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xenon afl retrofit

AFL / Xenon retrofit
#1
[Image: 9nd4_zpsea5fce57.jpg]

Some of you will know I'm trying to do a AFL / Xenon's retrofit so I'm just posting all the info here.

So I got 1 Xenon unit











plugged it in to see what happened.





The connector on the halogen unit fits the xenon, there are more pins on the halogen unit then the xenon unit.

Once turned key to pos 2 it made a lovely sound like it was trying to level.

The computer told me I was missing my D1S bulb or to at least check it anyway.

The only thing I found though was if I flashed nothing happened although hard to see with the bonnet propped by a bit wood.

Guys can you help me find a ballast and D1S with igniter please.

Found these D1S's on EBay but not sure.
[Image: Rusty-2_zpsuzrvgsp6.GIF]
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
I can do programming and retrofits using genuine GM MDI and Dealer software.
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#2
Rather than keep digging into the workshop I'll add this lot here.

Headlamp Levelling Rear Suspension Height Sensor Exciter Plate Replacement

Headlamp Levelling Rear Suspension Height Sensor Replacement

Headlamp Levelling Front Suspension Height Sensor Exciter Plate Replacement

Headlamp Levelling Front Suspension Height Sensor Replacement

Headlamp Bracket Replacement (5-Door Hatchback 68)

Headlamp Wiring Harness Replacement

Headlamp Wiring Harness Connector Bracket Replacement

Headlamp Control Module Replacement

Headlamp Control Module Bracket Replacement

Headlamp Ballast Replacement

Control Module References

Headlamp Control Module Programming and Setup

Headlamp Control Module Scan Tool Information
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
I can do programming and retrofits using genuine GM MDI and Dealer software.
Reply
#3


Just to give you a table of part numbers and prices for 5-door.
Those in red are the part numbers I needed there are a few options depending on trim etc of car.


