Koji Style Headlights (02-03) - Instructions
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This is a discussion on Koji Style Headlights (02-03) - Instructions within the Exterior and Appearance forums, part of the Tutorials & DIY category; Some people are having trouble with the word document so I thought it might be a good idea to just ...

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    Registered User koji's Avatar
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    Koji Style Headlights (02-03) - Instructions

    Some people are having trouble with the word document so I thought it might be a good idea to just post the instructions here on the forum. You can find similar instructions on NASIOC as well, but I'll post them here for posterity. Note: WILL POST MORE PICS OF THE PROCESS OVER THE NEXT 2 WEEKS.

    Tools Required:
    • 10mm Socket Wrench
    • Narrow Flat Head Screwdriver
    • Phillips Head Screwdriver
    • Hack saw or dremel
    • File
    • Box Cutter

    Materials Required:
    • 2 1&1/2 X 1&1/4 PVC connector. (Home Depot Item SKU 034481062271) *Note: SKU's will vary by region.
    • 1 Can High Temp Engine Paint
    • Dust mask for painting
    • Masking Tape
    • Epoxy (90 second dry)
    • 1 Tube of High Temp & Waterproof Silicone Sealer
    • Rubbing Alcohol
    • Lint Free Cloths
    • Drop Cloths
    • Oven
    • Baking Sheet
    Last edited by koji; 12-01-2002 at 05:08 PM.

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    Registered User koji's Avatar
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    Step 1: Headlight Removal
    1. Remove the Grill. There are 4 snap in connectors on the top of the grill and two connectors at the bottom. Use a flash light because the bottom ones are hard to see. The top ones pull right out. The bottom ones don’t. You will need to use a longish flat head screwdriver to push down on the bottom connectors. Push down and pull lightly . Once the two bottom connectors are loosened, gently pull off the front grill.

    2. There are 3 10mm connector bolts that hold the head light in place. Two are visible from under the hood, one is only visible after you have removed the grill. Unbolt all 3 bolts on each side.
    (The correct bolts have a 7 on them)

    3. Carefully remove the head lights from the car. It will seem like there is something else holding them in there at first. Wiggleing is required

    The upper grill fastner:
    Attached Thumbnails Attached Thumbnails upperfastner.gif  

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    Registered User koji's Avatar
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    Removing the lower grill fastner:
    Attached Thumbnails Attached Thumbnails lowerfastner.gif  

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    Registered User koji's Avatar
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    Step 2: Disassemble Lights
    1. Remove the main projector bulb by unscrewing the plastic retainer. After the retainer is removed the bulb just pulls straight out.
    2. Remove the remaining two bulbs by turning counter clockwise and pulling.
    3. Using your Phillips head screwdriver unscrew the wiring harness from the head light housing.

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    Registered User koji's Avatar
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    Step 3: Baking Bread??

    1. Preheat oven to 250 degrees

    2. Clean the outside of the housings with Windex or Glass plus. Baked on bugs will suck to get off.

    3. Do the following steps one headlight at a time (unless you have another person helping:
    a. Place headlight in the oven on a cookie sheet and bake for 20 minutes. Make sure the housing is on the middle shelf of the oven.
    b. Throw your gloves on and remove the housing from the oven. (Duh )
    c. There are 8 nubs on the back part of the housing and 1 screw that hold the entire assembly together. Remove the screw, then use your narrow flat head screwdriver to gently work the front of the housings over at these points.
    d. After you have loosened all the nubs there’s nothing holding the housings together but silicon. Pull gently and they will come apart.

    4. Set aside the headlight portion of the housing (black part where you attach the bulbs & harnesses)

    5. Take other half of housing (clear outer headlight shell & shiny reflector) and remove screws (2) holding the aforementioned pieces together and separate them.

    6. Clean any dirt, silicone adhesive, or any other residue off the shiny housing frame Use some mild degreaser or bug & tar remover.

    7. After you clean gunk off the frame, use some rubbing alcohol to make sure that the surface is clean and that the paint adheres well. Use a lint-free rag when doing this final prep step or else you will get lint and other particles stuck on the surface when you paint the frame.

    8. Remove both the clear plastic bulb cover, and the orange turn signal bulb cover.
    Last edited by koji; 12-01-2002 at 04:57 PM.

