TeddyBGame

<center><img src="http://pictureposter.audiworld.com/32631/hid_vs_halogen.jpg"></center><p>
There has been a lot of HID/Xenon questions over the past week so I thought I dig up some old URLs of mine and "repost" a collection of my knowledge in this arena. If you click the link below you be sent to a site that has a lot of great Xenon/HID background info...yeah..yeah...there is a big Ebay logo at the top of this site...and this dude apparently sells a lot of HID components via Ebay....I'm not promoting his site to help him sell more HID stuff...this is just a good site with some great background info on bulb colors/lifespan, ballast/ignitors and projectors etc.

Points of interest within this site:
A) The "Components Information" section is interesting. Good background on bulb and ballast lifespans.
B) The "OEM retrofit discussion group" will launch you into a whole different userforum (lots of A6 related info worth searching...review at your own risk (you can easily kill 4 hours searching through those archives). Also, I've learned that the HID/Xenon projectors found in 1998+ A6 housings are the most "sought after" by "ricers (no disrespect)" looking to modify their Honda's and Toyota's to add a Xenon capability. Basically, that is probably why so many of them have been stolen from our precious A6s.
C) If you look under the "Cars with OEM HID" section...scroll down within the table to the row labeled "1998-2001 A6".. the picture labeled "Car in Mist" is my Avant.


The information below is applicable to anyone with a 1998+ A6 2.8/2.7T/allroad/4.2 without the OEM Xenon option (I would be shocked if any 4.2 or S6 did not come standard with Xenon's or Bi-Xenon's) and would like to understand how to make that OEM upgrade (without buying a $400 HID kit), here are some rules of thumb:

1998+A6 (1999+ Avant) 2.8 / 2.7T / allroad (even the 4.2 allroad):
1) The headlight housings from the 1998+A6 (1999+ Avant) 2.8 / 2.7T / allroad (even the 4.2 allroad) are completely interchangeable (FYI - search under username TraderAlex, I advised him on buying a set of used HID housings form an allroad to fit into his A6 Avant - perfect fit..plug and play). The slope of the hood/grille is what makes these housings interchangeable. The HID projector is just for low beam (60MM) - see link below for more details.

Upgrade Option 1A:
In the event that someone is considering purchasing a set of Bi-Xenon projectors from ebay to retrofit into your existing housings...I would seriously recommend against you doing this. It would require some major Dremel work...and there is no guarantee that it will fit correctly. I've seen the inside of these housings and there really isn't enough space to work with.
Bottomline: You might invest a lot of man hours and approximately $400 in HID components and it might not function properly. This is just a caution to you all (and I don't want to question anyone's "creative engineering skills") as I've put a lot of thought behind doing this myself.

Upgrade Option 1B:
Another option that I am currently exporing (for the sake of research) is whether or not the HID components (specifically the 60MM projector) will fit into the space where the OEM Halogen projector/reflector fits. After close inspection of a set of halogen and HID housings (60MM and not Bi-Xenon), I can see that these components can be interchanged. The only other big issue would be correctly wiring the D2S bulb to the ballast/ignightor (this would require cutting out the backside of your existing halogen housing - there is a removable black cover under two metal clips) and mounting the ballast underneath or someplace else in the engine compartment. At the end of the day, you could probably spend $130 for the DOT or E-code A6 Xenon projectors; $200 for the OEM A6/Hella ballast/ignightors; $100 for a set of used/matched D2S bulbs...all amounting to approximately $430-$450 on these components (not including your time to put it all together, removing the bumper etc). My upgrade cost me $500 for the two housings and $80 for the install. These housings can be purchased directly from your dealer for approximately $600-$700/each!
Bottomline: This is a much better option (IMHO) if someone can't find two complete matched Xenon housings in the used/salvage market. FYI - I waited 7 months in watching ebay before I found a matched set. I ended up buying 5 housings in total before I found two that were a perfect match; sold the other 3 and made my $$ back ...and then some.. Also, I was able to locate a local Audi Tech that did the install for me. I paid him $80 and he did the work afterhours in his personal garage (took him 1 hour total....sweeeeeeeet.) *Please note: If your car didn't come with the OEM Xenon package, then your new Xenon's will not have the capability to automatically adjust the Xenon beam (a DOT requirement for any OEM Xenon setup) or "auto-level". Basically, if you have a large load of stuff in the trunk area, your car's headlights will aim up. With auto-leveling, a sensor in the rear suspension area will tell the Xenon housing to dip the beam down - as to not blind oncoming traffic. This hasn't been an issue for me as I've had my Xenon's installed for 15+ months. Also, I believe that an allroad equipped with halogens low-beams, I am pretty sure that there is a similar system in place to account for the 4-level height adjustment.

