Upgrading your BMW E46’s headlights is a popular E46 Modification. A common issue with the factory-installed ZKW xenon headlights is projector burnout. A popular solution is swapping them for AL (Magneti Marelli) xenon headlights. This guide outlines the simple bracket modification required for a seamless installation. Electronically, the AL units are direct replacements, making this a relatively straightforward E46 modification.
Why Swap ZKW for AL Xenon Headlights?
The primary reason for this E46 modification is to address the common problem of burnt-out projectors in the ZKW headlights. While ZKW lenses are known for their clarity and sharp cutoff, the AL xenon headlights offer a reliable alternative when the ZKW projectors fail. This swap provides a cost-effective solution to restore proper headlight function without requiring significant rewiring or complex modifications.
The Bracket Modification Process
The only physical adjustment needed for this E46 modification is a minor alteration to the existing headlight bracket. The AL headlight unit has a slightly protruding igniter, requiring additional clearance. This is easily achieved by trimming a small section of the ZKW bracket.
The image above highlights the difference between the ZKW (bottom) and AL (top) headlights. Note the protruding igniter housing on the AL unit.
The modification itself is straightforward. You can use a dremel for a precise cut, but even a simple serrated pocket knife will suffice. The goal is to remove just enough material to allow the AL igniter to fit comfortably without interference.
This image shows the interference caused by the AL igniter on the unmodified ZKW bracket.
The ZKW bracket before modification.
The ZKW bracket after the modification. The small section removed provides the necessary clearance for the AL igniter.
Additional Tips for a Perfect Fit
While the bracket modification is the primary step, ensuring proper fitment is crucial. Some users have reported minor gaps after the swap, particularly on the passenger side. This can often be resolved by correctly engaging the sliding rails on the inside of the turn signal lights with the corresponding rails on the headlight assembly.
Properly aligned corner lights are essential for a gap-free fit.
This image demonstrates the correct alignment of the headlight and corner light assemblies.
Lens Swapping: An Optional Upgrade
For those seeking optimal light output, consider swapping the AL lenses with the clearer ZKW lenses. While more involved, this process can significantly improve visibility. Numerous online resources, including video tutorials, offer step-by-step guidance for this procedure.
Conclusion
Swapping ZKW for AL xenon headlights is a practical E46 modification that addresses a common issue with the original equipment. The simple bracket modification, coupled with careful attention to fitment details, makes this an achievable upgrade for most E46 owners. This modification not only restores headlight functionality but also offers potential for enhanced visibility with optional lens swapping.
