Electrical R60 Xenon Retrofit project, made some progress
R60 Xenon Retrofit project, made some progress
So, I ended up getting my hands on brand newish xenon housings, and I sourced the factory bulbs and ballasts, its time to make this retrofit happen!
So far Ive plugged them in, nothing happens, so I coded the CAS, added in $522.
Now the car works still works with halogens, but when I hit the high beams nothing happens. What Im thinking is the wiring to run the bixenons if different, so I need to run new wires from the FRM.
Still though, even with the coding, the xenons dont power on. I did accidentally ground the ballast out on the body and the lights came on, which leads me to believe the ground pin is differnent on the xenon equipped cars.
My goal is to do a straight factory swap, once I get the headlights powered on, next its the high beams, after that I'll tackle the self leveling and finally I'l do the head light washing system if i dont get lazy!
Can someone with a xenon equipped r60 take a pic of the wires going to the headline harness and post it? This will help me IMMENSELY to figure this out
So far Ive plugged them in, nothing happens, so I coded the CAS, added in $522.
Now the car works still works with halogens, but when I hit the high beams nothing happens. What Im thinking is the wiring to run the bixenons if different, so I need to run new wires from the FRM.
Still though, even with the coding, the xenons dont power on. I did accidentally ground the ballast out on the body and the lights came on, which leads me to believe the ground pin is differnent on the xenon equipped cars.
My goal is to do a straight factory swap, once I get the headlights powered on, next its the high beams, after that I'll tackle the self leveling and finally I'l do the head light washing system if i dont get lazy!

Can someone with a xenon equipped r60 take a pic of the wires going to the headline harness and post it? This will help me IMMENSELY to figure this out
Last edited by Shoe Coupe; Dec 15, 2012 at 12:48 AM.
FWIW, I saw a countryman last week with reflector housings and an aftermarket HID kit. It looked nice and was not too dazzling to other drivers. They were a high color temperature, which isn't my cup of tea, but that may be why they weren't so blinding. They were at least 8000k if not 10000k. For $60 bucks on Amazon (or less if you are willing to wait from VVME.com) it might be a good option. Perhaps get a 35w kit, and some high color temp bulbs that aren't so bright.
FWIW, I saw a countryman last week with reflector housings and an aftermarket HID kit. It looked nice and was not too dazzling to other drivers. They were a high color temperature, which isn't my cup of tea, but that may be why they weren't so blinding. They were at least 8000k if not 10000k. For $60 bucks on Amazon (or less if you are willing to wait from VVME.com) it might be a good option. Perhaps get a 35w kit, and some high color temp bulbs that aren't so bright.
Made some huge progress today!!!!1

SO EXCITED!!!!!!
Details to follow. Suffice to say I got it all hooked up and powered on, not a single harness or wire was harmed in this process. :D :D :D

