VXOC Astra-J/GTC

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This How to will Cover How to fit the Mini H1 2.5 HID Projectors
into the Headlights for the Astra j 5 door


with standard Halogen Headlights
and will Give the Bi Xenon look without the Price Tag of fitting AFL
and this is also the Correct way to fit HIDs
as they Need Projectors to give the Correct Light Pattern.

PARTS NEEDED.......

1. Set of Mini H1 2.5 HID RHD Projector Lenses.
http://www.ebay.co.uk/itm/151349891904?_trksid=p2059210.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

2. Butyl Headlight Glue.
http://www.ebay.co.uk/itm/261561165192?_trksid=p2059210.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

3. Headlights.
New or Used or use your Own but Think of Resale
as the Car will only Use HIDS so a Spare Pair may be Best.
as you can put the Standard ones Back in the Car
and sell the Projector Lights when the Time comes to Sell.
   
4. HID kit.
you Must Get a H1 HID kit to fit the Projectors
http://www.hids-direct.co.uk/h1-canbus-t...-slim-35w/

5. Black Heat Resistant paint
to paint the Halogen Reflector
And to give a better look inside the Headlight again optional.
   
STEP ONE............

This is what you Get with the MINI H1 HID RHD 2.5 Projector Lenses
it is very Important you Get RHD Projectors for the UK or the Light Pattern will be Wrong
the First step will be to Dismantle the Projectors and Clean the Lenses
to Remove any Dust Dirt or Finger prints from the Projector Lenses.

[Image: hids003_zps3324630c.jpg]

Remove the 4 Screws at the Front and pull the Lens away
and Make a Note of How the Projector Plate with the Solenoid for High and Low beam
all goes Back Together and Clean the Glass and Reassemble
you can test the Solenoid works by Adding a 9 volt Battery
and see if it Moves the Plate up and Down
but i will Talk about that later on But now is a Good time to Test it works
the High and Low beam Function is Optional
you can Have it or Leave it just as a Low Beam it is Completely up to you.

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Now fit the Chrome Shroud Cover to the Projector
it will need 4 small Screws to fit it Together.

[Image: hidstwo007_zpseec59801.jpg]

[Image: hidstwo008_zpsb6a95c03.jpg]

[Image: hidstwo009_zpse6121797.jpg]

[Image: hids001_zpsef69fa45.jpg]

Next fit the Large Crush Washer to the back of the Projector
remove the Three screws and Remove the Holding plate and Retaining nut
and Add the Crush Washer this will Help hold the Projector into the Reflector housing.

[Image: hids002_zpsf4fd3f4f.jpg]

[Image: hidstwo001_zps00889766.jpg]

[Image: hidstwo002_zps4a656490.jpg]

[Image: hidstwo003_zps874f3564.jpg]

[Image: hidstwo004_zps75f0b07e.jpg]

[Image: hidstwo005_zps1c76e272.jpg]

[Image: hidstwo006_zps1638fb76.jpg]

The Projector is now Ready to fit into the Headlight.

STEP TWO............

Remove the Lens Covers from the Headlights
i did try to Heat the Headlights and Try to Pull the Cover off
but no luck Getting the Glue to stay Melted
there are also some Staples that will Need to be Removed around the Light unit  
so i Opted to Dremil the Headlights apart
i will now Need extra Bonding but it will all go Back together
and be Water tight when i Reseal them.

[Image: drem001_zps675e6ed9.jpg]

[Image: lin001_zps68a0d19f.jpg]

So the First job is to Clean all the Excess Plastic from the Light Covers and the Light Units
so a Good Seal can be Made when it is Time to Reseal them.
and then Drill two Holes for the Two Wires on the Projector Lights that will go to the High Beam
and file Down the the Lip for the Light Bulb so the crush washer will fit Better

[Image: bb002_zps7d0e8a65.jpg]

[Image: bb003_zps1b10970c.jpg]

Then Prime and Paint the Chrome Reflector to give a much Better look
Rub the Chrome down with 600 Grit and use Metal Etch Primer and Heat Resistant paint.