AFL List
[TR]
[TD]Part Number[/TD]
[TD]Description[/TD]
[TD]Quantity[/TD]
[TD]Price[/TD]
[TD]Cheaper Price Other[/TD]
[/TR]
[TR]
[TD]13366017[/TD]
[TD]CONTROL UNIT, HEADLAMP 5 DOOR HATCH, SALOON, ESTATE 35, 68, 69[/TD]
[TD]1[/TD]
[TD]£138.00[/TD]
[TD]Used with Xenon Headlamps[/TD]
[/TR]
[TR]
[TD]13268698[/TD]
[TD]SWITCH, ASSY., HEADLAMP, RHD, BLACK (FOR AUTOMATIC HEADLAMP LEVELLING SYSTEM) (FOR HEADLAMPS, AUTOMATIC ON-OFF) (FOR FRONT FOGLAMPS) (PRODUCTION NO. 12777338, EK)[/TD]
[TD]1[/TD]
[TD]£51.96
Vauxhall
[/TD]
[TD]£39.04
Autovaux
[/TD]
[/TR]
[TR]
[TD]13278005[/TD]
[TD]CONTROL UNIT, HEADLAMP IGNITION, BALLAST[/TD]
[TD]2[/TD]
[TD]£174.60
Each Vauxhall[/TD]
[TD]£166.84
Each Autovaux[/TD]
[/TR]
[TR]
[TD]9270371[/TD]
[TD]BULB, 12V/55W, HEADLAMP, CORNERING LIGHT (H11)[/TD]
[TD]2[/TD]
[TD][/TD]
[TD]Came with unit[/TD]
[/TR]
[TR]
[TD]93169040[/TD]
[TD]BULB 12V/35W, HEADLAMP, XENON (D1S)[/TD]
[TD]2[/TD]
[TD]£134.50
Each Vauxhall[/TD]
[TD]£54.00
Pair Ebay[/TD]
[/TR]
[TR]
[TD]12767661[/TD]
[TD]SOCKET, BULB, HEADLAMP, XENON (FOR D1S)[/TD]
[TD]2[/TD]
[TD]£9.00
Pair Vauxhall[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13306933
13398144[/TD]
[TD]HEADLAMP, ASSY., LESS BULB, LH[/TD]
[TD]1[/TD]
[TD]Varies form
£432.75[/TD]
[TD]Not Sourced yet[/TD]
[/TR]
[TR]
[TD]13306934[/TD]
[TD]HEADLAMP, ASSY., LESS BULB, RH[/TD]
[TD]1[/TD]
[TD]£432.75
Vauxhall[/TD]
[TD]£100
Ebay[/TD]
[/TR]
[TR]
[TD]13579487[/TD]
[TD]SENSOR, STEERING ANGLE[/TD]
[TD]1[/TD]
[TD]£50.40
Vauxhall[/TD]
[TD]£52.18
Autovaux[/TD]
[/TR]
[TR]
[TD]13347457[/TD]
[TD]SENSOR, HEADLAMP LEVELLING, REAR SUSPENSION[/TD]
[TD]1[/TD]
[TD][/TD]
[TD]£57.72
Autovaux[/TD]
[/TR]
[TR]
[TD]13353935[/TD]
[TD]PLATE, EXCITER, HEADLAMP LEVELLING SENSOR, REAR SUSPENSION[/TD]
[TD]1[/TD]
[TD]£4.20[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]11507067[/TD]
[TD]NUT, M6, HEADLAMP LEVELLING SENSOR, REAR SUSPENSION[/TD]
[TD]1[/TD]
[TD]£0.84[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]11516397[/TD]
[TD]NUT, M4.2, PLATE, HEADLAMP LEVELLING SENSOR, FRONT SUSPENSION[/TD]
[TD]1[/TD]
[TD]£1.44[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]16609457[/TD]
[TD]SCREW, M4.2 X 20, PLATE, HEADLAMP LEVELLING SENSOR, FRONT SUSPENSION[/TD]
[TD]1[/TD]
[TD]£3.30[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13287929[/TD]
[TD]PLATE, EXCITER, HEADLAMP LEVELLING SENSOR, FRONT SUSPENSION[/TD]
[TD]1[/TD]
[TD]£4.98[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]93299196[/TD]
[TD]RIVET NUT, M6, HEADLAMP LEVELLING SENSOR, FRONT SUSPENSION[/TD]
[TD]1[/TD]
[TD]£1.68[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]11519376[/TD]
[TD]SCREW, HEX.HD., M6 X 20, HEADLAMP LEVELLING SENSOR, FRONT SUSPENSION[/TD]
[TD]4[/TD]
[TD]£3.30[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]12845300[/TD]
[TD]SENSOR, HEADLAMP LEVELLING, FRONT SUSPENSION[/TD]
[TD]1[/TD]
[TD][/TD]
[TD]£52.52
Autovaux[/TD]
[/TR]
[TR]
[TD]13258411[/TD]
[TD]RETAINER, NOZZLE, HEADLAMP WASHER, LH5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT SPORTIVE PACK[/TD]
[TD]1[/TD]
[TD]£2.52[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13258412[/TD]
[TD]RETAINER, NOZZLE, HEADLAMP WASHER, RH5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT SPORTIVE PACK[/TD]
[TD]1[/TD]
[TD]£2.52[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13264300[/TD]
[TD]SEAL RING, PUMP, RESERVOIR, HEADLAMP WASHER (OPTIONAL WITH 13393775)[/TD]
[TD]1[/TD]
[TD]£1.20[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13250357[/TD]
[TD]PUMP, RESERVOIR, WINDSCREEN WASHERHATCH, ESTATE 08, 35, 68[/TD]
[TD]1[/TD]
[TD]£14.40[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13361913[/TD]
[TD]RESERVOIR, ASSY., FLUID, LARGE (FOR HEADLAMP WASH) (SERVICE REPAIR) (PRE-DRILLED)[/TD]
[TD]1[/TD]
[TD]£40.80[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]90561305[/TD]
[TD]SCREW, M5 X 20, HEADLAMP WASHER NOZZLE[/TD]
[TD]4[/TD]
[TD]£5.28[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13374195[/TD]
[TD]NOZZLE, HEADLAMP WASH, WITH ACTUATOR, LH 5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT SPORTIVE PACK[/TD]
[TD]1[/TD]
[TD]£30.00[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13374196[/TD]
[TD]NOZZLE, HEADLAMP WASH, WITH ACTUATOR, RH 5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT SPORTIVE PACK[/TD]
[TD]1[/TD]
[TD]£30.00[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13368824[/TD]
[TD]COVER, HEADLAMP WASHER NOZZLE HOLE, LH 5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT SPORTIVE PACK, EXCEPT BI -TURBO[/TD]
[TD]1[/TD]
[TD]£13.74[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13368825[/TD]
[TD]COVER, HEADLAMP WASHER NOZZLE HOLE, RH 5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT SPORTIVE PACK, EXCEPT BI -TURBO[/TD]
[TD]1[/TD]
[TD]£13.74[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13374199[/TD]
[TD]RETAINER, COVER, HEADLAMP WASHER, RH 5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT BI -TURBO, EXCEPT SPORTIVE PACK[/TD]
[TD]1[/TD]
[TD]£0.84[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13374198[/TD]
[TD]RETAINER, COVER, HEADLAMP WASHER, LH 5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT BI -TURBO, EXCEPT SPORTIVE PACK[/TD]
[TD]1[/TD]
[TD]£0.84[/TD]
[TD][/TD]
[/TR]
[TR]
[TD]13374197[/TD]
[TD]HOSE, HEADLAMP WASHER 5 DOOR HATCH, SALOON, ESTATE 35, 68, 69, EXCEPT SPORTIVE PACK[/TD]
[TD]1[/TD]
[TD][/TD]
[TD]£11.54
Autovaux
[/TD]
[/TR]
[TR]
[TD]13395653[/TD]
[TD]PANEL, FRONT END (FOR HEADLAMP WASH) (FOR FRONT AND REAR PARKING PILOT, POC UD5)[/TD]
[TD]1[/TD]
[TD]£240.00[/TD]
[TD][/TD]
[/TR]



Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
I can do programming and retrofits using genuine GM MDI and Dealer software.
Reply
#4
A link to the RPO codes

I have now worked through all the wiring etc,

I've fitted the rear levelling sensor and have the wiring in the car for that.

I've got the front levelling sensor to fit and then I need to get the looms into the car from the font end.

Then it will be a case of running the wires and then a case of testing out what happens etc.
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
I can do programming and retrofits using genuine GM MDI and Dealer software.
Reply
#5
Good luck with this one. It's one I'm interested in when I originally ordered my car I had spec'd AFL's but the car ended up been delayed by another 2 months So took the car they offered me that was the same as what I ordered but had leather fitted instead of AFL's.

Do you still need the other light assembly?
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#6
No mate, I have all the parts now I think.
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
I can do programming and retrofits using genuine GM MDI and Dealer software.
Reply
#7
really looking forward to the out come rusty
i am sure you will get it all working.
Reply
#8
The tomato ketchup keeps photo bombing! Hope this works ASAP as I need your old lights lol
Reply
#9
Is there any way possible to fit a HID kit to my 5door with normal halogen H7r bulb headlights. It would seem that there a lot of kits being advertised with super canbus units, and they make me think it may have become possible, to fit these and not have bulb out warnings.


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#10
Migwell030744 Wrote:Is there any way possible to fit a HID kit to my 5door with normal halogen H7r bulb headlights. It would seem that there a lot of kits being advertised with super canbus units, and they make me think it may have become possible, to fit these and not have bulb out warnings.


Sent from my iPad using Tapatalk

I don't recommend anyone to fit HIDS into a halogen unit.

I did speak with a company a while ago about the possibility of using a Xenon unit with HIDS and they said it was possible quite how without modification to the unit I don't know after all you want it to work on a halogen system.
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
I can do programming and retrofits using genuine GM MDI and Dealer software.
Reply
#11
Hi Rusty. Just had a reply from lush lighting city. He has fitted a set in the last week, to a car like mine, he said there no problems with flickering or bulb out warnings, etc. They need to be H7R bulbs though. He even sent my a photograph of the car with them fitted & working. Migwell



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#12
fitting HIDS with out projector lenses is not recommended
the light pattern from the HIDS with out projector lenses will be thrown
all over the ROAD and will have a scatted looking pattern
you will be blinding on coming traffic.

have a good read through this
https://www.google.co.uk/url?sa=t&rct=j&...2401,d.ZGU
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#13
I had thought of installing a HID kit in my car as above but after tucpal's warning I looked further into it and came up with this about the subject. I am NOT now going to do the upgrade. and can't aford to swap the whole headlight system for projectors.

The latest directive from VOSA includes their view that unless strict criteria are met, after-market HID kits may not be legal.

There is some confusion regarding the change in legislation towards HID kits. Although we are still trying to determine the full details here is some text that may help! Many thanks to the MX3 Forum guys who bought it to my attention

Here is the relevant text -

"In the Department's view it is not legal to sell or use after market HID lighting kits, for converting conventional Halogen headlamps to HID Xenon. If a customer wants to convert his vehicle to Xenon HID he must purchase completely new Xenon HID headlamps. The reason for this is that the existing lens and reflector are designed around a Halogen filament bulb, working to very precise tolerances. If one places a HID "burner" (bulb) in the headlamp, the beam pattern will not be correct, there will be glare in some places and not enough light in other places within the beam pattern.
The following is the legal rationale:

The Road Vehicle Lighting Regulations 1989 regulate the situation in the UK.
Under these Regulations, HID/Gas Discharge/Xenon headlamps are not mentioned and therefore they are not permitted according to the strict letter of the law.

However new vehicles have HID headlamps. This is because they comply to European type approval Regulations. The UK cannot refuse to register a vehicle with a European type approval. These are to ECE Regulation 98 (for the HID headlamps which are tested on a rig in a laboratory) and ECE Regulation 48 (Lighting Installation on the vehicle).

For the after market, a used vehicle cannot obtain type approval because it is only applicable for new vehicles. However we feel that saying "HID is banned in the after market" would not be reasonable. Instead we should make analogies with new vehicles. It would be reasonable to require HID in the after market to meet the same safety standards as on new vehicles. The same level of safety should apply.

