Our work starts now.If you are tired of removing the bumper keep the headlight in a safe place till you get fully fresh and it is important.
step 1:-Before baking
1.Remove all the bulbs and holders in the housing like headlight(high/low),parklight,indicator light.
2.Remove the bulb holder and the screws that is fixes it.(These two are not using anymore.So keep the bulb holder and its screw to keep somewhere if you want to reverse this retrofit to factory at some point)
3.Remove all the screws on the housing.
4.Check out whether any screws left out or not.
6.Keep all the screw in a packet to avoid it getting missed out.
If you missed out unscrewing any screws it can make your headlight break while plying.So check thoroughly.
step 2:-Its baking time for headlights
It is not for your breakfast.So dont leave the kitchen while baking it in oven if you are using oven method.I done heatgun method so i can tell only about it.But oven method is less time consuming and evenly baked than heatgun method.
The use of headgun comes with a bit of care and handling.A heatgun with 350 to 600 degree centigrade is fine.Increase a bit more distance between heat gun and housing if you are feeling too much hot on the plastic surface.
This process is time consuming and should be done with care.So take a break, fresh up and get ready for an hour's work.In the below picture you can see a screw driver point to the back.This place you have to warmup the plastic with the heat gun and move the heatgun
1.Take a soft tower or cloth and place it in a flat surface and keep the headlight facing the lens downwards touching down.Be careful the lens not to get scratched.Make it more cushioned with something if you are not satisfied.
2.Switch the heatgun on and hold for 3 or 4 seconds before applying.This gives ample time for the heatgun coil to warmup.
3.Start from the bottom side corner and warm from the back of the housing (black plastic side) instead of warming up the lens.(Have to thank naveen of Automotive india forum for this suggestion).It works better than warming the lens and also there is less likely for you to melt the lens due to over heat.
4.If you can see butyl outside of the housing somewhere before warming.Try a test on it so you can understand how much head needed for the butyl to get soften.You only need to soften the butyl to ply it.
5.If you are confident touch the plastic in a flash of time to feel the heat is enough or not.I done like this to confirm it even though it is not a safe way.But for me it was easy to make out.
6.Do it evenly in a slow and steady manner 3 or 4 times and keep the hotgun aside switching it off.
7.Now start removing the tabs in the headlight housing from the lens with a small screw driver.Do this gently otherwise the plastic tabs may break.
8.During this time the heat in the plastic makes the butyl to soften.
9.Now start plying with a flat screw driver from the bottom corner of the headlight.Always use bottom corner as it hides the irregularities caused while plying under the bumper while you fix it back.
10.Once you got a grip on the corner to ply it and got enough space while plying,you can use a much wider screw driver to ply it more easily.
11.Ply equally on both side of a corner will make the things easier.
12.If you are feeling very while hard plying apply more heat with the heatgun.You can use heatgun while plying in this stage for more heat. There might be some sounds while plying. Don’t be afraid it the sound of releasing the butyl from the housing.
14.Your headlight housing should come out by now. This is a time consuming job. So do this with patience and care. Take your own time. It will give you good results. If you rush in while plying you will end up breaking it.
15.Keep the lens in a secured place where no dust can reach.
Step 3:-Retrofitting MH1 projectors
Even though MH1 projectors are said to be plug and play, there might be some alterations to be done depends on the type of reflector you are using. Many of the reflectors need not have to do any alteration for fixing this projector. Some of the things you need to know before installing the MH1 projectors into the housing.
1.If you are using h4 or H1 adaptor plate,take it out from the projector package and check whether the adaptor is accurately clocked to 12'o clock.If it is,then you escaped from trimming the inner tooth of the h4(or H1) adaptor plate.
2.Check whether anything is blocking the way in the back of the housing for the H1 bulb holder in getting fixed properly. If there is something then you need to trim that part of the reflector.
3.Clean the projector and the lens thoroughtly and make sure no dust or fingerprint is there in it.
Fixing the Shroud
Note:- Do these steps one projector at a time.
1.Mix the 2-part epoxy(in some places it is called M seal) and stick in the outer circumference where we insert the shroud. Don’t touch the lens while doing this.
2.Wash your hand thoroughly and quickly come back.
3.Take the shroud which we have kept in with the shroud centric rings inside it.Slide the shroud to projectors keeping the wiring should be in perfectly on the bottom.It will take 10 mins to half an hour for the epoxy to set.
4.dont touch it for a while and make sure that you aligned the shrouds properly.Once the epoxy is set it is almost impossible to rotate the shroud to align it later.
5.Repeat these steps with the second projector.
Fixing MH1 projectors
1. Take off everything that is on the back of the projector like the bulb holder and the hex lock-rings.
2. Insert the washer on the back of the projector.
3. Insert projector through the front of the reflector. Run the CCFL and projector soleroid wire.
4. Clock the projector to 12 o clock.(Do this by looking the top notch on the back of the projector)
5. Insert the h4(for h4 headlights) or H1(for H1 headlights) adaptors thorough the back of the reflector.
6. Screw the Hex lock-ring. Be atmost care not to cross thread it as it is very sensitive.
7. Fix the bulb holder with the three screws.All of the screws should go deep down. Otherwise the screws will block the way of the bulb and also will not be fixed correctly.(Take care not to cross thread these screws) and fix the bulb.
8. Once this is done ,clean the lens and reflector thoroughly and screw one or two screws to fit the lens temporarily and keep it aside.Don’t seal them now.If something goes wrong you may need to ply it again.So It is the last thing to do.
9. Now take the relay ,ballast and the wire-harness to the vehicle and fix it properly.Do not connect to the supply now. Black wire with connectors always go to the negative and red to positive.
10. Take the light housing and fix it on the car and test connect the wires including the auto-leveler. (Do not fix the plastic plug of the projector or the to the pins)
11. Now connect the wire-harness to the car power supply
12. Now keep the car about 25 feet in a level ground opposite to a wall.
13. Switch on the light and check whether the cut-off is perfectly horizontal.
14. If is cutoff if horizontal then check the working of auto-leveler.
15. Remove connections from the headlight and take the housing out.
16. Remove the screws in the housing
17. Heat the housing with heatgun and put the tabs and finally fix all the screws back.
18. Fix the headlight back
19.Now connect the plastic connectors to pins and connect them to the wireharness
MH1 in my wagonR
I dont know what all things i left out in these steps and there are a lot of photos missing...This is my first retrofit so please forgive if i missed out and friends please add comments and suggestions which i leftout...cheers