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E39 (1997 - 2003)
The BMW 5-Series (E39 chassis) was introduced in the United States as a 1997 model year car and lasted until the 2004 when the E60 chassis was released. The United States saw several variations including the 525i, 528i, 530i and 540i. -- View the E39 Wiki

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Old 01-05-2017, 02:18 AM
mutyo051026 mutyo051026 is offline
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Mein Auto: 2003 BMW 525i Sedan
HID Conversion Write-up.

Since I finally completed 55W HID conversion project for low beam on my 03 525i with halogen projector, here I write all the necessary items and wiring setup as a record so that hopefully it will be helpful for others who want to do the same thing without spending unnecessary efforts and money. I assume you have original headlight units and don't have a software to delete "check low beam" error message on the dash.

The number in the pictures corresponds with the item number in the list below.

What you will need:
1. 35W or 55W HID Kit. I bought Kensun 55W/6000K/H7 HID kit with Digital Ballasts from Amazon for $65. (No picture is posted for this)
2. HID bulb adapter for E39. You can't install HID bulb without this adapter. This is what I get from Amazon for $8. If you buy the same thing you will need to do a small modification to make them fit on the headlight housing, but it's easy so don't worry and get them.
3. DDM Tuning Heavy Duty Dual Relay HID Harness Universal 9006 Inputs/Outputs. Make sure to get this "heavy duty & dual relay" version, since there is another dual relay harness but non-heavy duty version from DDM. This was $25 from Amazon again. I know it's a little bit pricey compared to other relay harness sold for around $10, but believe me, it's worth it. I asked DDM the difference heavy duty version and non-heavy duty version, and they said the heavy duty version uses thicker wires (14 gauge) and has better water resistant. This "thicker wire" is the main reason to get this, because the cheap relay harness that I tried previously didn't fire up one of the bulbs due to its thin wires (and it was always the bulb on the passenger side, because the longer wire goes to the passenger side). You have to get "dual relay" to delete error message.
4. 2 x 6ohm/55W Load Resistor with 9006/HB4 Input and Output. I got this from eBay for $6. Make sure to get the ones with 9006/HB4 input and output, otherwise it won't fit. And DO NOT buy the error canceller that looks like the one shown in picture #6. I tried this but it did NOY delete the error for the low beam, although it worked for the fog lamp!
5. Stainless steel wire. Any types of stainless wires will be ok. I got this from Home Depot for about $3. You will use them to fix the load resistor on the vehicle.

That's all you will need. The total cost is $100+

Once you get them, you just put them all together and install it. But before installing them, don't forget to modify the bulb adapter. You will need to cut off about 1/3 of this plastic tab from its tip since the tip will interfere with the headlight housing (see picture A).

Picture 7 - 12 show how I routed the wires and fixed the ballasts and load resistors in place, and picture 13 shows how everything is connected. The yellow lines indicate the wires from relay harness.

You can use double-sided tape to place the ballasts, but I used bolts and nuts because there weren't many places to stick them on. You should use the wire, not double-sided tape, to fix the load resistors in the air because it becomes very hot when you turn on the lights.

The result was awesome. No flickering, no errors, and great view in the night!! I was worrying about the cut-off line of the light, but it wasn't pretty good although not perfect. Don't forget to aim the light after installing HID!!

Let me know if you have any questions!!
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Last edited by mutyo051026; 01-05-2017 at 02:34 AM.
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  #2  
Old 06-06-2019, 01:03 PM
elahmad's Avatar
elahmad elahmad is offline
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Location: NJ
 
Join Date: Aug 2016
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Mein Auto: 2002 BMW 530i Sport Packg
any update to this?

looks like a lot of things to do for the HID retrofit to the halogens :/

Don't mind doing it but is this the only way it works without errors?
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2003 525i, e39, hid conversion, hid conversion kit


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