Therefore a HID headlamp unit sold in the after market should:

1. be type approved to ECE Regulation 98 as a component.
2. when fitted to the vehicle should enable ECE Regulation 48 to be complied with (although no government inspection will take place).
3. Comply with RVLR as far as "use" is concerned.

In practice this means:

1. The headlamp unit (outer lens, reflector, bulb) shall be type approved to ECE 98 and be "e-marked" to demonstrate this. That can only be done by the headlamp supplier - Hella, Valeo etc. who must test the headlamp in an independent laboratory.
2. Once fitted to the vehicle it must have headlamp cleaning and self-levelling (which can be for the headlamp or can be in the vehicle suspension - some expensive estate cars have "self-levelling suspension" and that is adequate). Also the dipped beam must stay on with the main beam.
3. The headlamp must be maintained in good working order, kept clean, and aligned/adjusted correctly like any other headlamp.
Under the Road Traffic Act 1988 it is an offence to supply, fit or use vehicle parts which are not legal.
In summary it is not permitted to convert an existing halogen headlamp unit for use with HID bulbs. The entire headlamp unit must be replaced with one designed and approved for use with HID bulbs and it must be installed in accordance with the rules stated above."


If you are found to be using lights which don't comply, in all likelihood, you may be reported to the Procurator Fiscal and may end up with a fine.

The above seems to be a precursor to the new MOT criteria slated to come into existance on New Years Eve 2011 (for 2012), this is from the MOT Testers VOSA bullitin explaining the new EU MOT regulations which were ratified this year, and includes amongst other things, the testing of wiring harnesses, the testing for illegal HID kits and, wait for it, chipped ECU's, whatever that means The article is quite long, but here is a small extract .....

"As far as changes to the test content are concerned, VOSA has already been analysing the requirements of the new Directive and working out how to implement them. We started this earlier in the year by talking with representatives of the MOT trade at our regular Trade User Group and VTS Council meetings. Both VOSA and the Department for Transport (DfT) are keen to ensure that any changes to the test are introduced in as practical a way as possible, keeping the burden on the trade to a minimum and ideally keeping the changes cost neutral.

In many cases, the changes shouldn’t necessarily lead to an increase in average test times. A good example is the malfunction indicator lamps on the dashboard that indicate defective electronic power steering, electronic stability control and secondary restraint systems. Testers already check the dashboard for other lamps, so no extra time would be required for this addition to the test.

Electrical wiring and batteries are now included in the test’s scope, but testers already check the vehicle structure where wiring is secured – often along the same routes as other testable items, such as brake pipes in the engine compartment. So again, this doesn’t look like an additional burden on the tester. In the pre-computerisation days, testers often (wrongly) failed vehicles for insecure batteries, so they must have been looking at them then! Now, it means that when we implement the new Directive, vehicles can legitimately fail for battery insecurity, for no extra tester effort.Other items – such as headlamp bulb and unit incompatibility, headlamp levelling devices and illegal engine ‘chipping’ – will need further thought before we can get a workable solution for MOT stations."
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#14
For the mot side of things, hid's do not require headlamp levelling or washing system to be fitted. But if they are fitted, then they must work. Having said that, the levelling system can be faulty and still pass. As it's almost impossible to test the levelling side of things during an mot, the benefit of doubt goes to the vehicle presenter!

Strange thing is, when on refresher courses we get told that the lighting regs are the same for mot's and construction and use regs. Which really doesn't make sense now with the way hids are tested for an mot!
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#15
nice posts there
i agree if you can fit the projectors they will look more genuine
and i am sure the light pattern will be much better
some mot places will pass them others are not so nice about them
but HIDS with out reflectors is just a don't do it
you wont fool anyone and blinding oncoming traffic is just not ok
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#16
Just a quick update to say I've spent the day fitting the front levelling sensor and getting all wiring into the car, I'll start hooking it all up next week.
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
I can do programming and retrofits using genuine GM MDI and Dealer software.
Reply
#17
GOOD i really hope this works mate :cool
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#18
Not long to go now hopefully

Sent from my LT26i using Tapatalk
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#19
Just a quick update to say I got the AFL module all wired up and the passenger side all back together, Got all the wires run to the drivers side for the BCM ready to hook up and also got the Wires ready to hook up to the fuse box.
Astra-J 2.0 CDTI S/S
Retrofitted AFL, TPMS, Navi950, BT, DAB, Rear Camera, Infinity sound system, Towbar, Flexfloor & more.
I can do programming and retrofits using genuine GM MDI and Dealer software.
Reply
#20
You've been a busy bee.

Sent from my LT26i using Tapatalk
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#21
Right a small update.

I've hooked up all the wiring and I have tested.