Hedlights W211 E55 to E63 Conversion
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From: CA
MB
Hedlights W211 E55 to E63 Conversion
Hi all, as I promise to some of you guys, here is my post how I did the hedligth conversion from old style to new style (E55 to E63) also you can check https://mbworld.org/forums/w211-amg/355829-e55.html for more pictures of my E63 conversion. This work as factory on my car, all MB OEM parts, if you try to follow my instructions I am not responsable for any damage, all your own risk 
Conversion was from non Xenon to non Xenon
Parts you need :
Male Socket PN 211 545 11 28 (as description this is a male plug)
Pin Bushing PN 023 545 0626 (this is another male plug)
Contact PIN PN 000 540 3805 you need ten (10) for non xenon(16) for Xenon
(contact pin is a male pin adaptor (single) with a wire attached from factory, so you can insert this part inside of a male plug to made a contact.
(The male plugs are emty, no wires inside, you need to set up the plug)
Conversion was from non Xenon to non Xenon
Parts you need :
Male Socket PN 211 545 11 28 (as description this is a male plug)
Pin Bushing PN 023 545 0626 (this is another male plug)
Contact PIN PN 000 540 3805 you need ten (10) for non xenon(16) for Xenon
(contact pin is a male pin adaptor (single) with a wire attached from factory, so you can insert this part inside of a male plug to made a contact.
(The male plugs are emty, no wires inside, you need to set up the plug)
Thread Starter
Super Member
Joined: Dec 2004
Posts: 921
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From: CA
MB
First, you have to remove the front bumper, thanks to yatch master, check his link how to remove the front bumper.... The picture is in reference at the old style non xenon headlight, you can see the plugs (4) but one is w/o connection, (plug with 3 wires connected to the headlight but this wires are not conected to anything this plug is for xenon headlights) so if you have xenon you will see the female conector at the headlight.
Note: If you switch non xenon for Xenon (same old style) you just need to plug this connector to your xenon headlight, the xenon headlight will have a real female conection, then plug the rest, do the star diagnostic for xenon recognize... and you will have xenon lights
Note: If you switch non xenon for Xenon (same old style) you just need to plug this connector to your xenon headlight, the xenon headlight will have a real female conection, then plug the rest, do the star diagnostic for xenon recognize... and you will have xenon lights
Thread Starter
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Joined: Dec 2004
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From: CA
MB
What you see in this picture is 4 plugs, plugs that you disconect from your headlight, like I said, if you have Xenon you have use for all 4 plugs, if not you still have all 4 connected but you only use 3 plugs.
Thread Starter
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Joined: Dec 2004
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From: CA
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This picture show PN 000 540 3805 called Contact PIN, is the connector with the white wire, each wire represent one part in this case, for this reason you need 10 (ten) for non xenon conection, 16 for xenon. I connect w/o the plug for test, the hard part is all the new wires are the same color (white), so you need to be very careful not to cross wires at the time you do the connection, go one by one, you dont want the blinker on when you need the highbeam 
Thread Starter
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Joined: Dec 2004
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From: CA
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This is the best part... this work for me, remember everything you do is your responsability...
Each number on your left represent the conector number, the conector show the numbers printed, you can miss it. Each side, driver and passenger have different wiring colors
WIRING
Driver Side:
1) Ground - Brown color (you can put all brown together)
2) Low beam - Yellow / Black
3) Hi beam - White / yellow
4) Park lamps - Thing black/white, located on a small connector above the hi beam plug
5) Signal - black / grey located on the main conector
Passenger side:
1) Ground - Brown
2) Low beam - Yellow (just yellow, this is different front driver side)
3) Hi Beam - White/yellow
4) Park lamps - grey/red (different than driver side)
5) Signal - Black/grey (different than driver side)
what I do, I incert (for example) wire #1 to the conector, then I connect to wire number one (brown color), you can cut the female connector from your car and connect wire to wire or just tap the wire so you don't need to cut anything, (I tap the wire), then I do wire #2, etc. one by one, take some time but you will do a better job.
The picture show the new plug with all wires (contact pin) in the plug, showing in my new dusty headlight, the new headlight will have one plug, not four (4) if you have Xenon will show two plugs.
Each number on your left represent the conector number, the conector show the numbers printed, you can miss it. Each side, driver and passenger have different wiring colors
WIRING
Driver Side:
1) Ground - Brown color (you can put all brown together)
2) Low beam - Yellow / Black
3) Hi beam - White / yellow
4) Park lamps - Thing black/white, located on a small connector above the hi beam plug
5) Signal - black / grey located on the main conector
Passenger side:
1) Ground - Brown
2) Low beam - Yellow (just yellow, this is different front driver side)
3) Hi Beam - White/yellow
4) Park lamps - grey/red (different than driver side)
5) Signal - Black/grey (different than driver side)
what I do, I incert (for example) wire #1 to the conector, then I connect to wire number one (brown color), you can cut the female connector from your car and connect wire to wire or just tap the wire so you don't need to cut anything, (I tap the wire), then I do wire #2, etc. one by one, take some time but you will do a better job.
