bnk6.jpg

Step 3

Removing the headlight plastics. There are four plastic screws.... yes plastic :shifty on the plastic covers. Also one metal screw connected to the fender. Remove all and pull piece straight out.
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[Denton]

Step 4

Time to remove the headlights themselves. Obviously remove the bulbs or connectors if you haven't already. From the front you have three metal screws. Two on top, one bottom towards kidney. Then you have two you must access from the engine bay. Hard to explain, one you can see is located behind the headlight assembly between the low beam and corner light. The other is on the fender under the hood supports. It's hidden and hard to get out... err.... hard to get in later :shifty Hope the pics help.
http://img338.imageshack.us/img338/627/dsc0680xl6.jpg
http://img101.imageshack.us/img101/9452/dsc0685nb4.jpg

That should be it for the headlights. They're out!

Step 5: Preparing HID

Cool, so you've got the H1 headlights for the Ellipsoids.... but wait... they still don't connect right. Ahh, never fear this douche bag is here... to help, kind of. Most HID kits are going to require you to drill a hole through the H1 end cap. No problem, most HID kits come with rubber gaskets just for this issue. Just measure the size hole you need and make a nice hole in the middle. The gasket will keep it moisture tight. I really can't explain how to do this any better. Pics maybe?
http://img212.imageshack.us/img212/1601/dsc0688vd2.jpg
http://img135.imageshack.us/img135/7701/tightfitxo2.jpg

[Denton]

Step 5: Continued...

Find a place to mount the ballasts. It needs to be well vented because they can get pretty hot. Denton's were both mounted onto his wheel well (obviously in the engine bay). No pics sorry. The standard low beam connector will plug right into the ballast so no modification. You can run relays to the battery if you want, but I find no need. Upgrade your headlight fuses to 15A. I also don't have any pics for a way to fix an error message as his 525i didn't throw any. There's a great website that will fix the error if you get it.
http://img527.imageshack.us/img527/2941/dsc0692ph5.jpg

Step 6: High beams/City lights
To wire the the high beams for the Hella Euros you just need to cut and splice the h1 connector on. Make sure you're connecting matching wires. Also make sure you're making clean connections, use heat shrink or quiksplices or something. For city lights, Denton just used his front sidemarkers. They're straight plug and play and since he was adding Euro trim, it worked out perfectly.

Step 7

Start back at Step 4 and read backwards to put everything back together. Check, double check, and triple check to make sure you don't forget a bolt or leave something unfinished before you attach bigger parts. I forgot two bolts and it cost us another 10 minutes to take things off to put them back on. I really disappoint myself sometimes.
http://img340.imageshack.us/img340/387/dsc0705kc3.jpg

I think that covers everything. Make sure you let the HID's burn in for a few minutes.

If I've missed something or overlooked a bolt, PLEASE let me know so I can fix it and not confuse any more people than I have to.

Again this is not professional so don't follow it to heart and blame me for broken stuff. Just trying to help out.

Criticism open! This is here to help everyone, so throw your opinions out and be heard!!

Overall Friday was fun, wish we could have gotten more done though. Everyone send Denton (4500 rpm) a PM requesting pics of his new lamps/bulbs. They're amazing looking at night!!! Also.... remind him she needs a bath. He has one of the most sound 5ers I've ever had the pleasure to work on, and she's dirty? Just screwing with you man.

Props to Lowell for great packaging on his parts. Same goes to Mel @ Abrahamsmotorsport.com I've loved their business and I believe Denton did too. Seventhstoned gets props as well for sticking to his word. He was a great sport in making sure Denton got those Ellipsoids. wtg guys!

[Qube]

McCullochs suck! Heh. To each their own. Three sets of older McCullochs crapped out quickly. New ones must be much better then :)

I suggest expanding a bit on Step 2... perhaps suggesting the use of a long screwdriver to depress and release the grill surround? To me, it's easier than removing the bumper.

Great writeup and pics!

[GoldenOne]

Nice job! I've been weary about doing the Euro Hella Lamps with HID's because of having to cut hole into the fitting. I guess it doesnt look too bad to do now.