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    Registered User koji's Avatar
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    Step 4: PVC Piping

    1. Assuming that you bought the right PVC connector, there is a wider portion at the bottom that will be useless for what you’re going to do. Using a fine toothed hack saw, and using the wider portion as a guide, cut off the bottom of the PVC pipe.

    2. File down the rough edges of the PVC connector until they are smooth and flat. This part takes some elbow grease, but if you did a good job cutting, you’ll have no problems.

    3. Measure the PVC connector against the orange turn signal cover. They will be equal in diameter and nearly equal in height.

    4. Use a razor blade and rubbing alcohol to clean off the tag.
    Attached Thumbnails Attached Thumbnails pvc_after.jpg  

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    Registered User koji's Avatar
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    Step 5: Cleaning and painting

    1. Mask the inside of the reflector housings where the Orange turn signal housing was. Be careful on this step to work the tape in a circle.

    2. Throw on your dust mask and make one last check to ensure that the frame's surface is clean and free from lint, dirt, etc. Spray a thin coat of paint on the chrome housings and the PVC pipe. Follow the directions on the back of the can & hold can 6-10 inches away from frame to avoid drips.

    a. Make sure when painting the PVC pipe to let it dry thoroughly before attempting to paint the insides. If you put on too much paint while your coating the insides you’ll have a gummy front end that never dries. I would recommend laying the piece on it side and fastening it down before attempting to paint it. Then rotating after each coat to insure an even coating.

    3. Repeat painting process & apply several more thin coats. ( I used 5) Allow at least 20-30 minutes between each coat to make sure paint is dry and avoid drips & runs) *Note: This will depend partially on room temperature and in this case, hotter is better.

    4. After last coat of paint is applied to frame and PVC and dry, gently wipe surface clean w/a slightly damp rag. (It's a good idea to wait at least 2-3 hours to make sure paint is completely dry)


    Pic of the masked reflector:
    Attached Thumbnails Attached Thumbnails masked_prepainting.jpg  

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    Registered User koji's Avatar
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    All painted and ready to go:
    Attached Thumbnails Attached Thumbnails postpainting_1.jpg  

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    Step 6: Reassembly

    1. Reinstall clear parking light bulb cover onto painted frame.

    2. Install the painted PVC piping into the frame with Epoxy.

    3. Clean clear outer headlight housing (inside AND outside) again to ensure that no dirt or dust gets caught inside the light when you reassemble it.

    4. Preheat oven again to 250 degrees, and after oven is warm, put the back part of the light housing (w/the UNPAINTED reflective portion for the headlight) in the oven for 20 minutes to re-soften the silicone adhesive for reassembly.

    5. After removing the housing from the oven, apply a thin bead of silicone sealant in the seam of the housing.

    6. While the housing & silicone is still warm, firmly but carefully, press the halves of the housings back together and keep pressure on them for a minute or two to ensure a tight seal.

    7. Clean any excess silicone off the housings and let the adhesive dry for 1-2 hours.

    8. If your paranoid about moisture getting in there you can put a thin bead of silicone around the outside of the housings where the two halves attach (think caulk around the tub).

    9. After silicone is dry, reattach bulb housings & wiring harnesses to back of headlight housing.

  11. #10
    Registered User koji's Avatar
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    Enjoy your hard work and spend $500+ dollars you saved into your engine.

    Your lights now look like this:
    Attached Thumbnails Attached Thumbnails finished light1.jpg  

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    [QUOTE]Originally posted by koji
    [B]Step 4: PVC Piping

    What is the purpose of the PVC Piping?

  13. #12
    Registered User racerWRX's Avatar
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    look at the turn sig.. on the hlght closely
    have you ever been 4 bagged ???

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    Originally posted by racerWRX
    look at the turn sig.. on the hlght closely
    Can't you just put back the orange bulb covers? And do you have to trim the orange bulb covers to fit it in the pvc pipe?

  15. #14
    Registered User racerWRX's Avatar
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    just something different
    have you ever been 4 bagged ???

  16. #15
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    Originally posted by racerWRX
    just something different
    but you don't really need to do the pvc pipe mod, right? Because I was thinking of koji'ing my hl but I want to skip the pipe mod...

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