CGTBrad

My cousin is in need of a passenger side headlight for is 2000 2.8 FWD Non Xenon. TIA =)

TeddyBGame

YGM.

CGTBrad

Thanks I'll pass on the info.

eh?6Q

The following is a step-by-step procedure with pictures of the conversion of a pre-facelift ('98-'01) halogen headlight to bi-xenon:

The shape of both headlight housings are different, but the internal guts can be transferred easily.

The chrome plastic shrouds that came with the xenon projectors have to follow along since the projector diameter is different and the mounting posts are longer and positioned differently.

The good news is that the shrouds fit inside the black housing in-place of the older ones without any modifications.

<img src="http://pictureposter.audiworld.com/55916/a1_upgrade_from_halogen_to_bi-xenon.jpg">

Split open both housings with a heatgun (see instructions for clear-corner in the tech section):
<img src="http://pictureposter.audiworld.com/55916/a_dissassemble_w_heatgun.jpg">

Have a micro-fibre cloth to clean-up all the chrome pieces.

I found this foam pad great to protect the chrome shround from scratches during dissassembly:
<img src="http://pictureposter.audiworld.com/55916/a_foam_pad.jpg">

Remove reflector lower mounting-point (twist counter-clockwise).
<img src="http://pictureposter.audiworld.com/55916/a_motor_mounting_point.jpg">
Remove turn-signal reflector:
<img src="http://pictureposter.audiworld.com/55916/a_remove_flasher_reflector.jpg">

Release shround:
<img src="http://pictureposter.audiworld.com/55916/b_release_upper_mounting_point.jpg">
<img src="http://pictureposter.audiworld.com/55916/b_release_upper_mounting_point_from_behind.jpg">

Repeat above for the three other headlights (1 halogen, two Bi-xenons).

Cut bi-xenon wires (to free-up the wiring harness):
<img src="http://pictureposter.audiworld.com/55916/c_cut_bi-xenon_wires.jpg">

Release turn-signal wiring:
<img src="http://pictureposter.audiworld.com/55916/c_release_flasher_wiring.jpg">

Remove wiring harness:
<img src="http://pictureposter.audiworld.com/55916/d_remove_wiring_harness.jpg">

In the original halogen headlight outer shell, make a hole for the ballast wiring harness:
<img src="http://pictureposter.audiworld.com/55916/e1_drill_four_corners.jpg">

<img src="http://pictureposter.audiworld.com/55916/e2_drill_smaller_holes.jpg">

<img src="http://pictureposter.audiworld.com/55916/e3_cleanup_along_the_edges.jpg">

Insert the bi-xenon wiring harness:
<img src="http://pictureposter.audiworld.com/55916/f1_insert_xenon_wire_harness.jpg">

<img src="http://pictureposter.audiworld.com/55916/f2_route_plug_for_ballast.jpg">

Optional steps begin here VVVVVVVVVVVVVVVVVV

Unscrew projector from shroud :
<img src="http://pictureposter.audiworld.com/55916/g2_unscrew_projector.jpg">

Remove shield (optional):
<img src="http://pictureposter.audiworld.com/55916/g4_remove_shield.jpg">

Re-attach Projector (if previously detached)

Optional steps end here ^^^^^^^^^^^^^^^^^^^^

Insert motor mount:
<img src="http://pictureposter.audiworld.com/55916/h_insert_motor_mount.jpg">

Begin the re-assembly process - in reverse order (Install the remaining bi-xenon parts into the halogen headlight - Except re-use the original turn-signal reflector.)

Reconnect (solder) the bi-xenon wires that were cut earlier.

Re-attach original halogen lens using heat-gun to soften the goo.

All done!
<img src="http://pictureposter.audiworld.com/55916/z1_all_done.jpg">

Note the slight difference in shape of the reflector shows a gap when viewed from the side. Not visible from straight-on (see above).
<img src="http://pictureposter.audiworld.com/55916/z3_ready_to_install.jpg">

Test:
<img src="http://pictureposter.audiworld.com/55916/z2_test.jpg">

Installed:
<img src="http://pictureposter.audiworld.com/55916/z4_installed.jpg">

I found it *_easier_* to remove the ballast before, and attach it afterwards. Have a magnet on a telescoping wand handy!

Substitute the 15 amp fuses with 20 amps.

Canadian cars require DRL's, and in 99 an A6 they were the low-beams. The xenon's do not like losing power upon cranking the engine since they are just warming up. They often shut-down. A simple cut and splice of one cable in the switch harness moves the DRL function to the fog lights. I have to check my notes - ask me later.

CGTBrad

Uh thanks! But that's not the info I needed =)

CGTBrad

Thanks guys - we're all taken care of! =)

Sarge

How did you reattach the outer lenses after using the heat gun to remove them? just squirt some epoxy on there? Any special kind?

Thanks!

TeddyBGame

Nice work...very impressed.

eh?6Q

...push all the way in, then re-attach the "C" clips.

Did this over 2 years ago for clear-corners, and to clean the magnifying-glass and inner side of the plastic lens. Never a leak, nor fog inside.

BTW: reinserting the entire housing back into the car, I found the C clip underneath closest to the flasher was interfering against the chrome trim. I removed it, since the lens at that end inserts into a deep groove that will not allow it to move.

carbonLORD

Where were you when I needed these on my 2.8?

Great work!