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Projector Retrofit Install Notes

DIY Projector Retrofit Kit Installation Guide

Before starting the installation, please read through the following instructions to ensure you have everything required for a smooth install. This guide covers the installation of our DIY projector retrofit kits into your factory headlights. 

Before You Begin

Required tools:

  • Screwdrivers
  • Trim removal tools (a flat blade screwdriver can also be used)
  • Multigrips / pliers
  • Oven
  • Silicone (optional)
  • Spray paint & primer (optional for blacked out headlights)

Recommended:

Before permanently sealing the headlights, test all wiring and projector functions. This makes any adjustments or troubleshooting much easier whilst everything is still accessible.

Opening the Headlights

Disassembly

Begin by removing:

  • All screws securing the headlight together
  • Any clips around the perimeter of the housing
  • Factory globes, globe holders, dust covers, and removable accessories

Once stripped down:

  • Preheat the oven to approximately 120°C 
  • Place the headlight into the oven for roughly 3–5 minutes until the factory sealant softens

Carefully separate the lens from the housing:

  • Work slowly around the edges using trim tools or a flat blade screwdriver
  • Avoid using excessive force — if the glue becomes firm again, simply reheat the headlight and continue

Repeat the process for the second headlight.

Optional Painting

If you plan on blacking out the headlights:

  • Remove any trims or shrouds you wish to paint
  • Thoroughly clean and prepare all surfaces
  • Prime and paint as desired
  • Allow sufficient drying time before reassembly

Once dry, reinstall all painted components before continuing.

Installing the Projectors

Mounting the Projector

  • Slide the metal washer over the rear of the projector
  • Slide the rubber grommet on behind the washer, this will sit between the reflector housing and the projector washer.
  • Feed the projector through the factory globe opening inside the reflector housing

Position the projector so that:

  • The wiring exits neatly through the rear of the housing
  • The cut-off shield sits perfectly level with the ground

For the cleanest results, route shroud parker cables through the threaded shaft of the projector like the rest of the cables. To do this undo the 2 torx head bolts and run cables through the channels being careful not to pinch cable when reinstalling 

Additional holes/notches can be drilled/cut if required for wiring clearance.

Securing the Projector

  • Install the H4 locking washer onto the rear of the projector
  • Tighten the retaining nut securely using multigrips or a suitable tool

 

Resealing the Headlights

Before resealing:

  • Inspect the inside of the lens and housing carefully
  • Remove all fingerprints, dust, debris, or marks
  • Ensure wiring is routed neatly and will not interfere with sealing

Sealing Procedure

  • Refit the lens onto the rear housing
  • Preheat the oven again to 100°C – 120°C (non fan-forced only)
  • Place the headlight back into the oven for approximately 3–5 minutes until the sealant softens again

Once heated:

  • Firmly press the lens and housing together evenly around the entire perimeter
  • Reinstall all screws and clips
  • Double-check that the housing is fully seated and sealed all the way around

Finally:

  • Reinstall all globe holders, indicators, parkers, and dust covers
  • Apply additional silicone sealant if required to improve waterproofing

Testing & Beam Alignment

Before reinstalling bumpers or finalising the installation:

  • Test low beam operation
  • Test high beam operation
  • Confirm projector cut-off alignment
  • Check indicators and parkers function correctly

Once fitted to the vehicle:

  • Park on level ground facing a wall
  • Turn the headlights on and inspect the beam pattern
  • Use long multigrips to rotate projector by the threaded shaft to achieve a perfectly level beam
  • Adjust the headlights until both cut-offs sit level and project straight ahead

Note:

These projectors produce substantially more usable light output than factory halogen headlights. Correct alignment is extremely important to maximise visibility whilst preventing glare for oncoming drivers.

Important Information

  • Professional installation is recommended
  • Always test components before final assembly
  • Avoid touching projector lenses or chrome surfaces with bare hands
  • Ensure headlights are completely sealed before installation back into the vehicle
  • Never force headlights apart or together when the sealant is cold — reheat as required