Just some notes I think will help someone trying to tackle this. I would like to thank Jon publicly for his help on this, and answering my several texts and emails.
This build replaces the normal ZKW headlights with AL headlights (SAT bowls) and ZKW lenses.
"Nice to have" tool list, above and beyond normal sockets and screwdrivers.
- Telescoping magnet pickup. Perfect for "getting started" the inner/lower headlight Torx screws.
- Torx sockets. You will need a tiny Torx bit to remove one screw on the ZKW lense housings. In addition you will need regular Torx set.
- Six inch extensions.
- Glass cleaner. Ensure you use on inside/outside of ZKW lenses and on outer headlight lenses just prior to final install.
- Electronic parts cleaner.
- One set of used AL headlights
- Your set of ZKW's, or ZKW lenses from the http://www.theretrofitsource.com/pro...roducts_id=136
1. Drain windshield fluid reservoir > I used a Motive Power extractor to do this. This is only necessary if you plan to fully remove the headlight washers. This headlight swap can be done without removing the headlight washers though. Be advised.
2. Remove interference > I removed my intake to facilitate room on the drivers side. Nothing needs to be removed on the passenger side.
3. Go ahead and unplug all lighting connections. There will be 4 connections on each headlight, and a couple of more, if you have angel eyes installed.
4. Remove 4 screws on each headlight. 2 above, and two below. The two below are Torx and the two above are normal bolts. You can use the below video to facilitate removal. Like I said though.....the headlight washers need not be fully removed to remove the headlights.
5. Now that you have the headlights out of the car.....go to a somewhat clean area....with a lot of room to facilitate breakdown and removal of your ZKW lenses for install into your AL headlights with SAT bowls. I used the below video, and I thank Jon for providing it. Now remember....in the below video he is disassembling AL headlights. NOT ZKW's. The ZKW's are different in three regards.
1. The upper center socket needs to additionally be jarred loose, and...
2. The inner hinge will have to be disconnected to facilitate removal, VA and...
3. Actual lense removal differs on the ZKW's.
I will post pictures of the three items mentioned above when time permits.
The above steps should get the ZKW headlights out of the car and get the AL headlights rebuilt with ZKW lenses.
6. Modification of ZKW headlight brackets to receive AL headlights > The picture below will describe exactly what you need to do to facilitate install of your newly rebuilt AL headlights with ZKW lenses.
But DW.....why do I need to modify my headlight brackets? The box on the bottom of the AL headlights interfere with the headlight bracket. That is the major reason.
Drivers side before
Drivers side after bracket modification
Passenger side before
Passenger side bracket modification
7. After you get the headlight assemblies to seat properly, you're golden. Snug them down with your 4 hold down bolts, re-install intake, lower trim, and re-fill washer reservoir (if drained)
8. The last thing you'll want to do is perform the headlight aiming procedure. I used the below procedure as I could not find Trevors pic.
http://www.m3forum.net/m3forum//showthread.php?t=176238
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Originally Posted by johnrando