The picture show the new plug with all wires (contact pin) in the plug, showing in my new dusty headlight, the new headlight will have one plug, not four (4) if you have Xenon will show two plugs.
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Joined: Dec 2004
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From: CA
MB
This is the way how I tap the wires, this prevent to cut any wire from my car, you can get this to tap wires at any store like kragen, pep boys, southern auto, auto zone... also wallmart, k-mart, also the Cotact Pin wires are to long so I cut about 3 inches of each one. one by one, insert one wire to the plug, check the number in the plug, then look for the wire color on your car connector, tap it, continue with the next one....
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Thread Starter
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Joined: Dec 2004
Posts: 921
Likes: 36
From: CA
MB
Be clean !!! put the wires in order, use a wire tubing, use black tape and cover the conectors realy good, use a good brand of black tape. not a $1.00 store black tape, wrap not one or two times the connector, do at least 3 times !! now show one wire, one conector ... ready for the new style headlight !!
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Joined: Sep 2008
Posts: 3,575
Likes: 8
From: BC
Haters crazy
Nice! They look great. The only thing that stopped me from getting them was the fact you lose the bixenon and adaptive cornering functions, unless you buy the actual oem ones. I know the aftermarket ones self level.
MBWorld Fanatic!
Joined: Apr 2008
Posts: 2,540
Likes: 5
From: Arizona
2004 E55, 1997 E320 "Sold"
Those look sharp! I think I am going to just buy the different rings when I do my conversion and paint them black along with the grille. 
http://cgi.ebay.com/ebaymotors/Chrom...Q5fAccessories
http://cgi.ebay.com/ebaymotors/Chrom...Q5fAccessories
Junior Member
Joined: Feb 2006
Posts: 36
Likes: 0
From: Gothenburg, Sweden
2001 E55 AMG, 2004 E320 CDI
Excellent info as I am doing the same conversion but Xenon -> Xenon!
Do you, or anyone else, know how to wire up the xenon part too?
One thing that confuses with the new ones is that i have three connections on the driver side and only two on the passenger side. Both are oem ones and looks identical apart from the connections. Have seen the upper one plugged at another car so hopefully this isn't needed.
Thanks again for a great and very helpful post!
Do you, or anyone else, know how to wire up the xenon part too?
One thing that confuses with the new ones is that i have three connections on the driver side and only two on the passenger side. Both are oem ones and looks identical apart from the connections. Have seen the upper one plugged at another car so hopefully this isn't needed.
Thanks again for a great and very helpful post!
Newbie
Joined: Sep 2011
Posts: 11
Likes: 0
e class w211
Excellent info as I am doing the same conversion but Xenon -> Xenon!
Do you, or anyone else, know how to wire up the xenon part too?
One thing that confuses with the new ones is that i have three connections on the driver side and only two on the passenger side. Both are oem ones and looks identical apart from the connections. Have seen the upper one plugged at another car so hopefully this isn't needed.
Thanks again for a great and very helpful post!
Do you, or anyone else, know how to wire up the xenon part too?
One thing that confuses with the new ones is that i have three connections on the driver side and only two on the passenger side. Both are oem ones and looks identical apart from the connections. Have seen the upper one plugged at another car so hopefully this isn't needed.
Thanks again for a great and very helpful post!
Newbie
Joined: Sep 2011
Posts: 11
Likes: 0
e class w211
First, you have to remove the front bumper, thanks to yatch master, check his link how to remove the front bumper.... The picture is in reference at the old style non xenon headlight, you can see the plugs (4) but one is w/o connection, (plug with 3 wires connected to the headlight but this wires are not conected to anything this plug is for xenon headlights) so if you have xenon you will see the female conector at the headlight.
Note: If you switch non xenon for Xenon (same old style) you just need to plug this connector to your xenon headlight, the xenon headlight will have a real female conection, then plug the rest, do the star diagnostic for xenon recognize... and you will have xenon lights
Note: If you switch non xenon for Xenon (same old style) you just need to plug this connector to your xenon headlight, the xenon headlight will have a real female conection, then plug the rest, do the star diagnostic for xenon recognize... and you will have xenon lights
Member
Joined: Jun 2007
Posts: 209
Likes: 11
From: New Jersey
'04 E55 AMG
Would love some more details. I went ahead with a e55 xenon/auto level to e63 bi-xenon/auto level. My low beams work, high-beams work with the old halogen bulbs, LED city bulbs and blinkers work. Bi-xenon solenoid isn't triggered, auto-level will come on 1 minute after starting car or turning lights on, and will adjust once each time the high-beam is triggered. Haven't looked into it much.