The part numbers for the two kinds of HID housings are:
4B0-941-004AT or 4B0941004BF (passenger side)
4B0-941-003AT or 4B0941003BF (driver side)

2000+ 4.2 and 2002+ 3.0 / 2.7T / S6
2) The 2000+ 4.2 and 2002+ 3.0 / 2.7T / S6 all share the same headlight housings because of the slope of the hood/grille. All 2002+ A6/S6 (unfortunately this doesn't include the 2.7T and 4.2 allroad) came equipped with Bi-Xenon's for low beam and high-beam (halogen/xenon working together)...this is a 90MM projector. See link below for more details on Bi-Xenon components.

Upgrade Option 2A:
This is just an educated guess - it is conceiveable that anyone with a 2000/2001 A6 4.2 can replace their existing Xenon housings with the Bi-Xenon housings from a 2002+ A6/S6. Just like my mod and this would be a plug/play upgrade that would still interface with your OEM auto-leveling components. What is weird, is that I've seen my Xenon's next to the Xenon's from a 2001 4.2 and for some reason, the projectors look smaller [and less bright] than mine. Anyway...I digress.

Upgrade Option 2B:
If you have a 2002+ A6 3.0 / 2.7T without the Xenon option (follow option 1B above). The only difference would be that you'd be installing the 90MM Bi-Xenon projectors vs. the 60MM versions. Also, you'll have two extra (18 gauge) wires coming out of the Bi-Xenon projectors, and these would need to be spliced into the wiring for the high-beams (in order to trigger the shutter to direct the Xenon light into a high-beam pattern). Again, this is all in theory as I don't have "hands-on" experience with these particular housings....just an educated guess. The D2S bulbs and Hella ballasts/ignightor will remain the same a option 1B above.

I am unsure about the exact part numbers for the 4.2 or 2002+ housings...they are probably pretty similar to ones listed under Option 1B. If you had the two different housings side-by-side in a picture, you could immediately tell which one would fit the slope of a 4.2/2002+ A6 hood/grille.

Outside of the US?:
For A6 (C5) owners who live in Canada, Europe etc, some of the information above will still apply. I believe that the European version of our Xenon auto-leveling mechanisms is managed by a three level switch (located just below the **** for the headlights). Different standards for different regions of the world. Also, you folks tend to operate with DRLs (daytime running lights) and your Xenon projectors have a different (better than US DOT versions) standards on beam "cut-off" patterns etc.

Buying Tips (Ebay etc):
As stated above, I have a bit of experience with buying these from salvage yards etc. Here are some guidelines to work under:

1) Mounting Tabs: If any of the two upper mounting tabs are broken...chances are this headlight was from a car that was in an accident (or it was stolen).

2) Inner auto-leveling motor: If this housing was involved in an accident, most likely the inner housing (the piece that holds the high / low beam, projectors etc.) will become dislodged from the auto-leveling motor...or broken. To the naked eye, the housing will look ok and function properly (usage of high / low beam, blinkers etc.) However, if the inner pieces are broken..the inner housing cannot be correctly leveled (either manually or via the auto-level function). Basically, the housing is useless..other than for HID components. Don't buy one of these housings unless you plan on stripping it for parts.

