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Who wants a Volvo P1 specific, WMM safe, HID Retrofit?

68K views 362 replies 43 participants last post by  Bernie (NoVA) 
#1 · (Edited)
SwedeSpeed P1 (C30, S40, V50, C70) HID Retrofit Index
  1. SKBOWE Plug-and-Play harness for P1 HID conversion (you are here)
  2. Background info, general questions, and share your HID setup <- Non-SKBOWE HID install issues/discussion/WMM kills
  3. KBOWE How-To (Original 2009 Version) build your own PWM filter <- if you want to build your own
  4. Original 2009 investigation and technical discussion on S40 HID issues <- Technical/Engineering discussion on the CEM, PWM, WMM, and alternate designs
  5. ForceFed's E46 D2S Bi-Xenon Projector Retrofit guide
  6. Rewire OEM Bi-Xenon headlights to work on the halogen harness
  7. DRL Disable Alone not enough for safe Aftermarket HID retrofits
  8. LizardOfBodom's EU/RHD Bosch ("E46") Bi-Xenon replica retrofitting writeup + angle eyes + running lights

This thread is for discussion of the SKBOWE PWM filter, a plug-and-play error harness that I developed to help the P1 community with HID retrofits. If you have a question that's not related to the SKBOWE, please see if it fits in one of the other HID threads (above) before posting here or starting a new one.

Lets face it, the OEM halogen headlights in our cars suck. We should all know by now the issues with HID retrofits, and that the DIY solution is not trivial since it takes some soldering and hacks up the CEM harness. I have been PMed dozens of times over the years asking for a better way...

So... I found something really sweet ;) If you are interested in a commercial, plug-and-play (no cut wires!) solution that was designed specifically for Volvo P1 cars (S40, V50, C30, C70) check out:

https://www.skbowe.com/ - Shipping Now! Limited Quantity Remaining

Orders as of October 2017 (82 total): boulderc30, V50toS40, thefisch33, rhags138, persianelf, nhiggins, S40R-by-design, walky_talky20, taskmule, viggen, Puddlepirate56, chrisasdf, Noswal, beachnut, stevien1, evy0311, MJC70, MCRDSM-S40, hq_, et al... *
  • Prototype: #001A (test) #002 (mine), #003 (display unit/open box)
  • Batch 1: #004-#028 CLOSED & SHIPPED (JUL 2017)
  • Batch 2: #029-#050 CLOSED & SHIPPED (DEC 2017)
  • Batch 3: #051-#075 CLOSED & SHIPPED (FEB 2018)
  • Batch 4: #075-#100 - Shipping Now (OCT 2018)
* Don't see your username here? PM me with your SN#



Click here to see SKBOWE Installs!!

rhags138 (007) - Install
mgm7890 (024) - Install + writeup
:thumbup: SirScarFace - Install
:thumbup: Saab - Install

SKBOWEs have shipped all over...

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Useful Snip

For those of you looking for projectors, I put together a reference sheet to help you identify compatible Bosch AL 3-inch "E46" projectors in auctions or at salvage yards:



See the full resolution PDF here: https://www.theeshadow.com/files/volvo/e46/guide/al_projector_guide_v1_web.pdf

You want to look for "Gen 2" projectors, they have the best optics and the wiring is simple. Gen 1 requires a solenoid controller for bi-xenon functionality. All projectors with black plastic rings will fit D2S, the ones with octagon-shaped bulb holders might need a simple modification (bending a small tab) to allow them to take D2S bulbs.

If junkyard hunting and eBay stalking aren't your thing, Nick has been nice enough to hold a few for us:
matched sets of gen 2 projectors... PM if you're interested.
Here are some projector beam patterns:

<a href="https://www.skbowe.com/a/2017/08/01/al-projector-e46-identification-chart-selection-guide-pdf/" target="_blank"><img width="683" height="1024" src="https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-683x1024.jpg" class="attachment-large size-large" alt="" srcset="https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-683x1024.jpg 683w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-200x300.jpg 200w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-768x1152.jpg 768w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-1200x1800.jpg 1200w" sizes="(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 984px) 61vw, (max-width: 1362px) 45vw, 600px"></a>

SKBOWE install is plug-and-play:
</img>
</img>

Survey Stats as of May 2017: 87 responses, 82 on board.