[Image: black004_zps99c9ebde.jpg]

Next place some Metal tape around the Back of the Projector
to stop any Light escaping out the Back of the Projector
and make a Note of the Top.

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[Image: black001_zpsa6adace4.jpg]

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STEP THREE..........

Fit the Projectors into the Headlight units Position and Reseal the Headlights.

First cut the Connector on the Projector and Thread the Two Wires through the two Holes you made
then Place the Projector inside the Headlight making sure the End marked Top is Up
and as Level as Possible.

[Image: hid4001_zpsc2bd302b.jpg]

[Image: hid4002_zps5beb542b.jpg]

Now from the back Add the small Crush washer First
then the Plate and then the Nut and lock it all Down
making sure the Projector stays as Level as Possible
and does not turn when you Tighten the Nut up use Long nose Pliers.

[Image: hid4003_zps8037fbd7.jpg]

[Image: hid4004_zps5bed7bd9.jpg]

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Next Add the Holding Plate and add the Three screws.

[Image: hid4006_zps6e061f63.jpg]

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[Image: hid4008_zps98f57f96.jpg]

You can fine Tune the Horizontal Level by Turning the Holding plate
And this is Best done Before you Resale the Covers
fit the Lights back to the car and Then get the Horizontal Line
correct First

It is now Time to Reseal the Headlights and give them a Real Good Clean before hand
use Butyl Windscreen Seal Glue simply apply it around the Headlight unit
heat the Glue and press Down the Light Cover and allow 72 hrs to Cure and Harden
then Apply more if Necessary this will give you a good Water Tight Seal
i also put some Gorilla tape around the seal as it will Remain Tacky
and i dont want the Seal Bonding to Anything else when they go Back in to the car  
a Good seal is Better than Looks
you will not See the Join when the Lights are back in the car.

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STEP FOUR.............

Fit the Bulbs back in to the Headlights units
i will be Fitting the LED DRL,s and a How to can be Found Here.

http://www.vxoc.org.uk/forum/Thread-HOW-...a-J-5-door

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[Image: wire005_zpsf262e19c.jpg]

Next Take the two Wires from the Projector
and Splice them in to the two wires for the High beam
this will make the Solenoid open and close on the Projector
and turn High and Low beam on the Projector
so you will Have two High Beam Lights now
this is Totally optional you do not have to do This
if you just want the Projector to stay as the Main Beam only.

[Image: wire002_zps79ac4282.jpg]

[Image: wire003_zps84c58635.jpg]

[Image: wire006_zpsc85a9b55.jpg]

Next the HID KIT can be Wired up so it is all Ready to fit and go Back into the car
i will be Using A, H1 HID KIT as that is What Type oBbulb the Projectors use
i have chosen the Terminator 35w, H1, 6000k, HID kit from HIDS DIRECT
as this looks the Best and the kit is Error Free,

[Image: hid002_zps78ed6a86.jpg]

make the Hole in the Center as the Bulb will need a Bit more Room
i did Redo the Hole as it was in the Wrong Place and added a Cap from the Hid Kit
so there is a bit More Room as the Bulb was a Tight Fit with just the cap
making Adjustment Harder but this will cure the Problem and still be Water Tight  

[Image: caps002_zps6c596149.jpg]

[Image: hid004_zpsfc60edc9.jpg]

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Remove the Metal Clips for the H7 Holder
then it will Fit back in to the Headlight unit

[Image: hid005_zps751150ab.jpg]

I will mount the Ballasts inside the Engine Bay somewhere Safe
and Wire the Ballasts up for the DRL,s also as they are Already Mounted in the Engine Bay.  

STEP FIVE...........

Fit the new Headlights back into the car and Adjust the Light Pattern
here is a Link on How to Remove the Front bumper.

http://www.vxoc.org.uk/forum/Thread-How-...r-Facelift

This will be a Basic Light Adjustment
and if you are Unsure get the Light Pattern
adjusted by your Local Garage.

Here is the Basic rule on Adjustment
but he is Adjusting for LHD but the same will Apply for RHD.

It is much Easier to Adjust the Light Pattern with the Light Units fitted to the car
without or Before you fit the Front Covers back on
i Suggest you get This Correct first
Before you Bond the Cover back on.  

