HOW TO: remove bumper and install HID bulbs!

[trinydex]

http://forums.evolutionm.net/showthread.php?t=67956


Well, I finally took the time to install upgraded D2S HID bulbs.Â* It involves removing the bumper and headlight assembly.Â* So I thought I'd walk everyone through it.Â* Let me know if I forget anything.

Things you'll need:
10mm Socket wrench
flat head screwdriver
philips screwdriver
philip head drive bit
garage ramps
spotlight

Time 2-3 hours.

*NOTE:Â* Since you're removing cosmetic materials (bumper & headlight), be cautious not to scratch either while doing this.


Remove 2 bolts and 3 clips on top of the front bumper

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_be2ff0a2.jpg


Remove the non-marked clips by prying with flat head screw driver.Â* Pop up 1/4" and you will be able to pull the entire clip out.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_ecfa4f47.jpg


Under each wheel well, remove 1 bolt and 2 philip head clips.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_bbd539f9.jpg


I used a philip head drill bit to unscrew the clip.Â* You may have to apply no pressure in order for the threads to catch.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_c83e8ab8.jpg


Next remove ~10 philips head clips right behind the black plastic lip.Â* You shouldn't have to remove any other clips holding the under carriage.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_e0f40b27.jpg


Now unscrew the two bolts holding the intercooler screen.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_bd7bb209.jpg


Now slightly pull the bumper down on near the wheel to 'unhook' a tab, but don't yank off the bumper just yet.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_6353f679.jpg


You'll have to disconnect the intercooler spray tubing.Â* Near the driver side headlamp on the bumper, you can disconnect the tubing from a white coupling.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_b9f27617.jpg


With the bumper slight pulled forward, get underneath the vehicle to reach and pop off a clip holder for the tubing.Â* You will need a long skinny fork like tool to rock the clip loose.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_d0816f9e.jpg


Now you should be able to carefully pull the front bumper off.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_25a5891f.jpg


Starting with the driver side headlamp....
Remove the clip on the inside of the headlamp.Â* This will allow you access to one bolt.Â* Unscrew the two top bolts.Â* Remove the forward most bolt near the wheel. (4 bolts total)

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_2df569b8.jpg


You'll need to remove the fog and high beam bulb (turn counter clockwise).Â* Unplug the headlight harness (below and between the fog and high bulbs).Â* You'll need to grasp the release buttons which are on top and bottom of the harness.Â* *NOTE:Â* Be careful not to touch the bulbs!!!

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_ddeaab58.jpg


Now looking at the back of the headlight assembly, unscrew the only screw and turn cover counter clockwise.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_ec1b7375.jpg


Turn plug CC

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_ff56b31a.jpg


Push retaining ping down and out.Â* After it releases, you can swing it open.Â* You can just pull the bulb out.Â* *NOTE: DON'T TOUCH THE BULB!!!

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_3fdb7045.jpg


Compare old with the new in box.Â* Make sure you don't accidently use this 'old' bulb for the passenger headlamp.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_f7b625d0.jpg


Reverse the install for the headlamp assembly, and install back on the car.Â*

*NOTE:Â* When installing the headlight assembly on the car, make sure the gasket near the amber turn signals are on the outside of the fender.Â*

Turn on the car and test all three bulbs.


For the passenger side headlight assembly....
You need to remove the resevoir tank and its 2 bolts first.Â* Then you can tackle the 1 clip and 4 bolts on the headlight.Â* For some odd reason, the wires and harnesses are a little tighter on this side, so be patient.

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_9b75e2c0.jpg


Follow the bulb replacement instructions above, reinstall headlight assembly with note on headlamp gasket.Â* Turn on car and test all three bulbs.Â*

Bam, the new bulbs are in...Â* Now reverse bumper removal instructions.
Hopefully your EVO looks like this...

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_3d7a1286.jpg


It's really hard to take pictures of light.Â* So my pics don't really do justice.Â* This is the best one though - drivers side has upgraded bulb while passenger side still has stock bulb.Â* The new bulbs are rated 5800K.Â* Stock are rated at 4300K.

4300K - yellow/white output
5100K - white/blue output
5800K - blue/purple output

Anything adverstised higher than 6000K isn't worth installing.Â* Bulbs with that high of Kelvin rating actually emit a lower brightness light.

I got my bulbs from European AutoSport http://www.europeanautosport.com/evo.htm

Hope this helps {thumbup}

http://www.socalevo.net/gallery/albums/userpics/10991/mURI_temp_55cb2b7c.jpg

[Terenus]

Just a reminder, this is for Evos with stock HIDs (D2S bulbs). Evos with halogens need to buy a HID conversion kit that comes with a ballast and igniter that you will have to find a place to install.