VENDOR INFORMATION

We need a reliable manufacturer / distributor for high volume manufacturing of a specialized error canceling circuit designed specifically for the Volvo P1 series. A complete validated production ready design is available. If you are a vendor and are interested in taking on this project, please contact me!
 
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#108 ·
5 SKBOWEs delivered already, and 15 out for delivery today :thumbup:

Looks like Denver got the short end of the stick :(
 
#109 ·
Received mine yesterday!
 
#110 ·
And it's not installed yet? :p

Pics or it didn't happen.
 
#112 · (Edited)
Don't let the DRL disable hold up your 35W install - just keep LSM in II until you get to it. Every SKBOWE runs a 50W Morimoto kit for 10 minutes on simulated DRL during testing (if it can run that, it can run anything) so nothing will explode ** if it gets switched by accident. It's just not great for any of the stuff long term (especially on a hot day after driving hard, etc), if it was always on DRL it's something like taking the expected life from 20,000 hours to 5,000 hours.

BTW do you know the other dude in Philly?

Edit:

** Depending on you kits wattage and design, running a KBOWE + HID with the LSM in Position 0 might trigger a hidden (silent) short circuit DTC (aka VIDA code) for a headlight circuit out of range low. If this happens, that side will be disabled until you remove the key and restart the car. There will be no warning displayed, and switching from 0 to II while the car is on (or the key is in) will not re-start the ballast. Restarting the car in position 0 will probably result in another error, making it seem like a fuse is blown or something is hooked up wrong. If this happens, take the key out, turn the LSM to II, and restart the car.

...But rather than explain all of that and have to deal with confused people, the "official" guidance is disable DRL. Alternately, you can disable Position 0: https://www.skbowe.com/a/2017/09/27/how-to-drl-disarm-aka-lsm-position-0-disable/

EDIT: Fixed the above to read correctly (thanks Fwinns)
 
#116 ·
Don't let the DRL disable hold up your 35W install ... nothing will explode if it gets switched by accident.
Let me clarify (also edited above) "nothing will explode"

Depending on you kits wattage and design, it might trigger a hidden (silent) short circuit DTC (aka VIDA code) for a headlight circuit out of range low. If this happens, that side will be disabled until you remove the key and restart the car. There will be no warning displayed, and switching from 0 to II while the car is on (or the key is in) will not re-start the ballast. Restarting the car in position 0 will probably result in another error, making it seem like a fuse is blown or something is hooked up wrong.

But rather than explain all of that and have to deal with confused people, the "official" guidance is disable DRL.
 
#117 ·
Yeah, I understand. I'm just forgetful some times and wanted to idiot proof it against myself. Plus, last time my wife left it in II overnight and killed the batt. Anyway, I ordered a cheap Kensun 35w kit from Amazon and it is supposed to arrive tomorrow. So I might install the projectors, and everything else tomorrow night if I can get around to it. Just finished wiring my 30a/240v brew panel today and everything works except the contactor coils. Now I have to troubleshoot that. Ill probably just do the headlights tomorrow though. They are more straight forward and I'm an electrical noob so ill go with the easiest thing first I'm sure. Thank god that these headlight housings come out so easily. Its the 5th straight day with the heat index above 100. Ill take pics and document

Sent from my VS995 using Tapatalk
 
#120 ·
Not a fan of Kensun. I had them on a previous car and I had to send different components of the kit back three separate times. When you finally get a working kit, they work well and last a long time.

Sent from my iPhone using Tapatalk
 
#119 ·
Installed and working. Ill get some nightshots and fine tuning tonight hopefully. Writeup soon to follow......hopefully. I did take pics and document. The only thing left to do is figuring how to splice in the shield actuator for bi-xenon. Thank you for delivering this to the community.


Sent from my VS995 using Tapatalk
 
#121 ·
Installed and working. Ill get some nightshots and fine tuning tonight hopefully. Writeup soon to follow......hopefully. I did take pics and document. The only thing left to do is figuring how to splice in the shield actuator for bi-xenon. Thank you for delivering this to the community.
Dang son ... from your first post to this one it was 2 hours, nice work!

