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View Full Version : HOW TO: remove bumper and install HID bulbs!



trinydex
10-08-2007, 11:08 AM
http://forums.evolutionm.net/showthread.php?t=67956


Well, I finally took the time to install upgraded D2S HID bulbs. It involves removing the bumper and headlight assembly. So I thought I'd walk everyone through it. 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: 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. 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. 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. 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. 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. 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. This will allow you access to one bolt. Unscrew the two top bolts. 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). Unplug the headlight harness (below and between the fog and high bulbs). You'll need to grasp the release buttons which are on top and bottom of the harness. *NOTE: 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. After it releases, you can swing it open. You can just pull the bulb out. *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. 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.

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

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. Then you can tackle the 1 clip and 4 bolts on the headlight. 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. Turn on car and test all three bulbs.

Bam, the new bulbs are in... 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. So my pics don't really do justice. This is the best one though - drivers side has upgraded bulb while passenger side still has stock bulb. The new bulbs are rated 5800K. 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. 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