[Vigorous]

Has anyone successfully DIY swapped out the OEM fresnel lens for a (3") ZKW-R CLEAR LENS?
http://www.theretrofitsource.com/pro...roducts_id=136

I'm definitely interested in more light output and sharper cut off. I've seen threads of the e46 guys doing it, just not on any e92's.
E46 Swap:
http://www.hidplanet.com/forums/show...enon-projector

I figure it can be done since ONEighty offers a similar service:

"Clear Euro Projector Xenon Lenses:

• OEM xenon projector lenses use fresnel lenses, they are normally semi-frosted, or have small lines embedded into the glass, along with a big bulged line across it. This is made to dim the beam and soften the output of your projectors for US DOT standards so you're not getting the full performance out of your projectors as you should. These replacement lenses sharpen the output, and clarity for best light distribution. For even better results, some modification to the cut off shield (the high-beam flap) is required."

[Ortsac]

This would be great! Somebody should know how to do this

[G-Bus]

We need more info on this as I plan to do this as well. I just want to see some DIYs regarding the how-to's to taking the whole E90 headlight apart.

[NocturnalEVO]

bump for an answer

did anybody end up doin the ZKW-R ?

[e90TiAg335i]

Originally Posted by NocturnalEVO

bump for an answer

did anybody end up doin the ZKW-R ?

I did this on my 2010 e90. I'd have to look back at my order for what I ended up with though. The fist set had to be offset too far forward to even get a decent cut-off. The set I'm using now I had to put a spacer in the lens holder and trim the tabs on the shroud to hold the lens in place. The lens fits perfect inside the cutout in the shroud. PITA to install but much brighter lights and really nice cut-off with a tinge of blue.

Looked up my orders. The first order was the 3" ZKW-R and didn't work. Focus point way off. Second order, what's in the car now, was 3" STi-R lenses. Don't bother with the tuning kit. I think I used 1/8" abs for a spacer.

[NocturnalEVO]

Thanks for the response! I wonder if its the same between e90 an e92, as I have an e92

[wisco]

I just finished a project where I installed ZKW-R projector lenses, Osram CIB bulbs and Umnitza's Orion V4's. Total cost of parts $600. Took quite some time for the full project and a lot of fabrication.

To help answer your question, the ZKW-R is a very well worth project to take on just in itself. The cut off line is so much crisper. Whatever you do, do not forget to put brand new D1S bulbs in if you are still running your stock xenons from 2007. You're probably running at about 70% brightness with your 5 year old bulbs.

Regarding installation - you basically need to drop the bumper, heat up your lights (I used a Infrared heat lamp used for curing paint) but an oven or heatgun will work just fine!. Remove the lens, remove the large angel eye, remove projector shroud, remove 2 of the 4 bolts holding the projector lens bracket, bend bracket forward and swap the lens. I decided not to adjust the lens or space it at all because I felt the cut off line was pretty darn good as it was. I am going to research that aspect of the project a bit more, as the cut off line looked great to me from 15 feet away but it's not 100% perfect. Also going to research the mod they talk about regarding the high beam flap. I'm guessing it has to do with a straighter cut off or a slightly brighter hot spot right in the middle of the beam pattern. Ideally I want my cut off line completely straight across - not stepped up or stepped up to the right. More to come on that. If you're near Milwaukee or Chicago I could probably help you do the swap - feel free to PM me. Let me see if I can find some pics to post up.

[wisco]

Here are some pics.

[Vigorous]

YES!!!
Thanks for the awesome pics! I was still debating on this.

[onesuperboi]

What do you need and use to power up the headlights for testing?

[wisco]

To power up the headlights I searched google for "e92 headlight wiring diagram" or "pinout"... The large middle pin is 12v and the large pin on either side is negative. you can use your underhood battery post and any ground with a long lead from the hood if you're working on a bench and don't have a spare battery sitting around.

Although I love the results and the new xenon bulbs have actually gotten 10-20% brighter after a few hours of use, I still may take the headlights apart again and play with spacing the projector just a tad to perfect the cut off line. Also I strongly recommend you cut the high beam flap straight across to make the beam completely straight across rather than stepped up.

[Alvine90]

Originally Posted by e90TiAg335i

I did this on my 2010 e90. I'd have to look back at my order for what I ended up with though. The fist set had to be offset too far forward to even get a decent cut-off. The set I'm using now I had to put a spacer in the lens holder and trim the tabs on the shroud to hold the lens in place. The lens fits perfect inside the cutout in the shroud. PITA to install but much brighter lights and really nice cut-off with a tinge of blue.

Looked up my orders. The first order was the 3" ZKW-R and didn't work. Focus point way off. Second order, what's in the car now, was 3" STi-R lenses. Don't bother with the tuning kit. I think I used 1/8" abs for a spacer.

Were your projectors like this when you opened up your headlights?

[e90TiAg335i]

Originally Posted by Alvine90

Were your projectors like this when you opened up your headlights?

They look pretty close if not the same. Pic isn't the best and it's been a while since I looked at them.

[onesuperboi]

Originally Posted by wisco

To power up the headlights I searched google for "e92 headlight wiring diagram" or "pinout"... The large middle pin is 12v and the large pin on either side is negative. you can use your underhood battery post and any ground with a long lead from the hood if you're working on a bench and don't have a spare battery sitting around.

Although I love the results and the new xenon bulbs have actually gotten 10-20% brighter after a few hours of use, I still may take the headlights apart again and play with spacing the projector just a tad to perfect the cut off line. Also I strongly recommend you cut the high beam flap straight across to make the beam completely straight across rather than stepped up.

Thank you for your response.

Do you have any pics of the high beam flap? How did you cut it?

Sorry for all the questions, but you've been the most detailed one so far with the e90 platform. I researched and had someone do a clear lens swap, blackout, and Orion v4 for me , but I'm not satisfied with the cutoff. I also have an issue with the left headlight (cutoff point is more yellow) and I'm not sure if it's because of spacing of the lens or the cut off shield.

I based my opinion off this website.

http://forums.swedespeed.com/showthr...000K-35W/page2

I am thinking of trying to fix it myself...

[Alvine90]

so that means e90 pre lci and lci need sti-r and coupes use zkw-r since their projectors are similar to the e46 bosch al

[kisho]

Aren't both of those 3" lenses?

[e90TiAg335i]

Originally Posted by kisho

Aren't both of those 3" lenses?

Yes they are but the focal point is different.

[kisho]

Originally Posted by e90TiAg335i

Yes they are but the focal point is different.

Ahh ok. Thanks for the tip.

[Sherj]

Here is a good thread on how to do the swap on LENS swap E92 http://www.m3post.com/forums/showthread.php?t=847884. I also added some additional images myself to make the whole process a little bit more easier, it is on page 2.

[Reckless335]

Not exactly sure the purpose of the "step" in the cutoff, but isn't it to determine where the center of the light is? If you have just a straight line going across, how will you tell where the center of the beam is when you go to center them? Center on the horizontal axis obviously

[4doorbmwpower]

so gents... i read all of this and my question is.. for my 2007 BMW 335i E90, what lenses do i need. i am currently getting my headlights completely customed and want to do this also. From my understanding i need x2 3'' ZKW-R (what stock, A, B, hella?) and thats it? arent there two lenses in each housing? for the Bixenon AHL lights? im not to smart on lights.. turbos i got you but lights... not me. all help accepted

[4doorbmwpower]

orrrrr sti-r... i think? and what specific one are there different "stocks" for them also