I've been lurking these retrofit posts for 2+ years now, and now that the S40 is my DD I'm thinking about it more seriously. The thing is I hardly ever drive at night. I know that sounds odd, but if we're cruising out after dusk it was either in my old DD (the '04 S80) or now the newer S80 (the wife's whip). I guess I need to pull the trigger though, especially with shadow's new invention :)
 
#122 ·
Nice! So fired up the first try?

The last one from batch 1 just sold so thanks everyone who supported me in this. I will be building batch 2 when the caps get in and hopefully that will keep SS stocked for the next few years.

:beer:
 
#124 ·
So I can confirm that not all BMW E46 cars came with "E46" projectors...

This one was advertised as "1999-2001 BMW E46 323i 325i 330i":







It has a 3" projector, but no bi-xenon flapper! Waste of $60...

Nick - We really need to get a guide together...
 
#125 ·
Bummer... :/
From what I know, only later versions of E46 (after FL) had bi-xenons. Earlier ones only had standard ones. Both version use THE SAME Bosch projector (technically Bosch AL "E46") but with fixed or movable flapper. Like an upgraded version. At least thats what was happening in EU markets. I guess the safest choice is to ask for pic of projector from the lamps maybe...
As for price-wise, not sure how much parts for beemers are in US, but in here it was much cheaper for me to get brand new aftermarket projectors (already with clear lenses) than trying to source used OEM ones and replacing the lenses. Maybe worth considering?

BTW on Kensun kits - Have been using their ballasts for 2 years now on 2 cars - had an issue on 1 ballast that died month after purchase and was replaced FOC no problem, all other still work as new. For the price you can get them, I think its a very good product comparing to other nonames sold for similar money on Ebay.
Sadly, sourcing Morimoto or anythng decent in EU is almost impossible :/
 
#126 ·
Bummer... :/
Seriously. I'm trying to do a detailed writeup on the projector swap option, guess I'll have to try again...

From what I know, only later versions of E46 (after FL) had bi-xenons. Earlier ones only had standard ones. Both version use THE SAME Bosch projector (technically Bosch AL "E46") but with fixed or movable flapper. Like an upgraded version. At least thats what was happening in EU markets. I guess the safest choice is to ask for pic of projector from the lamps maybe...
Interesting and good to know. Yeah it looks like the 2006 coupes have bi-xenons, but others do not.

The one pictured above does not have ignitor-on-bulb, there is a separate ignitor unit just like the aftermarket ones (well, much larger) - basically the equivalent of an AMP ballast + D2S converter.

This is convincing me more and more that the OEM projector is fine w/rebased except for the lens. It is just so unlikely that the ellipsoidal reflectors have different profiles. Maybe I'll take this one apart and replace the lens with a screen to see how well it's actually focused, and do the same with the OEM projector + rebased bulb.

As for price-wise, not sure how much parts for beemers are in US, but in here it was much cheaper for me to get brand new aftermarket projectors (already with clear lenses) than trying to source used OEM ones and replacing the lenses. Maybe worth considering?
Nick looked at the replica vs OEM projectors (not sure if he posted here, but pics at ) and the replicas are inferior quality. Here if you wait on eBay you can find the (apparently wrong) older headlights for < $100, but it looks like the new ones are vastly more. Every now and then there is a loose projector but they are getting increasingly rare.

BTW on Kensun kits - Have been using their ballasts for 2 years now on 2 cars - had an issue on 1 ballast that died month after purchase and was replaced FOC no problem, all other still work as new. For the price you can get them, I think its a very good product comparing to other nonames sold for similar money on Ebay.
The nice thing about the SKBOWE is you can run any ballast you want - and when the ballast dies the car tells you that a bulb has failed! If Kensun is the new DDM Slim but with 1-day shipping, I say go for it.

Sadly, sourcing Morimoto or anythng decent in EU is almost impossible :/
Have you had a look at HID50? They primarily sell for motorcycles (which have a much harder life than cars) but do sell car kits too. The owner (Les) commissions his own production runs and (like me) uses only top-notch components. They were one of the first 50W kits on the market, and they still have some of the best products out there. Pretty expensive and inconvenient to ship to the US, but if you are in the UK or IE it's worth checking out.
 
