Mounting MDX projector

The directions on this page have been updated (4/05) and now describe 2 different methods of mounting the MDX projectors into the housing.

I. (Steps 1 through 19) I initially mounted the projectors in the housing by dropping them into the hole in the mounting bracket and bolting them in. When mounting a MDX projector with the MDX bezels is best to use the second method described on this page, using the bezels gives the headlight a real clean finish but lead to some problems if method I is used. However if MDX bezels aren�t going to be used to do your retrofit, the gap between the smaller MDX lens and the chrome shroud can be reduced using method I, because the projector sits closer to the chrome shroud.

II. (Steps A through D) The newer of the two methods, in which the aiming bracket sits between the reflector bowl and the cutoff shield/lens portion of the projector. Placing the bracket in the middle of the projector assembly has several advantages:
- The increased distance between the lens and reflector slightly narrows and better focuses the pattern of light emmited, improving down the road illumination.
- The increased distance between the cutoff shield and reflector gives more color at the cutoff. More color can be obtained if the shield and reflector are further separated by adding washers between them. (See Page 6 for details)
- Difficult adjustment of the headlight was a problem with the old method if the MDX bezel was used in the retrofit. Using the new method the projector (& bezel) sits further back in the housing and away from the chrome shroud, allowing adequate room for adjustment.

Tools (minimum)
1. Drill
-a. 1/8� drill bit (if planning to use bezel)
-b. 11/64� drill bit (can use up to ��)
2. Flat & Philips head screwdriver
3. Tin shears
4. Razor
5. Small plastic ruler

Items
-Aftermarket halo projector headlights for Nissan maxima 00-03
-From 2004 Acura MDX projector headlight
-Projector
-Circular rubber gasket from rear
-Bezel (optional)

From the home depot
-Hardware isle
1. #8-32 x 1-1/4� bolts and nuts (x8) (#8 in picture)
2. #6 x �� flat head Philips screw (x 8 will be needed if you plan to use the bezel, #6 in photo)
-Paint isle
3. Thread lock (#2 in picture)

All other items needed for making D2S bulb holder see page 3
-Paint isle
1. JB quick weld
-Electrical isle
2.1 �� plastic insulating bushing (x 2) (#3 in picture)
3.1 x � reducing washer (x 2) (#4 in picture)
4. 1 � male adapter (x 2) or any item with a plastic 1 � thread (#5 in picture)
-Hardware isle
5. #6-32 x �� set screw (socket) (x2) (#7 in picture)

METHOD I

****** Since the MDX projector lens is smaller than the original H3 projector there will be space between the lens and chrome shroud. The benefit of using the bezel is that it will hide the gap, a drawback of the bezel if methode 1 is used, is that there is not enough space between the chrome shroud and the projector for the bezel to fit properly, the bezel is squeezed tightly between the two making adjustment tough but not impossible, adjustment can be done by turning the adjusting screws while moving the back projector in the desired direction by hand. The following contains directions for mounting the MDX projector with a bezel attached, but it is recomended tht methode II be used with the bezel *****
Procedure

1.Remove headlight from car and open (Described in LED write-up see page 2)

2.Remove all bulbs and wires attached to high and low beams.

3. Remove projector mounting bracket from housing by turning vertical and horizontal adjusting screws counterclockwise & depressing the two tabs on the orbital mount attached to housing.

4.Remove H3 projector from bracket.

5.On the MDX projector reflector bowl there are two seams of raised plastic from manufacturing, use a razor to clean these off. FIG 1

6.Place MDX projector into bracket, you will notice a portion of the bracket and horizontal adjusting screw will interfere with proper placement. Two areas need to be removed from the projector mounting plate, use tin shears or other cutting tool for removal. (FIG 2 � black area with red border).
7.Disassemble projector and with a straight edge make a line from edge to edge on the back (where light will shine onto)of the mounting plate even with raised portion (lower cutoff of projected light).FIG 3

8.Place plate on front of bracket & from behind center the line that you have drawn between the holes the old projector used once in proper position, secure with tape. FIG 4

9.Mark the location of the holes indicated in FIG 5* on bracket and drill bracket with 11/64� drill bit.
*the location of the top left hole had to be moved b/c a rivet holding a small piece onto bracket (outlined in red FIG 6) was in the way. This piece was only present in my passenger light, if not present on yours, use hole to left, already in mounting plate.

10.Reassemble projector and secure in bracket using 4 -. #8-32 x 1-1/4� bolts and nuts.
* If not using bezel make mounting plate parallel with bracket, by using a small ruler and checking to see it is an equal distance apart the whole way round.


**If using bezel mount so that bracket and plate are 1 cm at top and around 1.8cm at bottom, this will place the projector and bezel further back from chrome when adjusted properly and make beam adjustment easier. FIG 7, 8, 9

11. Using seams of projector centered between holes used to mount old projectors if sufficient for rotational alignment of projectors, but not perfect. And once closed, if cutoffs are not straight they can not be adjusted. For perfect alignment it is best to mount the projector/bracket back onto black portion of housing and remount on car. Then shine the projectors onto wall and adjust the rotation of projectors with lights on, this will achieve perfectly straight cutoffs. If the possibility slightly crooked cutoffs does not bother you, just center seams between holes.

12. Once you are satisfied with the position of projectors in brackets secure 4 bolts with thread lock.

13. To mount the bezel to the projector drill 4 holes in side of bezel approximately �� from bottom at 12, 3, 6 & 9 O�clock position and insert 4 - #6 x �� flat head Philips screws, FIG 10,11.


14. Place and center bezel onto projector, lightly turn screws until tips make contact w/ projector, and is secure. **Be gentle the bezel and projector plastic is very brittle and over tightening will can crack one if not both of these. FIG 12,13

15. Mount bracket back onto black portion of housing, reattach high beam wiring cut or seal off low beam wires.

16. Place rubber gasket around the projector and into the opening in the back. FIG 14

17. Reassemble, bake in oven use pliers or channel locks to squeeze together clear and portions of housing to finish closing up projector, mount on car and adjust as needed.

Done

METHOD II

A. Follow method 1 -steps 1-8

B. Use vise grips or C clamps to secure the cutoff shield tightly to the bracket, then using the cutoff shield as a jig drill the 6 holes indicated in figure A,, The position of these holes is very important, use the appropriate size bit for each hole and make sure the shield doesn�t move as you drill the holes

C. Assemble the projector with bracket and 1-3* washers between reflector and shield. There are small knobs on the reflector preventing it from sitting flush against the bracket, use a file to shave them down, so it sits flat. The sequence of parts should be as follows:
Using 1 washer; reflector � bracket � washer � shield � lens.
Using 2-3 washers; - reflector � washer(s)- bracket - washer � shield � lens.
Fig B.

*See Page 6 for information about the # of washers.
*Do not use thread lock when assembling projector. It will weaken the black plastic of the lens holder substantially, and will cause it to literally shatter into pieces. Longer screws may be required depending on the # of washers used.

Page 2 - How to replace LEDs in Halo's for 2000-2004 Maxima projector headlights.

PAGE 3-How to make D2S bulb holder on MDX projector.

Page 5 -How to make clear lenses for turn/parking lights on 2000-2004 Maxima projector headlights.

Page 6 - MDX Projector adjustment (Washer Mod).

Page 7 - Pics of my car all fooked up.