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Thread: Anyone with ZKW to AL conversion, could you help?

  1. Anyone with ZKW to AL conversion, could you help?

    Hey folks, kind of out there request. If you have done the conversion, could you tell me if the smaller of the two connectors on the ballast (gray plastic case) has 3 prongs or 1? This is the connector responsible for hi/low flap opening.

    The car is undergoing a front end refresh and the shop is telling me the new al light connector is not locking into place and had 1 prong instead of 3. The number of prongs is less relevant, what's relevant is if you have 1 prong version, are you having trouble locking the connector in place.
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  2. #2
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    Something's not right. My first ZHP had ZKW from the factory, and I bolted AL right up to it. Everything connected and worked perfect.
    2003 Oxford Green ZSP 5MT 330i
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  3. #3
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    Quote Originally Posted by Avetiso View Post
    Something's not right. My first ZHP had ZKW from the factory, and I bolted AL right up to it. Everything connected and worked perfect.
    This was my experience as well.
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  4. #4
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    Quote Originally Posted by Avetiso View Post
    Something's not right. My first ZHP had ZKW from the factory, and I bolted AL right up to it. Everything connected and worked perfect.
    You had to modify the brackets though, correct? I know I did. The ZKW brackets wouldn't fit the ZKW housings. I know this is OT from the question, but I'm hoping this will jar my memory:









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  5. #5
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    Quote Originally Posted by danewilson77 View Post
    You had to modify the brackets though, correct? I know I did. The ZKW brackets wouldn't fit the ZKW housings. I know this is OT from the question, but I'm hoping this will jar my memory:









    My car was hit and the OEM brackets were broken. I simply bought AL brackets when I was replacing. So in my case, I didn't have to, but OP will have to if he intends on keeping his ZKW brackets.

    Sorry for the confusion!

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  6. #6
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    Now....about those plugs....
    "Flame suit NOT REQUIRED!!!"
    Call Me Dane l 2/2004 330i ZHP l 18x8 ET45 BBS CK's wrapped with Michelin Pilot Sport AS3+ @ 245-40-18 l KW V1 Coilovers in front l KW V1 springs w/ Bilstein B8 dampeners in rear l BMW Performance Rotors l UUC StrutBarbarian l Racing Dynamics Rear Strut Bar l Jim Conforti Shark Injector l Light Birch Interior Trim l Bimmian Celly Mount l M3 Trunk Mat l l e90 Performance E-Brake & Shift Knob l M3 Tri-Stitched Boots l AL Headlight Retrofit with ZKW Lenses l CobyWheel Wrap w/M3 Stitching l LCM sw 4.5 triple blink and rear fogs

  7. #7
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    Quote Originally Posted by ZHPRegistry.net View Post
    Hey folks, kind of out there request. If you have done the conversion, could you tell me if the smaller of the two connectors on the ballast (gray plastic case) has 3 prongs or 1? This is the connector responsible for hi/low flap opening.

    The car is undergoing a front end refresh and the shop is telling me the new al light connector is not locking into place and had 1 prong instead of 3. The number of prongs is less relevant, what's relevant is if you have 1 prong version, are you having trouble locking the connector in place.
    The bixenon connection should have one MQS connection. It's a simple 0/1 function. Did they have to add any wires?? I went from Halogens to full OEM AL bi-xenon on my 328i and the only thing I had to add were two additional plugs from pins 2 and 32 of the LCM and those connected to the bi-xenon shutter on the ballast.

    I hope they are not trying to put the DRL/Flash-to-pass connection on the ballast...

    There are five connections per side. Corner light, xenon low beam, xenon high beam, DRL/f2p, and the auto level.

    Hope it gets sorted.
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  8. Thanks all.

    Ok, looks like the plugging issue is simply my harness on one side is a bit stiff. As for the lights. The smaller plug on the ballast referred to as x10606 connector in the BMW WDS used to house 3 pins. 1st is a diagnostic connection of some sort, 2nd one is something that isn't even described in the WDS and the 3rd one is the actual hi beam flap which uses the ground from the main connector to the ballast. The newer AL lights came with the only 1 pin for the flap. Older AL lights have all 3.
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  9. #9
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    Cool. If you're all set, I'll move this to the lighting section.
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