[trinydex]

I know what you have been thinking. The stock HID’s are not very white. They are around 3400 kelvin. I am going to show you detailed instructions on how to install a new HID bulb. You can buy 3000 Kelvin( Yellow), 6000 Kelvin ( Blue-white), 8000 Kelvin ( Blue Blue-White), 12000 Kelvin( Blue-Purple) or even 14000 Kelvin ( Deep Purple). For more info on this subject, click here.click here (http://www.xtralights.com/index.asp?PageAction=VIEWCATS&Category=5&smc=1121304681395)

Normally, You need to remove the entire bumper in order to access the headlights, but I will show you how to do a half bumper removal for those of you who still have the undertray on. Those w/o can remove the entire bumper very easily and will not need this guide.
First, the tools:
10 mm socket, long or short, but I recommend using a ¼ inch drive because it’s smaller and will be easier to get into tight spaces, and the ratchet will do minimal damage if dropped.
Short Phillips head #2 screwdriver, a stubby will do fine but use a #2 cause the smaller one will strip heads.
Small regular screwdriver
Needle Nose Pliers
Several CLEAN rags. I like to use those nifty microfiber towels.
Blue Painters Tape, wider is better
Masking Tape, wider is better
If you use a Leatherman or some other multi-tool, then it will kill 3 birds w/ one stone.
A pair of D2S HID bulbs of your preference.
Why masking tape??? I will get to that later.

http://gallery.evolutionm.net/data/500/263291-med.JPG
First use the blue masking tape to completely tape off the fenders and headlights, preferably individually, and remove front plate bracket if it is on.
http://gallery.evolutionm.net/data/500/263292-med.JPG
Next cover the blue tape w/ regular masking tape. Lots of layers on the bottom of the fender, at least 3. This step is extremely important if you have an aftermarket fiberglass or CF bumper like me.
http://gallery.evolutionm.net/data/500/263293-med.JPG
Using stubby Phillips Head, remove the 2 clips in the wheelwell, turn your steering wheel if needed for better access.
http://gallery.evolutionm.net/data/500/263294.JPG
Next using 10mm socket, remove screw directly above the 2 clips mentioned before.
http://www.socalevo.net/gallery/albums/userpics/10991/5-xl.jpg
Now using Flathead, pop out your retaining clips that are near the hood release.
http://www.socalevo.net/gallery/albums/userpics/10991/6-xl.jpg
Then, remove the 2 10mm bolts outboard of the clips you just removed.
http://www.socalevo.net/gallery/albums/userpics/10991/7-xl.jpg
You can now move your bumper forward, putting a rag under the front. You might snag your bumper on the IC piping and hoses so be careful. The stock urethane bumper has a lot more flex and give than aftermarket Fiberglass and CF. If you have a stock bumper, there is a small white popper that connects the bumper to the headlight as well. You can see in this picture the reason for using the masking tape, to not scratch the fender. The day I did this picture was the same day I picked up the car from paint, so the paint on the fender is still fresh- reason for blue tape. I had scratched the fenders on bumper install!
Unbolt the forward bolt (light colored one)
http://www.socalevo.net/gallery/albums/userpics/10991/8-xl.jpg
You should pop the little connecter shown to make it easier, but not necessary if you have a ¼ inch ratchet. Under the connector is 2 bolts, (Brass colored), unbolt the lower one; the upper one connects to the radiator.
http://www.socalevo.net/gallery/albums/userpics/10991/9-xl.jpg
Next unbolt the top 2 headlight bolts. Do NOT use a screwdriver! The outer one has a square hole that will hold the headlight if necessary. You should be able to remove the headlight assembly, unplugging the main harness on the bottom, and the foglight and highbeam harnesses as well.
http://www.socalevo.net/gallery/albums/userpics/10991/10-xl.jpg
You will see a round cylinder behind the projector beam. Unscrew the Phillips head screw and then turn cover to loosen.
http://www.socalevo.net/gallery/albums/userpics/10991/11-xl.jpg
After removing cover you should be able to see the plug, turn to loosen.
http://www.socalevo.net/gallery/albums/userpics/10991/12-xl.jpg
Next is the bulb itself. Push on clip to remove, similar to an H4 (9004) headlamp like a Honda Civic. You should be able to remove bulb now, being careful not to touch the lamp. Compare bulbs to make sure that the holes match each other.

