6SpeedOnline - Porsche Forum and Luxury Car Resource - DIY: Porsche 997 Turbo: OEM Koito Bi-xenon Clear Lens Swap

Car's been down for a few weeks getting some other things done to it (Turbos, diverter valves, interior, etc) so I figured what better time than to improve the light output from the factory Koito bi-xenon projectors in my 997.1TT. The factory headlight projectors are also found in the Nissan Murano, 370Z, and Bentley Continental GT. Unmodified, they have a 3" fresnel lens and actually perform really well (naturally, being a Japanese- made, Koito product)

The OEM ballasts are Denso's 35w D2 units, and it came from the factory with standard Philips 85122 4300K D2S bulbs.

A headlight junky for a living, stock lighting isn't really my thing :)

This mod will work for all 997.1 Carrera's, Turbos, Boxsters, and Caymans. It will not work for the 997.2 or Cayenne headlights since they're not made by Koito (I believe they're AL or Valeo units)

The parts used for the upgrade:
- Osram D2S CBI 5000K bulbs: http://www.theretrofitsource.com/pro...ducts_id=10591
- STi-R clear lenses: http://www.theretrofitsource.com/pro...products_id=85

Lets get started by carefully removing the OEM rubber weather stripping from the outside of the housing. Just un-clips from a few points around the outside edge.

Attachment 494994

Attachment 494995
Next, we'll start to remove the front lens cover on the housing. Unlike a typical Koito headlight, its not sealed with Butyl rubber. Heat does nothing to the glue, so I didnt bother. A screw driver and some prying/scraping around the perimeter of the housing will do the trick. Dont use too much force, just enough to pop the seal between the lip on the rear-side of the front lens cover and the glue holding it in. Eventually, you can just lift it right off. Ta Da!

Attachment 494996

Attachment 494997

http://www.hidplanet.com/forums/atta...5&d=1335478202

Next, wrap up the lenses with serran wrap or something to keep the under-side from getting dusty. Nothing (NOTHING!) worse than dusty or scratched up insides of headlight lenses, ya dig?

http://i1049.photobucket.com/albums/...nsUpgrade7.jpg

Now we've gotta remove the chrome trim bezel inside the housing. Pretty easy. Just need to remove these two T20 Torx security screws on the bottom.

Attachment 494998

After the torx screws are removed, you can just use some light pressure and a big flat blade screw driver to push the trim out the front of the housing. There's nothing holding it in except for a bit of friction.

Attachment 494999

Attachment 495000

From here, we've got access to the projector. There are 2 screws that hold the lens retainer ring onto the front. Using a Philips screwdriver, the lens retainer and original fresnel projector lens can easily be removed.

One screw: Two screw:
Attachment 495001

Attachment 495002

All apart:

Attachment 495003

Now, its time to install the STi-R clear lens. But before that, make sure it's clean too. dust and fingerprints on the back-side of a projector lens are not cool.

Attachment 495004

Before you put the lens in, put in the metal spacer ring that normally comes with the STi-R clear lenses. (don't use the original green paper spacer along with it though)

Attachment 495005

Lens Spacer Installed:

Attachment 495006

Now re-install the STi-R clear lens in reverse order. Should be pretty easy. Tighten one side, then the other, then go back - to make sure the lens is seated perfectly centered/flat on the face of the projector.

Mmmmmm clear lens goodness

Attachment 495007

Now, it's time to re-seal the headlight. Before then, you will want to clear as much of the the original glue from the channel on the black rear housing. This step sucks because it's not very exciting, but realistically spending a half an hour scraping glue isn't as bad as a headlight full of moisture after it's rained, or you washed the car, so dont skip this step!

Glue scrapage:
Attachment 495008

From there, you can re-fill the channel with a fresh bead of silicone caulk. I used black RTV since it has about the same consistency as the original glue once dry.

Attachment 495009

Check out my super cool TRS logo on the bezel. The mark of goodness http://www.hidplanet.com/forums/imag...lies/smile.png

Press the front lens back onto the housing, making sure that all of the clips etc are aligned and it's fully seated back into the channel. Let dry, and enjoy!

Now, a quick before and after shot. (both of which are using the upgraded Osram CBI bulb)

Three things to notice:

1) Much better definition/sharpness to the cutoff line at the top of the beam pattern

2) More vivid color across the span of the cutoff line - as this band of colorful light passes in and out of the field of vision of on-lookers, it greatly enhances that "color flicker" effect they see from your headlights. So you get the exotic looks of high Kelvin bulbs (8000K etc) without the downside of reduced luminosity. (its important to note that as you move up the kelvin scale for HID bulbs, the intensity/luminosity goes down)

3) More intense light throughout the beam pattern for better down the road visibility, extra width, etc. Of course the more light that can pass through the glass on the front of the projector, the brighter it will be.

Cheers!

http://i1049.photobucket.com/albums/...oClearLens.jpg

Attachment 495010