I have read many threads in TN stating that you can swap a Gen 4.5 2000-2001 headlight into a Gen4 1997-1999. The problem with all the treads I have read, is that everyone states that you have to swap the front bumper, front bumper reinforcement, and some say fenders and the radiator support. I took it upon myself to do a swap for my car, with just the headlights, and a wiring upgrade. So, here is how it's done:
DISCLAIMER:
The following procedure is strictly for informative purposes. I do not reccomend anyone who is not experienced in modifying to do the following procedures. If you decide to persue any of the following procedures, you do so at your own risk. And as always, the use of the proper safety equipment is a must.
Parts needed:
Set of 2000-2001 Gen 4.5 headlights with bulbs {ebay} $130
High wattage harness for 9005 & 9006 bulbs {ebay} $38 -
www.sevensaturdays.com - part# CSI/WIR-9005-9006
H4 high wattage harness ( has one male H4 plug wired to one H4 female plug) {ebay} $18
Dremmel rotary tool with cut off discs {metal and plastic} {walmart}
Wire strippers and wire crimpers {walmart}
14-16 ga crimp terminals, or a solder gun with solder {walmart}
Heat shrink tubing {walmart}
25 Pack of black zip ties 7-10" long {walmart}
Dielectric greese / bulb grease {Walmart}
Dust mask {walmart}
Safety glasses / goggles {walmart}
ONE silver or black sharpie fine tip marker {walmart}
ONE extendable razor blade with extra blades {walmart}
ONE large 8" or 10" c-clamp {home depot}
ONE 4" x 8" x 1" piece of wood
STEP 1:
WIRING FOR THE NEW LIGHTS. I PURCHASED A HIGH WATTAGE 9005/9006 WIRING HARNESS FROM EBAY. I CHOSE TO PURCHASE A HARNESS BECAUSE IT IS PREWIRED WITH ALL THE CONNECTORS FOR THE BULBS AND RELAYS WITH WIRE LOOM AND EVERYTHING NEEDED FOR THE APPEARANCE AND QUALITY OF A PROFESSIONAL INSTALL. THE HARNESS HAS TWO FEMALE 9005 PLUGS, TWO FEMALE 9006 PLUGS AND TWO MALE PLUGS (ONE 9005 & ONE 9006) I THEN CUT THE TWO MALE PLUGS OFF THE HARNESS. I DISCARDED THESE AS THEY WILL NOT BE USED.
I ALSO PURCHASED A PAIR OF SHORT H4 HIGH WATTAGE PLUG JUMP HARNESS SO THAT I WOULD NOT NEED TO CUT ANY OF THE FACTORY WIRING. YOU ONLY NEED ONE MALE SECTION. CUT OFF A MALE SECTION. I MADE SURE I LEFT A COUPLE OF INCHES OF WIRING SO THAT I COULD SPLICE IT INTO THE 9005/9006 HIGH WATTAGE HARNESS WHERE I CUT THE MALE ENDS OFF OF IT. THE PIC SHOWS THE WIRING KITS I PURCHASED.
THEN I TOOK THE SECTION OF THE MALE H4 HARNESS AND WIRED IT TO THE 9005/9006 HIGH WATTAGE HARNESS.
THE H4 HARNESS HAS THREE WIRES TO STRIP:
1- GROUND (black)
1- HIGH BEAM POWER
1- LOW BEAM POWER
THE 9005/9006 HARNESS HAS FOUR WIRES TO STRIP:
2- GROUNDS (WIRE THESE TOGETHER) (black)
1 HIGH BEAM POWER
1 LOW BEAM POWER
ONCE I COMBINED THE TWO GROUND WIRES ON THE 9005/9006 HARNESS, I USED A TEST LIGHT T FIGURE THE PROPER HIGH BEAM / LOW BEAM POWER WIRES AND WIRED THEM UP. I USED CRIMP CONNECTORS AND HEAT SHRINK FOR A GOOD CONNECTION.
ONCE THE H4 MALE SECTION WAS WIRED ONTO THE 9005/9006 HIGH WATTAGE HARNESS, I DISCONNECTED MY BATTERY, REMOVED THE HEADLIGHTS AND CORNERS, AND RAN THE WIRING FOR THE NEW HEADLIGHTS. THE MALE H4 PLUG IS ON THE SAME SIDE AS THE RELAYS, BATTERY AND GROUND CONNECTIONS (DRIVERS SIDE NEXT TO THE BATTERY). I USED BLACK ZIP TIES TO SECURE THE WIRING IN PLACE. THE 9005/9006 HIGH WATTAGE HARNESS HAS IT'S OWN GROUND AND POWER WIRES. HOOKED UP.
WIRING IS DONE!!
