DIY bixenon upgrade
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2000 S430
DIY bixenon upgrade
This post is the one I wish I had found when I went searching for how to upgrade my 2000 S430 with old xenons to 03-06 bi-xenons:
First, thanks to Frank, S500man, 2H S5, Skylaw and others who posted this info in various places.
Parts needed:
2 bixenon lights (various part #'s, but mine were A220 820 27 61 and A220 820 28 61)
2 5mm x .8 x 30mm bolts
2 5mm washers
2 high beam plugs (5-pin) A220 545 46 28
2 wires for high beam plugs A000 540 39 05
2 16 gauge U-blade wire ends for high beam wires
2 auto level plugs (4-pin) A000 153 08 42
8 wires for autolevel plugs A000 540 38 05
8 18 gauge splice couplers
** DO ALL WORK WITH CAR AND LIGHTS TURNED OFF**
1. Look at your new lights: They have 3 integrated male connector ports; a 6-pin, a 5-pin, and a 4-pin;
The 6 pin fits your existing 6 pin female plugs on your old lights without modification. If you only connect this part of your old harness to your new lights your low beams will work, but nothing else will. You will get turn signal malfunction messages.
The 5-pin (high beam) connector port only uses 3 pins. Pop open the plastic bulb door above this port. You will see a thick brown wire going from the bulb down to the far (driver's) side end of the port. This is true on both lights, so keep in mind the wiring on each light is not a mirror-image of the other.
The 4-pin is your auto level. You can drive without this and the lights will work fine, but some places may outlaw xenons without auto level mechanisms-so I've heard.
2. Assemble your wires into your 5-pin plugs: Push the female end of one A000 540 39 05 wire into the back of the high beam (5-pin) A220 545 46 28 plug (until it clicks into place) so that when the plug is inserted into the 5-pin port on the light, the new wire connects to the brown wire you observed in step 1. The other 2 wires in this port will not be used, so your 5-pin plug will have only one wire in it. Note the plugs are keyed so they can only be inserted one way into each light. Repeat for the other plug for the other light, noting that the wiring in the lights and therefore in your plugs cannot be mirror images of each other. Cut the male plug ends off, strip the insulation and crimp on the 16 gauge U-blade wire ends.
3. Remove your old lights: This means removing 2 bolts on the light (on top and on the inboard end) and 2 bolts on the bumper (in front of the radiator). Carefully loosen up the bumper and the lights from their mounts. Then pry out the bumper near the inboard corner of the light as you massage your headlight to come out. You do not need to pry the bumper much, or cause any damage to the car. Be careful not to force the light against the fender or bumper much. Watch where the light passes by the bumper on the underside too. It may seem impossible at first, but patience will prevail. The light will need to be yawed and rolled a bit to come out. Once you've done one, the rest are easy removal and installation. I did it without a helper and it worked fine.
4. Assemble your wires into your 4-pin auto level plugs: Insert the female ends of the A000 540 38 05 wires into the back of the new (4-pin) A000 153 08 42 plugs until they click into place. Cut off the male ends. The new plugs are labelled 1-4 next to each wire. Cut the wires to the old plug and splice them to the new wires, matching blue to 4, black to 3, red to 2, and green to 1.
5. Install your new lights: Use the longer 5mm x .8 x 30mm bolts with washers to secure the lights.
6. Insert your plugs into the lights: Attach the U-blades to a nearby chassis ground.
7. If you didn't have old xenons, you will need to get a dealer to activate xenons in your computer.
Done!
I was on the fence about if I should do this mod. I found a set of new OEM bixenons on ebay for $850 and did it- It is a great mod- the bling factor refreshes the whole car.
DIY bixenon bi-xenon xenon old new installation 2000 2001 2002 2003 2004 2005 2006
First, thanks to Frank, S500man, 2H S5, Skylaw and others who posted this info in various places.