#130 · (Edited)
Sorry I haven't been able to reply - I summarized the E46 situation before, but the bulk of the story is pretty dense and boring.

In short - "E46" projectors don't really exist...it's what we call Bosch Automotive Lighting's projector mounting and bowl dimension standards first introduced on - you guessed it - the E46 3-series. That means they have lots and lots of versions over the 2 decades they've been using those standards. AL's consistent dimensioning is a big reason why our stock halogens (also an "E46" variety) are so easy to swap out. Pretty much every headlight with an AL logo on it is using the "E46" standard in one form or another.

There are some designed for D1S, D2S, and D3S - some with twist-on plastic clamps, some with split twist-ons, a bunch with integrated clamps (look for the octagon!), the varieties go on...

---- There will be lots of links and images below here! ----

Gen 1 (as I call it) is aluminum with a vapor deposited aluminum finish, comes in single and bi-xenon flavors, and was mostly found in D2S form, but also came in two D1S flavors: Split-ring (1) and metal holster (1) (2) Lots of early models had single-xenons, which are easy to distinguish due to their lack of a shield solenoid and associated PCB (1) (2)

The single xenons we don't give a crap about, but they are on Late D2 Audi A8, Late E38 BMW 7 series, and maybe W220 Mercedes S-class.

The glorious, all-powerful bi-xenons can be found on quite a few things. The D2S ring versions are on:
This list is not exhaustive, but the ring ones seem to predominantly be on the actual E46 3 series.

The D1S metal holster versions may not be more common, but were found on (from what I can tell) not only more models, but more recent ones, too:
  • E70 BMW X5 (1)
  • W221 S-class (1) (2) (3)
  • 06-11 Cadillac DTS (1)
  • E90 3 series (1)
  • W204 C-class, B6 & B7 Audi A4 (1)
  • Mid-late L322 07-12 Range Rovers
There are a few one-off varieties that use the "E46" dimensioning and guidance, but are otherwise custom designs. The Ford Explorer bi-halogens and Fiat 500 projectors are the best examples I can think of. Some other random GM cars use E46 dimensions, as well.

Gen 2 is what is still in use on cars you can find on dealer lots today. The Germans have also expanded their territory, as this design is on many more American cars than the early models. Since AL decided to make a one-piece bulb holder and integrate it with the projector, they come in all kinds of tasty xenon flavors, from D1S and D2S to mercury-free D3S and D4S. All that changes among them is a small notch on the bulb holder to accept a particular base. The big change with this gen is the bowl geometry and construction - the bowl is a bit fatter and made of SiAl - Silumin. The vapor deposited coating is also thicker and localized to the reflector bowl, giving the exterior a distinct, raw cast finish.

The better bowl geometry, thicker layer of aluminum, and sheer age factor mean these ones are likely to be the best and most durable of the bunch. Luckily, these also seem to be the most common on Ebay. They're just never labeled "E46" if you look to buy them. Try and search for the cars listed below with "projector" in your search term:
  • KL Jeep Cherokees (1)
  • Most? Lincoln MKXs (it even comes engraved!)
  • R56/F56 Mini Coopers and probably other Minis since 2007 (1)
  • Cadillac XTS (1)
  • W205 C-class 2014+
  • B8 Audi A4/S4 (1) (2) (3)
  • W166 M-class possibly also W164?
  • X166 GL-class
  • PF Dodge Dart
  • 6G Camaro, 16-18 (1)

In fact, even Volvo has their own one-off version of the gen 2 E46 (1), which you can find on all 08+ S40/V50s with xenons. It has a shorter lens cradle with a much more convex lens. Shame they dropped these so quickly, as these projectors are really, really nice - widest beam pattern and sharpest cutoff of all stock E46 designs I've seen.
 
#131 ·
+3exp. top my lighting knowledge factor :)
Thanks for above, interesting stuff :thumbup:

(btw - call me lazy but reading this I have even less guilt after going with hassle-free, plug&play option :)
 
#132 ·
Thanks! Took a while to put the links together since half of my bookmarks were broken...

I dumped the TRS replicas within a few months of buying them. They may be hassle free but the Chinese clones are almost all garbage. Bad beam pattern, poorly aligned hotspot, and bad bowl geometry and reflector quality. All they had going for them was "clear lens!!1!" My experience with OEM projectors has been worth the digging, and I'm buying a few sets to hold onto and resell to make this a little easier for others.
 
