Upgrading your BMW E46’s headlights is a popular E46 Modification, especially when dealing with burnt-out ZKW projectors. A common solution is swapping the ZKW xenon headlights for AL (Magneti Marelli) xenon units. This guide outlines the simple bracket modification required for a seamless fit.
Why Swap to AL Xenon Headlights?
Electronically, ZKW and AL xenon headlights are direct replacements in the E46. The primary reason for the swap is the notorious projector burnout issue that plagues ZKW units. AL headlights offer a reliable alternative, and with a minor bracket adjustment, the installation is straightforward. The only physical difference lies in the igniter housing: the AL unit’s igniter protrudes slightly more than the ZKW’s.
This image shows the difference between ZKW and AL headlight units. The top unit is the AL, showcasing the protruding igniter.
The Bracket Modification Process
The modification involves trimming a small section of the ZKW bracket to accommodate the AL igniter. While you might be able to install the AL headlights without modification, the slight protrusion could make the process more difficult. This adjustment ensures a snug and hassle-free fit.
This image demonstrates how the AL headlight sits on the unmodified ZKW bracket.
The modification is surprisingly simple. Using a serrated knife or a Dremel tool, carefully remove the small section of the bracket that interferes with the AL igniter. The images below illustrate the before-and-after:
The ZKW bracket after the modification, showing the trimmed section.
Additional Tips for a Perfect Fit
While the bracket modification addresses the main compatibility issue, ensuring proper fitment requires attention to detail. Double-check the alignment of the headlights and corner lights. There are rails on both the headlight and turn signal housings that need to interlock for a flush fit. This prevents gaps and ensures a professional look.
This image highlights the corner light fitment and the importance of the rails.
A closer view of the corner light and headlight connection points.
Lens Clarity Considerations
While not directly related to the bracket modification, it’s worth noting that ZKW lenses are generally clearer than AL lenses. Some E46 owners choose to swap the lenses, combining the clearer ZKW lens with the more reliable AL headlight housing. This involves baking the headlight assembly to separate the lens from the housing, a process requiring patience and careful execution. Online tutorials can provide detailed guidance for this procedure.
Conclusion
Swapping ZKW for AL xenon headlights is a practical E46 modification that addresses a common issue. With a minor bracket modification, the process is straightforward and results in a reliable lighting upgrade. Ensuring proper alignment with the corner lights and potentially swapping lenses for improved clarity are additional steps to consider for optimizing your E46’s lighting performance.