[Image: ProjectorAiming_zps5df210bc.jpg]



I have marked the Positions with the Halogen set up all Ready
for the new Projector HID.S
to use as a Guide Line to follow.

[Image: light001_zps77a0dd75.jpg]

And Here is the new Projector HID Light Pattern.

[Image: hiiiid002_zps21895bd6.jpg]

And that is that all done. Doublethumbs

AS WITH ALL ELECTRICAL HOW TOO,S.
you do this at your own risk if you follow the how to correctly
there should be no problems thank you.
RESULTS.........

Here are the Pictures of the HID Projectors with the LED DRL,S
all Fitted and Working now. Smile

[Image: hids006_zpse3ac81aa.jpg]

[Image: hids002_zps1bd7cd1a.jpg]

[Image: hids004_zps36e707df.jpg]

[Image: hids001_zps33502e18.jpg]

[Image: hiddd002_zps7370634d.jpg]

And Here are some Pictures at night
to show you all the Light Pattern and Light output.

[Image: carpark002_zpsb88c54c4.jpg]

[Image: carpark005_zps1ecd32fd.jpg]

[Image: carpark006_zps28f75a28.jpg]

[Image: hiiiid003_zpsb1fd0bef.jpg]

Over all it was Well worth the Hassle and i am very happy
i love the Crisp Blueish white Light from the HIDS
they Match the LED DRL Perfectly
and the Projected Light is just so Much better. :cool

AS WITH ALL ELECTRICAL HOW TOO,S.
you do this at your own risk if you follow the how to correctly
there should be no problems thank you.
Mate that os awesome :-)


Sent from my iPhone using Tapatalk
Top work mate and a top write up.

How far from the wall are you when adjusting your lights?
25 feet they will get a proper adjustment next week just to be safe
i have been fine as no one has flashing me so far Lol
Nice work they look brighter than the oe afl
it was fun going to work this morning for a change
i love the way they light up the motorway nice and white
and they light up road signs really well
and looking at the step in the light pattern on walls is so addictive
i used the 6000k HID KIT a nice bluish white light
matching the LED DRL perfectly
i am sure the 4700k bulb would give better vision on the road
but not as white but ether one would look good i guess
thanks all.
Looking good! Are these MOT safe?
As long as the light pattern is correct and for RHD
and the lights are aliened correctly
basically there will be no problems with the headlight units with the projectors
the HID bulbs with projectors should be ok as the light pattern is correct
but HIDS with out projectors are a big no no
if you look at the light pattern with HIDS in a halogen reflector
the light pattern will be scatted unlike HIDS with projectors are clearly straight and defined
there may be a need for washer jets and self leveling to be 100% legal ?
but generally if the lights are aligned correctly there is no need to check them functions
in an mot so most likely wont be noticed unless your tester is having a bad day
loads of people have HIDS in there projectors and many get passes no problem
strictly specking with out the self leveler you will have to set the lights
a bit lower so you are not blinding the car in front in there rear view mirror when going over bumpy roads
if you are all aliened correctly you should not have an issue
with the mot and other drivers most people get a pull only due to miss aliened lights
drawing attention to them
but really HID bulbs are for off road use only anyway and are not legal
you can always just put the origanl units back in if you dont want to take the chance of having a fail
as they look like xenon units and the light pattern is correct they should pass.



i am sure Keven can answer this as this is his area of expertise
i wont have a problem with getting them through a MOT ether way
as long as there aimed correctly i will get a pass :cool
The GTC has projectors with manual leveling and no headlamp washers, I also noted the same on the new Zafira Tourer.

It's only the AFL systems that have the headlamp washers and auto leveling.
tomwalker23 Wrote:Looking good! Are these MOT safe?

Not a problem, HIDs 'may' be fitted with self levelling and wash sytems, and if so, must work.

Even if a car has a levelling system fitted, it's near impossible to check it's working properly, so the car must be issued with a pass. Likewise with washers, if someone glued down the washer jets and hid the pipework and wiring from view, it's a pass.

Having said all that, I don't know about the road laws, but I believe the lighting regs are the same for both mot's and the traffic cop laws, so all should be good assuming like Tucpal mentions that alignment and pattern are good.