STEP 2:
IN ORDER TO ACCOMODATE THE NEW 2000-2001 HEADLIGHTS, I HAD TO CUT THE EXISTING HOLE IN THE RADIATOR SUPPORT LARGER. I USED A DREMMEL TOOL WITH METAL REINFORCED CUT OFF WHEELS. YOU CAN SEE IN THE PIC BELOW, I USED A SILVER SHARPIE FINE TIP MARKER TO ILLUSTRATE THE PORTION THAT I NEEDED TO CUT. NOTE THAT ONCE I DO THIS, I WILL REMOVE THE LOWER OEM MOUNTING POINT FOR THE 1997-1999 HEADLIGHTS.
THE NEXT PIC SHOWS THE SECTION CUT OUT, AND I AM HOLDING A GROUND WIRE. I REMOVED THE BOLT AND USED THE DREMMEL TO CLEAN UP THIS GROUNDING POINT. MOST FACTORY GROUNDS ARE NOT THE BEST CONNECTION. I REMOVED THE PAINT AROUND THE MOUNTING POINT OF THE GROUND WITH THE DREMMEL, AND I APPLIED A SMALL AMOUNT OF DIELECTRIC GREASE TO HELP PREVENT CORROSION. THEN I REMOUNTED THE GROUND.
STEP 3
THE 2000-2001 HEADLIGHTS ARE TALLER, AND THEREFORE I NEEDED TO TRIM THE BUMPER SOME. THERE IS A LIP THAT NEEDS TO BE CUT OFF TO ALLOW THE LIGHTS TO FIT PROPERLY. TAKE A LOOK AT THE FOLLOWING PICS. AS BEFORE, I USED A SILVER SHARPIE TO ILLUSTRATE THE NECESSARY SECTIONS THAT NEED TO BE TRIMMED.
TRIMMING IN ACTION. ONCE I TRIM THE BUMPER, THEN I TRIM SOME OFF THE TOP OF THE SYRAFOAM BUMPER REINFORCEMENT. I DID THIS TO HELP THE BUMPER COVER FLEX A LITTLE MORE TO RELEIVE UNNECESSARY PRESSURE ON THE BOTTOM OF THE HEADLIGHTS ONCE INSTALLED. PICS FOR REFERENCE:
STEP 4
AT THIS POINT, THE CUTTING AND TRIMMING IS COMPLETED. NOW FOR THE BENDING. THE RADIATOR SUPPORT IS TOO WIDE AT THE TO FOR THE HEADLIGHTS TO SLIDE INTO PLACE. I USED A C-CLAMP TO COMPRESS THE UPPER PART OF THE RADIATOR SUPPORT. IN THE PIC, YOU WILL SEE THE C-CLAMP ON THE PART THAT NEEDS TO BE COMPRESSED. I TEIGHTENED THE CLAMP, PULLED IT BACK AND FORTH, TEIGHTENED THE CLAMP MORE, PULLED IT BACK AN FORTH, OVER AND OVER AGAIN UNTIL IT COMPRESSED THE RADIATOR SUPPORT. ALTHOUGH IT DOES NOT SHOW IT IN THE PIC, I SHOULD HAVE USED A PIECE OF WOOD ON THE TOP TO DISTRIBUTE THE PRESSURE ON THE TOP OF THE REDIATOR SUPPORT MORE EVENLY. SINCE I DID NOT USE A PIECE OF WOOD TO DISTRIBUTE THE PRESSURE ON THE TOP, I HAVE CLAMP MARKS, AND IT BENT THE TOP SOME. DAMN.
STEP 5
ON THE BACK OF THE 200-2001 HEADLIGHTS, THERE IS A LITTLE PLASTIC TAB I HAD TO CUT OFF. IN THE PICS BELOW, I USED THE SILVER SHARPIE MARKER TO SHOW. IN THE FIRST PIC, IT IS NEXT TO MY THUMB:
ONCE THE CLAMPING AND TRIMMING WAS DONE , I TEST FIT THE LIGHTS AND USED A HAMMER TO TAP THIS AREA TO A BIT TO ALIGN THE MOUNTING BOLT HOLE UP BETTER.
STEP 6
AT THIS POINT, THE LIGHTS FIT PRETTY WELL. ONE THING I NOTICED IS THAT THE MOUNTING HARDWARE FOR THE LIGHTS IS DIFFERENT FOR THE MOUNTING POINT NEAREST TO THE FRONT GRILL ON BOTH LIGHTS. ON THE 1997-1999 LIGHTS HAVE AN ADJUSTABLE MOUNT, AND THE 2000-2001 HEADLIGHTS HAVE A FIXED MOUNT. I DECIDED TO SWAP THE MOUNTS, SO THAT I WOULD HAVE THE ADJUSTABLE MOUNT ON THE NEW 2000-2001 HEADLIGHTS.
STEP 7
MOUNT THE LIGHTS, PLUG THEM IN, AND TRY THEM OUT.
TO BE CONTINUED:
COMING SOON: 2000-2001 CORNERS
The How To: 00-01 Headlight Conversion W/Minimal Parts - NO 56k!! NO 56k!!
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