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View Full Version : ZKW to AL Headlight Swap: Bracket modification


Oltorf
12-11-2017, 05:45 PM
Swapping ZKW xenons for AL xenons is a common solution to the burnt ZKW projector issue. Electronically, they are direct replacements. The only modification needed is to cut a small part off of the ZKW bracket. The AL bracket should fit both units. Here's how I did it. It's very easy.

Here is the difference between the ZKW and AL units:
https://i.imgur.com/frAcMAul.jpg

The AL unit is on the top. The igniter sticks out about a half-inch. It's the box that is sticking out. All you're doing it cutting off part of the bracket to make room for it. I suppose you could not modify the bracket at all and it wouldn't make a huge difference, except for being a bit harder to install.

Here is the unmodified ZKW bracket with the AL headlights:

https://i.imgur.com/z8eG9Hxl.jpg

Before mod:

https://i.imgur.com/Dk2QAdWl.jpg

After:

https://i.imgur.com/j7CcqrIl.jpg

That's it! I didn't even use a dremel. I just used a pocket knife with a serrated edge.
Oltorf
12-11-2017, 05:48 PM
The ZKW lenses are clearer and give a sharper cut-off than the foggy AL units. I swapped lenses while I was at it using this video as a guide:

https://www.youtube.com/watch?v=2Lcup1PYTC0&t=654s

It's tricky if you don't know how to do it, but easy the second time around.
cakM3
12-12-2017, 08:42 AM
I have done the ZKW lens retrofit to both my BMWs...

If you take your time this retrofit is not too difficult to do [emoji41]


Sent from my iPhone6S using Tapatalk Pro
derbo
12-12-2017, 01:38 PM
ZKW Lenses + AL headlight and City light retrofit was my old setup. :)
fredo
08-24-2020, 11:20 AM
Oltorf, how's the fitment after the bracket mod ? Check post #13 here, there's a gap on the passenger side.

http://www.zhpmafia.com/forums/showthread.php?23233-Replacing-ZKW-bi-xenon-with-Magneti-Marelli-(aka-AL)-headlight-assembly
Oltorf
08-25-2020, 03:44 PM
There should be a way to slide some rails on the inside of the turn signal lights into some outer rails on the headlight. That's how I got mine to fit closer together. They're easy to miss.
Oltorf
08-26-2020, 11:46 AM
Oltorf, how's the fitment after the bracket mod ? Check post #13 here, there's a gap on the passenger side.

http://www.zhpmafia.com/forums/showthread.php?23233-Replacing-ZKW-bi-xenon-with-Magneti-Marelli-(aka-AL)-headlight-assembly

https://uploads.tapatalk-cdn.com/20200826/278c6b086c35de81c747f4bd8837aa79.jpg
https://uploads.tapatalk-cdn.com/20200826/14385da853c0eb042bb3e85c22861f37.jpg

There are my corner lights. As long as they’re slid into the rails on the headlight there won’t be a gap.