One thing to remember though, the lights might be legal, but alarm bells may ring with the cops or mot tester that the car has had the 'boy racer' treatment elsewhere, so a slightly closer look for missing cats/dpf's, cut springs etc may follow.
i swapped the 6000k HID bulbs for the 5000k bulbs
as the 6000k was just to blue for my liking they gave a nice whitey blue but faded at distance
and the 5000k gives better lumens and vision on the road and still remains really white
much better in my opinion

[Image: hid001_zpsc13fca7b.jpg]
Looks awesome! I think there is something wrong with the lights i have fitted, the aftermarket units. It doesn't seem to have the right cut off points etc but I don't know how to adjust them :/
Go to a place that does MOTS mate they will do it for you, only charged me a fiver.


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Most after market units are for LHD on the Astra j so can you show me your headlights I only know of one set that are for RHD also can you show me the light patten on a wall most after market units are not adjustable and they tend to use narrow beam projectors that look like two half circles and they won't give as good a light patten or a good cut off line as I get on the mono mini h1 projectors
[MENTION=2]tucpal[/MENTION], i want to check on something. wasn't HID kits put down for MOT failure now or is this untrue?

as i am thinking of getting a kit

http://www.ebay.co.uk/itm/VAUXHALL-CANBU...3a8dcac6f2

http://www.ebay.co.uk/itm/NEW-CANBUS-TER...3393fdf9f0
No mate it is not correct or safe to put them in none projector headlights the light patten will not be correct
Ok, so i would need to get them other lights or do you retro fit for them projectors


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It would be the best option
tucpal Wrote:Most after market units are for LHD on the Astra j so can you show me your headlights I only know of one set that are for RHD also can you show me the light patten on a wall most after market units are not adjustable and they tend to use narrow beam projectors that look like two half circles and they won't give as good a light patten or a good cut off line as I get on the mono mini h1 projectors

ha sorry mate did note realize it was you today
some after market projectors give a narrow beam pattern
looks like yours fall into this category
if there is no up and down adjustment then it looks like it can not be adjusted
i would need to see the lights on a wall at about 25 feet to get a better idea
I have now gone down to the 4300k HID bulbs
and again the light out put on the road has improved again
i will be sticking with these from now on as i really like them
they are also still really white and give much better vision. :cool

[Image: hhhn001_zpse418df74.jpg]
wow Tucpal they do look amazing the output it awesome.... :P
I was recommended these HID bulbs
that have a metal plate for a better fit in the holder
and a better quality bulb all round
again i went for the 4300k
they are much better that the standard plastic base ones
and again the light out put has improved due to a better fit
and better bulb so there well recommended

[Image: h1metal_zpso6xejs32.jpg]

http://www.ebay.co.uk/itm/271705429800?_...EBIDX%3AIT
You must of spent £100's on sodding HID bulbs now mate.
ha ha but this is the first time i have used HIDS and i am learning all the time
that's the third set and at only £10 each it is worth playing about to get them correct
you live and learn and i want the best Lol

and i still have a smile on my face every time i go out at night
the Projector HIDS are excellent.
4300k is white? Or white with a hint of yellow?
It does have a hint of yellow but when look at it front on and from pictures it looks white.
Hmm. So
4300K is white with a hint of yellow
5000K is white. Just white
6000K is white with a hint of blue
Right?
Yes mate they say 4300K is the best I dropped down from 5000k to 4300k and think they are but I did get my lights adjusted when I did it as they where pointing down.
DNT Wrote:Hmm. So
4300K is white with a hint of yellow
5000K is white. Just white
6000K is white with a hint of blue
Right?

5000k also has a slight hint of blue

i would not go over 5000k as the vision on the road really does get worse
the 4300k are the best for vision and they still look white and they have not got any hint of blue at all
and match the LED DRL nicely the 4300k only really have a hint of yellow in the daylight
at night you can not see any yellow at all.

as you can tell it took me a couple of bulbs to realize the 4300k are the best

6000k look grate in the headlight nice diamond white with a blue tint
but they are just no good for vision on the road at all.