Parts needed:
2 bixenon lights (various part #'s, but mine were A220 820 27 61 and A220 820 28 61)
2 5mm x .8 x 30mm bolts
2 5mm washers
2 high beam plugs (5-pin) A220 545 46 28
2 wires for high beam plugs A000 540 39 05
2 16 gauge U-blade wire ends for high beam wires
2 auto level plugs (4-pin) A000 153 08 42
8 wires for autolevel plugs A000 540 38 05
8 18 gauge splice couplers
** DO ALL WORK WITH CAR AND LIGHTS TURNED OFF**
1. Look at your new lights: They have 3 integrated male connector ports; a 6-pin, a 5-pin, and a 4-pin;
The 6 pin fits your existing 6 pin female plugs on your old lights without modification. If you only connect this part of your old harness to your new lights your low beams will work, but nothing else will. You will get turn signal malfunction messages.
The 5-pin (high beam) connector port only uses 3 pins. Pop open the plastic bulb door above this port. You will see a thick brown wire going from the bulb down to the far (driver's) side end of the port. This is true on both lights, so keep in mind the wiring on each light is not a mirror-image of the other.
The 4-pin is your auto level. You can drive without this and the lights will work fine, but some places may outlaw xenons without auto level mechanisms-so I've heard.
2. Assemble your wires into your 5-pin plugs: Push the female end of one A000 540 39 05 wire into the back of the high beam (5-pin) A220 545 46 28 plug (until it clicks into place) so that when the plug is inserted into the 5-pin port on the light, the new wire connects to the brown wire you observed in step 1. The other 2 wires in this port will not be used, so your 5-pin plug will have only one wire in it. Note the plugs are keyed so they can only be inserted one way into each light. Repeat for the other plug for the other light, noting that the wiring in the lights and therefore in your plugs cannot be mirror images of each other. Cut the male plug ends off, strip the insulation and crimp on the 16 gauge U-blade wire ends.
3. Remove your old lights: This means removing 2 bolts on the light (on top and on the inboard end) and 2 bolts on the bumper (in front of the radiator). Carefully loosen up the bumper and the lights from their mounts. Then pry out the bumper near the inboard corner of the light as you massage your headlight to come out. You do not need to pry the bumper much, or cause any damage to the car. Be careful not to force the light against the fender or bumper much. Watch where the light passes by the bumper on the underside too. It may seem impossible at first, but patience will prevail. The light will need to be yawed and rolled a bit to come out. Once you've done one, the rest are easy removal and installation. I did it without a helper and it worked fine.
4. Assemble your wires into your 4-pin auto level plugs: Insert the female ends of the A000 540 38 05 wires into the back of the new (4-pin) A000 153 08 42 plugs until they click into place. Cut off the male ends. The new plugs are labelled 1-4 next to each wire. Cut the wires to the old plug and splice them to the new wires, matching blue to 4, black to 3, red to 2, and green to 1.
5. Install your new lights: Use the longer 5mm x .8 x 30mm bolts with washers to secure the lights.
6. Insert your plugs into the lights: Attach the U-blades to a nearby chassis ground.
7. If you didn't have old xenons, you will need to get a dealer to activate xenons in your computer.
Done!
I was on the fence about if I should do this mod. I found a set of new OEM bixenons on ebay for $850 and did it- It is a great mod- the bling factor refreshes the whole car.
DIY bixenon bi-xenon xenon old new installation 2000 2001 2002 2003 2004 2005 2006
Last edited by mcssci; May 1, 2008 at 11:26 AM.
Member
Joined: Apr 2004
Posts: 188
Likes: 3
From: Orange County
2011 Sienna SE, 01 S500, 05 LS430 UL
mcssci-I got your pm.
I apologize for not responding earlier but I updated my post with pictures with some of your wordings.
Glad you figured it out
Have you verified if the autolevel works properly?
https://mbworld.org/forums/newreply....te=1&p=2701754
I apologize for not responding earlier but I updated my post with pictures with some of your wordings.
Glad you figured it out
Have you verified if the autolevel works properly?
https://mbworld.org/forums/newreply....te=1&p=2701754
Last edited by 2H S5; May 28, 2008 at 09:05 PM.