3) Scratched plastic lense: Don't be alarmed if you find a used housing with scratches and pitting on the outer-most clear plastic lense. This is should be the least of your worries. Any good body shop can buff these pits/scratches out with a fine grit rubbing compound. Don't let this deter you from buying any used housing. FYI - one of mine had a big three inch "gash" near the blinker and my body guy buffed it out in 10 minutes.

4) D2S bulbs: When you obtain two matched Xenon housings or components, you should consider purchasing a matched set of Xenon bulbs (Osram or Philips D2S - not D2R!!!). You want them to be matched so that they have the same useful life. You can find them on Ebay for $80-$100 for a used set. It is much easier to replace the Xenon bulbs before you install the housings.

5) Finding the HID Housings/HID components: These are the folks on ebaymotors that tend to sell a lot of these components. I'm not an advocate of their business...I just know that these guys sell a lot of this stuff on ebay. If you do a search under "A6" and "Xenon" - and sort by price - you will probably see a few of these housings available in the $250 range. Also, if you check the links below, there is a separate HID Classifieds section and userforum for your research needs.

5a) Henry K Koson (ebay username: henrylampa) email: hkoson2@yahoo.com
5b) Dan Chan(ebay username: heydanchan) email: heydanchan@earthlink.net
5c) David Chow (ebay username: chowcman) email: chowcman@yahoo.ca

6) Post install:
Use the manual adjusters (the two white screws) on each housing to adjust. I just brought mine to my dealer and had them adjust the levels to Audi specs.

In conclusion:
To date, I only know of a handful of users on the A6 forum that have done this mod: Myself (TeddyBGame), Sarian Verconna, TraderAlex (using allroad HID housings), Sicherheitsgurt...and probably a few others have made the "leap" from Halogen to OEM Xenons. It's a small club; maybe we should have jackets made?. I am sharing this information because I spent a lot of time and research to determine how this upgrade. I'm not trying to promote the purchasing of potentially stolen headlights etc. I am merely trying to transfer my knowledge to the fine folks of the A6 forum. Also, I'm in the process of putting together a Tech Article (with pix etc) explaining most of my learning when I added a matched set of OEM Xenon housings into my 2001 Avant. What is above is 80% of what I know.

Standard Disclaimer: You assume all responsibility for any damage or unsatisfactory result obtained by following this modification. Please read it all beforehand, just to make sure you have the required DIY skills to perform it.

Other related Xenon posts of mine (and others):
<a href="https://forums.audiworld.com/a6/msgs/336685.phtml">research website</a>
<a href="https://forums.audiworld.com/a6/msgs/383330.phtml">background</a>
<a href="https://forums.audiworld.com/a6/msgs/207766.phtml">background</a>
<a href="https://forums.audiworld.com/a6/msgs/225430.phtml">background</a>
<a href="https://forums.audiworld.com/a6/msgs/228797.phtml">background</a>
<a href="https://forums.audiworld.com/a6/msgs/236504.phtml">background</a>
<a href="https://forums.audiworld.com/a6/msgs/298390.phtml">background</a>
<a href="https://forums.audiworld.com/a6/msgs/335475.phtml">color fading on xenon bulb</a>
<a href="https://forums.audiworld.com/a6/msgs/463480.phtml">background</a>
<a href="https://forums.audiworld.com/allroad/msgs/102492.phtml">lifespan of xenon bulb</a>
<a href="https://forums.audiworld.com/a6/msgs/475876.phtml">allroad HID's installed</a>
<a href="https://forums.audiworld.com/a6/msgs/476364.phtml">background</a>
<a href="https://forums.audiworld.com/a6/msgs/477786.phtml">broken inner housing</a>
<a href="https://forums.audiworld.com/allroad/msgs/104273.phtml">background</a>
<a href="http://faqlight.carpassion.info/hl-hid-bulbs.htm">facts on HID bulb technology color ratings etc</a>
<a href="https://forums.audiworld.com/a6/msgs/486303.phtml">background</a>
<a href="https://forums.audiworld.com/a6/msgs/501532.phtml">HID projectors installed in Halogen housings - Part 1</a>
<a href="https://forums.audiworld.com/a6/msgs/502148.phtml">HID projectors installed in Halogen housings - Part 2</a>
<a href="https://forums.audiworld.com/a6/msgs/509226.phtml">remove inner HID housing - part 1</a>
<a href="https://forums.audiworld.com/a6/msgs/509100.phtml">remove inner HID housing - part 2</a>