5000k are pure white with a paler hint off blue but again the vision is sacrificed for nice looking headlight.

4300k are much better for vision on the road if not the best here and still look pure white at night but have a yellow tint in the daylight.
It all makes sense now! Doublethumbs
i only upgraded to the last set of 4300k bulbs as they were better quality
bulbs what ever you go for H1, H7 etc the metal plate HIDS are well better built
and fit better than the standard plastic ones i was happy with the 4300k
i just wanted the best bulb out there and i now have it Thumbs
believe me there like search lights and you have not been flashed once with the projector they work really well.
I'm using 6000k HID's at the moment, they're fantastic. I think I'll get a set of 4300s though, just to see the difference, plus my passenger side bulb only comes on some of the times, and the driver side one flickers Haha. Cheap kits for you!
if you are are on the H1 bulbs like me get the ultra HIDS in the above link 4300k.
honestly there the best quality wise and for vision. Doublethumbs
Vauxhall uses PermaSeal to seal their headlight housings. Thats why its impossible to open the housing using the oven method. Many other manufacturers use Butyl sealant which is much easier to open using an oven. So the only way to open our headlights is by cutting them. Any issues since you retrofitted those projectors? Any moisture or haze in the housing?
at first they were misting up with the HIDS like many others have found
i just took some advise a drilled two small holes in the back of each cap and that solved the problem
I m really tempted to try this mod. But I need some help

Looking at the picture you cut across the line where lens meet the plastic (red arrows), right? But there is no glue there. Glue is between the plastic that is under the lens and the lens (yellow area). Where should I cut?
[Image: IMG_20150408_20074922.jpg]



Also, don't you think it would be better to use this method? It seems much more easier to open and reseal, or is it a bad idea?

https://www.youtube.com/watch?v=xSD-eW6tEGk

https://www.youtube.com/watch?v=JoX6y1wyyCQ
cut on the red line as it will make bonding it back together alot easier as you will have a good surface to bond too
the iron method is fine i would grab a cheep set on ebay then you can put the others back in at a later date
Ok guys, bought a cheap pair of chrome headlights off ebay...
Cutting the lense was a pain in the !@$#. I used a multi purpose tool because I found using dremel was way more difficult. I finally managed to open it but I'm stuck.
Do I have to completely remove the remaining chrome parts from the black case? 

This is where I've been so far:

[Image: P1010169.jpg]
no that is about it you can paint the reflector if you wish
then fit the projectors it may be best advised to fit the headlights back in and position
the light pattern at night to get it correct before you seal it all back together
Ok, a quick update with pics. Here is the projector mounted with a different shroud called "iris". I like it better than the shrouds the projectors came with. Lot of trimming needed though as they were big...

[Image: P1010175.jpg]

[Image: P1010173.jpg]



Also planning to use some 16x1w high power leds as daytime running lights in order to avoid bulb errors. Led driver is also needed...

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[Image: P1010185.jpg]


And now the noob question: How do you unclip the headlights????

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Also is there any pinout diagram?

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pull the brown tab on the side out
rusty will have a pin out
and i like the projectors they look very good
good idea on the led drl also
I'll look the pinout out tomorrow. Just a thought but what about adding some angle eyes or a DRL/indicator strip?


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Also make sure it is dust free before resealing and as clean as possible
I tried pulling the brown tab out but it was too tight and I thought if pulling harder it would brake. I ll give it a try today. I have thought about adding DRL/indicator strip, installation would be much easier instead of soldering tiny leds, but at daylight when the strip is on you can barely see it. Not too much light output. At night it is more visible though and i would say really beautiful but still not suitable for what it's meant to be, daytime running light...
When you take the headlight out you will have more room to get the clip out
A tip for you that I did when playing with Xenon lamps was to undo the top screws of the headlight which gave them abit play and allowed me make enough room for getting the tab pulled out.

It doesn't pull all the way out.
Ok thank you guys. To correct myself I used mini H1 projectors (the same that you used) with ORBIT shrouds, not iris as i stated before
I'll grab you pic later just got to out I'll also link the Pinouts of the headlamps
I stuck with the LED DRL as changing them is easier
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