RAVE: Somai Tech - E46 330i Bi-Xenon Projector Upgrade

AdiS

Well-known member
My 2004 E46 330i did not come with xenons fitted from the factory, and being the headlight snob that I am, I retrofitted factory xenons in the same week I got the car.

Then Serg_za purchased an HID + Projector conversion kit from Vsomai for his E46 330ci, and when we compared the output of his headlights to mine, I was kind of embarrassed.

Mine are on the left, Sergio's on the right (the projector alignment is a little off).

IMG-9741.jpg


I had always thought about doing a projector upgrade, and this gave me the push I needed. So I ordered the Morimoto D2S 4.0 projectors which at the time were the best available.

I put off fitment for quite a while because I knew it was a finicky job and I wanted it done right. So when it came down to it, I knew there was only one person for the job and that was Vsomai.

So a few weeks ago, I boxed up my headlights and shipped them off to Vishal to have the new projectors fitted into my OEM xenon headlights.

The fitment of these specific projectors were not necessarily straight forward, and Vishal was really excellent at adapting on the fly and even interacting with the original seller of the projectors. He got the install done inside of 12 hours, and my headlights were on their way home back to me inside of 36 hours. Really impressive turnaround time!

The results are simply spectacular. Below is a controlled comparison between my old projectors and the new ones. These were photographed in the exact same location, same distance from the wall, same exposure settings on my camera.

Before:
IMG-2858.jpg


IMG-2853.jpg


After:
IMG-2872.jpg


IMG-2871.jpg


Comparison:
IMG-2858-copy.jpg


IMG-2853-copy.jpg


Some more pics of the new light output:
IMG-2904.jpg


IMG-2909.jpg


IMG-2908.jpg


IMG-2907.jpg


As you can see, not only is the cutoff now razor sharp, but the spread of light is so much better - the light is much more evenly distributed with a huge hotspot in the centre.

I feel that these pictures don't really do the real-world difference justice. Having driven around now for 2 weeks, I notice the headlights shining on objects much further away than before. When driving home in the afternoon on a cloudy day, it is still light outside but with my headlights on i see the light and cutoff on buildings and cars when I saw nothing before.

Now its worth pointing out that my headlights were from a scrapyard and I think that contributed to some of the poor projector output, but I compared to my Z4 M factory xenons and these projectors are still way better.

If I had to do it all again, I wouldn't have bothered importing the 4.0s, I would have just gone with the FX-R's that Vsomai has in stock. Honestly, if this is something you want to do, just go with the stuff that Vishal has in stock, it will work out cheaper and easier. You also don't have to go the D2S route like I did, there are other projector kits like Serg used which will work on halogens and provide a very similar result.
 

Tinuva

Staff & Webmaster
Staff member
excellent upgrade!! :praise:


@AdiS - what about some pics of the headlights with the new projectors in?


Also, you pics do show sortoff what I see between 2 different headsets that I retrofitted as well to my and the wife's cars. The lines are much sharper on mine than on hers.

It does show that these lights have aged, and that they dont all age equal.
 

Divio

Honorary ///Member
Wow, that's the kinda results I need!

I reallllllly neeed to do this on my Ci,

I've tried H7 OEM's, Osram Nightbreaker + , Phillips Diamond Vision's then 35w & 55w HID's, from 4300k to 6000k and still my cellphone torch is brighter than all those combined.
:rofl:

It's these damn halogen projector's I have.....

A projector retrofit (with angel eyes) seem's to be the only way to go....

Just a Q on sealing...
How will it hold up with condensation etc, considering the facelift Ci's housing's are glued together....

clipboard02_7442864464.jpg
 

Blue Shirt

Well-known member
I have also installed OEM xenon headlights on three E46 cars, but I have disassembled the projectors and cleaned the lenses which were quite foggy and dusty.

The light output and cutoff was noticeably improved afterwards, although the light cutoff is still not as sharp as those shown in your pics of the aftermarket projectors.
 

AdiS

Well-known member
Divio said:
Just a Q on sealing...
How will it hold up with condensation etc, considering the facelift Ci's housing's are glued together....

I'm sure Vishal will be able to advise on this.

Blue Shirt said:
I have also installed OEM xenon headlights on three E46 cars, but I have disassembled the projectors and cleaned the lenses which were quite foggy and dusty.

The light output and cutoff was noticeably improved afterwards, although the light cutoff is still not as sharp as those shown in your pics of the aftermarket projectors.

Yea, look in brand new condition the OEM projectors aren't as bad as my pics would suggest, but the technology has obviously moved on a lot since the early 2000s.
 

Clint@MMS AUTO

BMWFanatics Advertiser
Official Advertiser
Oooh AdiS, did I read correct, You have a Z4M?

Pls show us when u have a chance.

Excellent work with the headlight projectors. :bravo:
 

TBP88

Well-known member
Also here for the "WTF Z4M pleasure" comments :)

Light spread looks great, my Z4M lights are like driving with two cellphones showing the way :(
 

Tinuva

Staff & Webmaster
Staff member
@AdiS

With the new projectors and bulbs, I assume you still use the OEM ballast+igniter? Would hate having the after market things hanging around in the engine bay.

Also I assume the bi-xenon would still work if that was wired in, or will the new projector not have the flap for that?
 

AdiS

Well-known member
Tinuva said:
@AdiS

With the new projectors and bulbs, I assume you still use the OEM ballast+igniter? Would hate having the after market things hanging around in the engine bay.

Also I assume the bi-xenon would still work if that was wired in, or will the new projector not have the flap for that?

Yes, in both cases.

In my specific situation, I had previously elected to replace the OEM ballasts with OEM Hella ballasts that are used in the E39 xenons. This is because the E46 ones fail like crazy, and the E39 Hella ballasts are super reliable and have the fastest warm-up times. But this is entirely irrelevant to a projector upgrade.

As long as you buy projectors that are bi-xenon, they will work with some wiring. I have yet to complete the wiring on mine, so right now I am running with halogen brights only. But I plan to remedy this when I have time.
 

rodga

Well-known member
Did you upgrade the angel eye rings at all?
Im looking to upgrade the AE on my e39 lights. Any suggestions?
 

Blue Shirt

Well-known member
AdiS said:
In my specific situation, I had previously elected to replace the OEM ballasts with OEM Hella ballasts that are used in the E39 xenons. This is because the E46 ones fail like crazy, and the E39 Hella ballasts are super reliable and have the fastest warm-up times. But this is entirely irrelevant to a projector upgrade.

I was not aware of the possibility to use E39 ballasts. Is it a direct replacement or how involved is the conversion?
 

AdiS

Well-known member
rodga said:
Did you upgrade the angel eye rings at all?
Im looking to upgrade the AE on my e39 lights. Any suggestions?


The E46 doesn’t have angel eye rings, and the aftermarket ones don’t look right to me.


Sent from my iPhone using Tapatalk


Blue Shirt said:
I was not aware of the possibility to use E39 ballasts. Is it a direct replacement or how involved is the conversion?

So it turns out that they can be quite easily used. I bought a used pair here: https://www.hidprojectors.com/collections/ballasts/products/hella-gen3-ballasts-35-watt-used

They are D2S, so all the plugs fit, you just have to find a way to get the igniter wire into the headlight to plug into the D2S bulb. I kind of hacked it, but it works and the quality and performance of the ballast is what matters most to me.

Vsomai was able to mount the ballast itself in the OEM ballast location by making a bracket.

<img src="https://i.ibb.co/qdjxNw2/IMG-1706.jpg" alt="IMG-1706" border="0" />
 
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