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In Reply to: Demon Eyes help, posted by BmwE38 on February 03, 2002 at 11:35:41:
1. Remove the headlights as per the 2001 installation pdf that Bruce posted here. There is no difference in the removal steps for the 95-98 and 99-2001 versions.
2. Once out of the car, remove the glass covers by releasing the metal spring clips, again this is the same as the 2001 steps.
3. Remove the lens frame by removing the three torx screws located at the top corners and one in the bottom center.
4. Remove the plastic diffusion lenses from the frame by lifting slightly on the clip at the top rear, and pull lens toward the rear to remove.
5. Glue LEDs in the holes at the end of the rings same as the 2001 steps.
6. Place rings with LEDs on the front of the difussion lenses centering them and holding ihn place with masking tape or equivalent. Mark the spot where the leds leads are + 1/16" so that you a hole in the plastic lens at this point will allow the leads to bend and pass through the lens.
7. Drill holes at these marks, @ 1/4" in diameter or the next smaller drill in my set which made it a bit tighter fit which I liked for securing the rings (7/32")
NOTE: when drilling holes in plastic lens, support them from the bottom with a piece of wood so that the pressure from the drill is not going to crack the plastic lens, also use a medium-slow speed and sharp drill bits are a must.
8. Once the holes are drilled bend the LED leads @90 degrees so they pass through these holes when fitting the rings back onto the front of the lenses. A few adjustments may be needed at this step, but this is normal.
8. Once it fits well, remove the rings and place some black shrink tubing over the ends of the rings and the LED leads so that the LED cannot be seen from the front of the headlight and the leads are covered. see 2001 instructions for a photo of this step.
9. Now replace the rings with shrink tubing in place, and bend the LED leads all the way back against the lens to hold the securely in place at these two points. I bent them so that the leads were hidden behind the rings itself.
10. Using a clear adhesive, (Silicone or epoxy) attach the rings to the difussion lenses at three points around the ring placing the glue so that it is a small dab not a large glob. The glue points will show up if they are too large, so keep them small.
11. Allow to dry, then reinstall the lenses with rings into the frame.
12. Wire the LEDS to each other adding resistors as per the 2001 instructions.
13. Drill or find a place to allow the wires to exit the headlight assembly. Use rubber grommet or silicone to seal the exit point from moisture.
14. Route wires and attach with wire ties or other clips to keep them out of the lighted area of the housing.
15. Attach the lens frame with lenses and rings into the headlight assembly, and reinstall glass covers.
15. Reinstall headlight into car (reverse of removal above)
16. Run the LED wires to the turn signal hot lead and ground per the 2001 instructions. Make sure the exposed wires are covered with tape or rubber tubing to protect tham and make them look like original wiring.
17. Enjoy!!!
Email me with questions if this is not clear, and I'll get my photos developed ASAP.
John
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