SO EXCITED!!!!!!
Details to follow. Suffice to say I got it all hooked up and powered on, not a single harness or wire was harmed in this process. :D :D :D
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very nice ! i'm sure a lot of people will be glad to see this done. the xeons are worth the cost, they were actually one of my must-haves when i picked up my cm.
... and the details... ?
You know... I havent decided. I have them on and they work, and theyre super bright, but to go any further, I need to modify wiring in the car. I know how to do it, but I'm torn making modifications to the electrical system
Keep in touch, if I decide to sell them, are you interested?
Keep in touch, if I decide to sell them, are you interested?
Next I'll be hopefully wiring the high beams. Been driving around two weeks without auto leveling, it's not THAT big of a deal. I have them adjusted just right and I havent noticed it shining high enough to blind anyone. I've also had my wife drive in front of my car and she said it she didnt notice any blinding.
The big hold up before was that I figured out the pinout on the Xenon headlights, but had no way of moving/adding wires to make it all work, the night I posted this I figured out how to remove individual wires from the plug.
Basically you have to move the ground wire from one pin to another. That will power the xenons up, but will cause them to flicker if you drive off. So as bearheros mentions in the r56 xenon retrofit thread, you have to code the car to know it has xenons, so you add a $522 to the VO, with that the headlights will work.
The problem then becomes the front turn signals and error messages. The dealer sells whole wires ready to be plugged into the harness, complete with the grommet at the end to make them water proof. I purchased a couple of these and had to rewire a second ground, this allows the high beams and turn signals to work. I attached the new ground to the factory ground point right below each headlight.
Next I will work on the high beams, this can either be done by swapping pins on the FRM or running new wires. I want to go the route of running new wires, which requires me to find the right sized wiring loom from the dealer. So that's what I'm tackling next.
No updates yet, I havent had time to run to the dealer and buy new wires to wire in the high beams yet. I will most likely tackle this after the holidays
update:
So i finally wired in the high beams! they work perfectly, and luckily i didnt have to buy new wires from the dealer. the good news is that our wiring harnesses are identical to the r56, as is the footrest module, so the instructions posted in the r56 section for retrofitting xenons work for us too.i mostly followed what bearheros has posted but found his instructions a big short but accurate
to get the high beams working, first and foremost $522 needs to be coded to the vehicle order. then you have to reset the footrest modue (frm). youdo this by writing a blank file to it, causing it to pull the $522 from the cas module and changing to support xenons
then you have to undo the wires from the healight harness, the yellow wire with blue stripes and move it from pin 5 on the harness to pin 12. be very careful releasing the pins as the headlight connector is very easy to damage.
next you have to access the footrest module on the drivers side kick panel. there are two connectors rather large on the underside of the frm, one is black, one is grey.
find the same wires you moved on the headlight harness, yellow with blue stripe. on the black harness it is pin 38, remove it, next find pin 6 on the grey harness. remove that too. combine both these wires and connect them to pin 41 on the grey harness. this is the bixenon control line, bam now the high beams work!
i was able to connect everything together without cutting or harming any harnesses and i can revert back to the factory setup without issue (all the modifications ive always performedhave been reversible as this is my philosophy)
ill post up more details and pictures later on if anyone is curious. feel free to contact me with questions
So i finally wired in the high beams! they work perfectly, and luckily i didnt have to buy new wires from the dealer. the good news is that our wiring harnesses are identical to the r56, as is the footrest module, so the instructions posted in the r56 section for retrofitting xenons work for us too.i mostly followed what bearheros has posted but found his instructions a big short but accurate
to get the high beams working, first and foremost $522 needs to be coded to the vehicle order. then you have to reset the footrest modue (frm). youdo this by writing a blank file to it, causing it to pull the $522 from the cas module and changing to support xenons
then you have to undo the wires from the healight harness, the yellow wire with blue stripes and move it from pin 5 on the harness to pin 12. be very careful releasing the pins as the headlight connector is very easy to damage.
next you have to access the footrest module on the drivers side kick panel. there are two connectors rather large on the underside of the frm, one is black, one is grey.
find the same wires you moved on the headlight harness, yellow with blue stripe. on the black harness it is pin 38, remove it, next find pin 6 on the grey harness. remove that too. combine both these wires and connect them to pin 41 on the grey harness. this is the bixenon control line, bam now the high beams work!
i was able to connect everything together without cutting or harming any harnesses and i can revert back to the factory setup without issue (all the modifications ive always performedhave been reversible as this is my philosophy)
ill post up more details and pictures later on if anyone is curious. feel free to contact me with questions
I would love to find someone to do this for me but am afraid the cost would be awfully high. I miss having xenons very much. Keep thinking of getting the driving lights to try to make up for the lack.
I never bothered to put in the levelers because it was a ton of work and I manually aimed them a bit on the low side and I havent seen it blind a single person. As far as parts. I dont have the part numbers handy, but you need the right and left xenon headlights for the countryman, you also need the h1 (or is it h2) xenon bulbs and the balasts that fit underneath the headlight assembly.
Then you just need the wiring pins I mentioned earlier in the post. You DEFINITELY need some coding done to make this work. Otherwise you'll fry your headlight harness.
That being said, my countryman is for sale. I will be removing this retrofit and selling the headlights if I get someone to buy my car.
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