DIY Headlight Kit Installation Guide

2 min read
DIY Headlight Kit Installation Guide - Bushdoof Lighting
Important Notes

Ensure all components are tested prior to Installation.
Download and pair Bluetooth apps below before starting to ensure functionality.
Headlight removal, wiring and installation guide available Here

Video Guide:


 

Overview:

This guide covers the process of retrofitting the Bushdoof DIY Headlight Kits into your existing headlights. Headlight removal and installation in the car are detailed in our Bi-LED Installation Guide, linked above.

What you'll need:

  • Screwdrivers
  • Trim removal tools (or a flat blade screwdriver can be used)
  • Multigrip
  • Spray paint & primer (optional, if custom painting)
  • Oven
  • Silicone

Step 1: Preparing Headlights

 

  • Remove all screws and unclip any clips securing the headlight together.
  • Remove the factory globe and globe holder(s) from the headlight.
  • Preheat oven to 100°C - 120°C (non-fan forced).
  • Place headlight in the oven for 3 - 5 minutes or until glue softens.
  • Slowly work around the headlight to carefully separate the lens from the housing.
  • Repeat steps for the second headlight
  • If you wish to paint chrome pieces, remove them now.
  • Prepare, prime, and paint any parts as desired.
  • Once painted & dry, reassemble all pieces.

 

Step 2: Projector Installation

  • Slide the billet washer (if Bi-LED) & then rubber shock absorber over the projector.
  • Insert the projector into the headlight, ensuring wiring exits at the rear (drill holes if necessary).
  • Slide the H4 locking washer over the back of the projector (use tab-less washer to allow for rotation adjustment).
  • Align projector with the divot facing perpendicular to the ground.
  • Install the locking nut and tighten securely.
  • Insert moisture pack and breather if required.


Step 3: Resealing Headlights

  • Ensure no dust, fingerprints, or marks are present inside the headlight.
  • Fit the front lens back onto the rear housing.
  • Preheat oven again to 100°C - 120°C (non-fan forced).
  • Place headlight in oven for 3 - 5 minutes or until glue softens.
  • Work your way around the headlight slowly pressing it together.
  • Install all screws and clips, ensuring a complete seal around the headlight.
  • Once the lens is sealed, reinstall the park light and indicator light globe holders to fully seal the unit.
  • Refit rubber boot and apply silicone sealant to waterproof if necessary.


Next Step

 


Wiring Diagram:

Downloads:

Have any questions?

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