#135 ·
Man, I think my brain is starting to melt :D All I can say is WOW Nick, thanks for all your knowledge. I'm getting more interested in doing a retrofit but have a few reservations. One being the oem real-deal e46 projectors versus the knock-offs from a plug-n-play perspective (I don't have time for a protracted hobby/project). Second being my existing housings ... plastic lenses are somewhat crummy (probably can be fixed, know how to do that), but more worrisome is the brittle wiring inside my housings. When I bought the car 2+ years ago I pulled the projectors to clean the lenses and tossed in a set of Silverstar Ultra's (yeah I know, yada,yada, yada) and the insulation on just about every wire I touched just crumbled in my fingers. I'm guessing this is due to the heat in FL, but probably more due to the heat generated by the DRL function that I can't turn off like I can in my other cars without greasing the dealer's palms :mad: . It's almost like I should pick up another set of lights, but then there's just more expense ... sigh.
 
#136 ·
wow nick's like the wikipedia of e46 projectors. very cool.

i bought my bixenon e46 from forcefed here...not sure if it was a replica or oem. would like to think it's oem since he added aftermarket zkr clear lenses (the replica trs sells come with generic clear lenses) and performance (cut off, etc) has been great.

nick would be doing the community a great service if he could source oem bixenon e46. the oem halogens are terrible


Sent from my iPhone using Tapatalk
 
#138 · (Edited)
#139 ·
I've updated https://www.skbowe.com/a/guide/ to include info the from Nick (hopefully I did it justice) and on the wiring. As always, open to comments & suggestions
 
#140 · (Edited)
For those of you looking for projectors, I put together a nice reference sheet to help you identify compatible Bosch AL 3-inch "E46" projectors in auctions or at salvage yards:



See the full resolution PDF here: https://www.skbowe.com/b/al_projector_guide_v1_web.pdf

You want to look for "Gen 2" projectors, they have the best optics and the wiring is simple. Gen 1 requires a solenoid controller for bi-xenon functionality.

The ones with octagon-shaped bulb holders might need a simple modification to allow them to take D2S bulbs. All of them with black plastic rings will fit D2S. Pics comparing beam patterns and cutoffs to come...
 
#141 ·
The ones with octagon-shaped bulb holders might need a simple modification to allow them to take D2S bulbs. All of them with black plastic rings will fit D2S. Pics comparing beam patterns and cutoffs to come...
Nice one, well done! :thumbup: But I must say, my aftermarket projectors looked MUCH better than this cr** on your last pic, wow!... I guess there is such thing as "better" Chineese copy :)
 
#142 ·
Aaaand the projector beam patterns...

<a href="https://www.skbowe.com/a/2017/08/01/al-projector-e46-identification-chart-selection-guide-pdf/" target="_blank"><img width="683" height="1024" src="https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-683x1024.jpg" class="attachment-large size-large" alt="" srcset="https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-683x1024.jpg 683w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-200x300.jpg 200w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-768x1152.jpg 768w, https://www.skbowe.com/a/wp-content/uploads/2017/08/al_projectors_hid_cutoffs_sixup_montauge-1200x1800.jpg 1200w" sizes="(max-width: 709px) 85vw, (max-width: 909px) 67vw, (max-width: 984px) 61vw, (max-width: 1362px) 45vw, 600px"></a>

Enjoy :beer:
 
#143 ·
Enjoy :beer:
I love light comparison pics! :partywave:

From what I see, it actually show how much wider the beam from OEM AL projectors is comparing to replicas. I have always noticed how wide the beam spread is on Audi A4's etc versus my replicas and now its side-by-side proof. I guess there is a lot to gain by going OEM projectors vs replicas.
Also - can you confirm that OEM AL1 and 2 are also bixenon? how come the opened shutter on replica creates razor sharp cutoff shape while the other just release a flood of light?
 
#144 ·
Sorry for the n00b question lol ... but the first pic is retro on stock projectors/lenses, yes? Doesn't seem too bad, but of course that's a short distance on a wall. Looks like there's still enough cutoff as to not invoke wrath from oncoming drivers?
 
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