Installation is reverse!

http://www.socalevo.net/gallery/albums/userpics/10991/13-xl.jpg

Here are pics i took of the light on a white wall, car was in same position both pics:
stock HID
http://www.socalevo.net/gallery/albums/userpics/10991/14-xl.jpg
new 6k HID:
http://www.socalevo.net/gallery/albums/userpics/10991/15-xl.jpg
stock Headlight:
http://www.socalevo.net/gallery/albums/userpics/10991/stockhid-xl.jpg
6k headlight:
http://www.socalevo.net/gallery/albums/userpics/10991/6khid-xl.jpg
8k headlight (My V6 accord)
http://www.socalevo.net/gallery/albums/userpics/10991/8khid-xl.jpg


any questions, PM me or email me directly @ [email protected]

[philthyevo]

I got an HID kit and the driver side bulb went out. Can I replace the HID bulb w/o doing ALLL of that and taking the bumper off?

[Terenus]

Nope, you will have to take it out again, lol. I know the feeling.

[ArBizZzLe]

bwhahhaa, thanks for the post Ten! lmfao.

I might get off my lazy ass and do it now :P

[Terenus]

bwhahhaa, thanks for the post Ten! lmfao.

I might get off my lazy ass and do it now :P


Haha, finally!

[philthyevo]

I would have to say that is probably the most annoying thing about an EVO.

[fusionchicken]

+1234. but honestly after a few times taking off/putting on the bumper, you get used to it and can do it pretty quickly :)

[MRchnk]

with the 9 everything is the same bit the 2 little clips in the front is where the intercooler bolt are guys

[fusionchicken]

^yup. the 2 IC bolts are covered by the little circular plastic covers, so those have to be popped off first in order to get to the bolts holding down the IC.

[trinydex]

pics someone, i'll update this piece o crap

[darkevo]

I would have to say that is probably the most annoying thing about an EVO.


+1Â* I remember when I did my HID kit on my 05, I got one side done without taking off the bumper, but had to take off the bumper for the other side..course I think in the mitsu manual, you're supposed to be able to do everything from the fender well.Â* I don't know why they made it so hard!!Â* I might just get an EVO X if changing the headlight bulbs is somewhat reasonable!Â* On my mustang, it's 2 pull out tabs and the whole thing pops out..atleast Ford got that right!!!Â* Â*:grin:

[MRchnk]

I would have to say that is probably the most annoying thing about an EVO.


+1 I remember when I did my HID kit on my 05, I got one side done without taking off the bumper, but had to take off the bumper for the other side..course I think in the mitsu manual, you're supposed to be able to do everything from the fender well. I don't know why they made it so hard!! I might just get an EVO X if changing the headlight bulbs is somewhat reasonable! On my mustang, it's 2 pull out tabs and the whole thing pops out..atleast Ford got that right!!! :grin:


yeah thats 1 thing out of a million that they got right

[JOOTZ]

well this thread makes it a little easy for some people

[MRchnk]

ill take pics and stuff in a couple of weeks when i put on my lip

[SimplEVO]

Just a reminder, this is for Evos with stock HIDs (D2S bulbs). Evos with halogens need to buy a HID conversion kit that comes with a ballast and igniter that you will have to find a place to install.


will it carry a 12000K on a stock ballast and igniter?
Is it legal to run a light purple or deep blue HID's?
Thanks!

[JDMboi]

^^^^i think so................do you have to take off the bumperÂ* to put h i dÂ* Â*on the high lights ???

[socal king]

hey what up bro! i was wondering is it the same for an evo 8 2004 rs? bc i dont have hids! do i have to but the light only? or do i have to buy a whole different wiring harness? idk but if you can get back to me i would appreciate it!

[EVOL EDO]

that was answered in the 2nd post. try reading



Just a reminder, this is for Evos with stock HIDs (D2S bulbs). Evos with halogens need to buy a HID conversion kit that comes with a ballast and igniter that you will have to find a place to install.

[050ggEVOixSE]

5,800K good for cops?





Just a reminder, this is for Evos with stock HIDs (D2S bulbs). Evos with halogens need to buy a HID conversion kit that comes with a ballast and igniter that you will have to find a place to install.


will it carry a 12000K on a stock ballast and igniter?
Is it legal to run a light purple or deep blue HID's?
Thanks!

[adotwhite]

^^^
yah as long as u dont go over 6K cops wont fuck with u
some will let u get away with 8k seeing as its a deep blue but not as ricey as 10k

but yah i jus put in some 5100K, i'll take pics tonight. took me about jus under 2 hours.
thanks for posting the write up, helped a lot!

[EvOBoOmBoOm]

i got busted for 6000k