2 Bi-Xenon Projectors from Infinity FX.
2 D2S Xenon Bulbs.
2 Ballast from Infinity FX.
1 5/16 threaded rod from Home Depot.
3 bags of nuts 5/16 from Home Depot.
3 bags of washers 5/16 from Home Depot.
2 packs of JB Weld from Home Depot
Some Primer.
Metallic Black Paint from Home Depot
Some Wires.
HID Planet Forum I learned a lot from this forum
Steps I took to Install FX Projectors into 4Runner Headlights:
1. Remove headlights.
2. Glass needs to be removed before you can proceed with retrofit.
3. Remove bulb from headlight.
4. Remove Headlight from Mounting Bracket.
5. Preheat Oven to 350, turned it off and put your headlight on a shelf for 6-8 min, Be careful not to overheat or it can melt the housing. Using a Flat Screwdriver or pottery knife carefully try to pry off the glass from housing, BE VERY CAREFUL not to brake the glass. The glass should separate from the seal. Picture of the headlight with glass removed.
6. You need to make a hole where original bulb was inserted much bigger so the rear of the projectors could be inserted. I used 2 ½ inch Hole-saw to do the job. Picture of the New Hole, Original Hole
7. I had to cut off original mounting brackets from FX Projector to make them more compact.
8. For each projector I cut 4, 3 inch long threaded rod for the one I got from Home Depot. Total of 4 nuts and 4 washers were used to create a mechanism that gets through the Headlight housing and will hold the projector in place. See picture
9. Make sure your projectors are clean inside, if not dissemble them and using 70% alcohol and Q- tips clean lenses and reflectors, DO NOT APPLY PRESSURE or you will scratch the reflectors. I also used Glasses cleaner pad to wipe it dry.
10. Alight projector against New Hole of the back of the housing, make sure that projector is completely horizontal to the housing (This is very important because alignment will create Horizontal Cut off line. If it’s not properly aligned you will have problem-aligning headlights.) Mark location for support rods and drill holes.
11. Make sure everything fits and reinstall headlight to make final adjustment to the projectors against the wall. Alignment Instructions
12. Tighten nut at the rear of the Original headlight housing I used blue thread lock on all nuts.
13. Don’t over tighten or you will break the housing.
14. You’re headlight now is almost completed.
15. Now you need to seal all the holes that were created in this process.
16. I used JB Weld compound for this purpose, some people use Hi Temperature silicone, Choice is yours.
17. Let it dry before doing anything else.
18. I didn’t want to leave projector open and wanted to cover an opening so it would look more like original installation. So, I cut a template out of cardboard and test fit it until I was satisfied with how it fits inside.
19. I then transfer template to a thin aluminum that I had in my garage and Cut out a faceplate. Some people use acrylic(like a mirror finish) for the face plate, I learned about it only after my retro was completed.
20. I new that I’ll be painting headlights with Metallic black paint so I sanded everything with 400 grids of send paper, cleaned it very well and attached newly created face plate to the projector housing with JB Weld and let it dry.
21. After everything was dried I covered projector lenses with Blue 3M tape and applied few coats of primer. Make few thin coats and then apply few coats of paint, Let it paint dry slightly between coats. Let it dry over night. Picture of completed headlight without glass.
22. To seal back headlight follow step 5, attach glass to the headlight with little pressure and put it in the oven for 6-8 min. After removing from an oven squeeze glass and headlight housing together, this will seal the glass, like the original.
23. Reinstall headlight into bracket, and install it back on your truck.
24. Realign both headlights following Alignment Instructions
25. For the wiring I decided to contact one guy that specializing in building custom harness, I simply didn’t have time to learn about making one which is not that hard just time consuming) The harness pugs in to existing H4 connectors from out headlights and utilize signal from Low and Hi beam to power Lo/Hi beam on Bi-Xenon projectors.
Take your time, don’t rush things and you’ll have beautiful retrofit. I was simply amazed how much my lighting improved. God luck with your project.