Update (June 29, 2005):
Halogen to HID upgrade (modifying your existing halogen housings)

Based on my knowledge of these housings, the major difference between the Halogen and HID are:

- HID projectors (attached to a similar housing via a special bracket - see gold bracket in pix)
- Auto leveling motors (heck...I don't use 'em - not needed for this mod. Ha!)
- Ballast (mounts underneath the halogen/HID housing) - It's important to get the one via ebay that is from an A6 as the bulb holder piece is at a specific/unique angle and special cover piece incorporated into the balast wiring.
- (optional) Rear cover for housing - (the HID version has an opening for the ballast/bulb wiring..but a dremel can do the trick to. You just need to create a good seal in the rear...or you'll get condensation.
- The low-beam bulb: Of course you need a D2S for these projectors.

I think that covers it. The wiring is the same...as the ballast just feeds off the same +/- as the low beam.

Aftermarket HID install in C5 A6 (not too shabby):
https://forums.audiworld.com/a6/msgs/263403.phtml

How to check for a bad HID bulb or ballast:
https://forums.audiworld.com/a6/msgs/717317.phtml

That's my story...and I'm sticking to it!
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February 2009 Update:
It's been about 5 1/2 years since I did this upgrade and I haven't had any issues with my car or electrical system or any related codes on the dashboard. The original D2S bulbs are still working fine after 5+ years of use (and I drive with my headlights on quite a bit during the daytime ~ 80% of the time). There is no visual issues with the electrical wiring going in/out of each headlight housing -- and I don't suspect there to be any issues in the near future as the Xenon housing require less juice than the Halogen's. Yeah, it sounds crazy but the Xenon's are much more power efficient than Halogen's. The outer clear plastic lenses are a bit pitted and foggy but that is a common problem with these housings. Time to polish them in the summer.
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Go Pats, Go Red Sox!!!!
-teddybgame

Vincent in Montreal

Wow, that's one long post!

mustbeaudi

Ted, guys like you provide the content that fuels my apreciation for AW

automata

Actually, I spent alot of time searching out and reading your posts on your upgrade. They were a great help. I ended up buying my lights from someone on ebay, he said that they were off a totaled A6. A couple of the tabs were broken on one of the housings but everything else was fine.
My installer, who also did the clear corner mod for me, didn't have to remove the bumper to install them. I myself removed and reinstalled the pasenger side housing without removing the bumper. I wonder why my car is like this and others have to remove the bumper?
Thanks Teddy, you may not have known, but all your previouse posts helped out.

TeddyBGame

Thanks....there's soo much intellectual property in this forum. I'm just glad Stoney's links exists

TeddyBGame

Glad to hear that my posts were helpful.

NJ4.2GUY

00 A6 4.2 it was in an accident and one headlight was replaced they are both xenon but they dont match in color the old one seems more yellow white and the new one is more blue.. is it possible to change just the bulb to make them match better? any ideas why it is like this?

urs6_ma

This is great information. I just bought an '02 A6 quattro avant that came with halogens

I snagged a set of bixenon lamps off ebay.de, eurocode lenses, clear corners and will be installing them in the next week or so.

I understand that I need to activate the xenon high beam. Anyone know how to do this?

Lee

jwilker

Great info! as usual

I'm wondering. Can the autoleveling mechanism be installed as an upgrade? meaning, can the motors and sensor be installed when I get my new HID housings installed?

iProDrive

WOW! "10,002 views" for a 2004-01-22 post!