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PostPosted: Sun Feb 22, 2015 9:06 pm 
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Year and Trim: 2006 Saab 9-3 SportCombi
Being that there are threads for taking apart headlights and retrofitting already I figured the more the merrier and I know someone will benefit from this write-up of how I go about the process of retrofitting.

So first off remove the headlight from the vehicle...

From there you will have to remove the wiring harness and miscellaneous rubber and plastic as the light will be totally disassembled and placed in the oven. There are two screws holding the wiring harness in place, a T15 bit is required to remove these screws.
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Then remove the rubber boots from around the headlight housing and the back of the reflector bowls along with the rubber trim around the headlight.
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From there there are a number of clips holding the headlight lens to the housing, remove these clips
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Now preheat your over to anywhere between 150 and 200 degrees for 10 minutes or so (I have gone above 200, just keep an eye on the headlight and don't forget about it, this is just to heat up the adhesive holding the lens to the housing making it easier to pry apart)
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Take the light out from the oven and pry the lens away with a flathead screwdriver starting from the outer edge of the light by the blinker side first.
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Remove the black bezel that covers the reflector bowls by prying at a number of tabs that hold it in
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Then to clear the amber corners there are four tabs that hold it in, remove the amber by prying at these tabs if you wish
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This is what you should have at this point
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Now remove the reflector bowl. There are three ball and sockets that hold the bowls to the housing. Remove the one that is easiest to get to first then work the rest out by careful prying, it is very easy to break these tabs so take your time as these are what i used to aim your headlights
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Now its time to cut the bowl. I have done retrofits before and know ballpark what to dremel out but you will have to cut out some and grind out more from there to fit whatever projector you have. I personally attach the projectors to the bowls so you keep the aiming capabilities of the headlights.
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Grab your gloves, safety glasses and air dremel, this is very dusty :)
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You'll have sort of round hole
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I dremeled my shrouds to fit under the black bezel
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Mocked up
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I then drilled holes into the cut up bowl to attach the shroud and projector to the bowl
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Now it is your choice to keep the bowl chrome or paint it black, I chose black to make the projector pop more. You can do whatever you want with the bowl because you will mot be using the reflection of the chrome anymore with the projectors.

To paint it black I taped off the high beam bowl off, try to etch the bowl up as much as you can with sandpaper before paint...paint does not like to stick to chrome..
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Painted to re-mocked up
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From there I screwed in the projector to the bowl, snapped the bowls back into the housing and placed the black bezel on, here is the finished product without the lens
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From there reheat the lens in the oven and put the lens back onto the housing, then in remove order of disassembly put the clips back on then the rubber boots and trim, and wiring. You'll then want to put the rubber brackets and seals onto the projectors to seal your headlight interior from the elements, remember to run the wires for the bi-xenon capabilities to the outside as well
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Now do this again and you'll have some nice headlights and better light output

On the vehicle
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I hope this helps someone! Enjoy! Let me know if you have questions regarding your future retrofits or contact Carl (nos4blood70) or better yet let him build one for you! ;)

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-Mike
2006 Saab 9-3 SportCombi
-17x8 OZ Racing Superleggera wheels- -GReddy Exhaust- -K&N Panel filter- Tinted Windows- -Blacked out side markers-
Tune coming soon
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2000 Bonneville SLE - Totalled


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PostPosted: Sun Feb 22, 2015 9:48 pm 
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Location: Chicago, IL
Year and Trim: 2003 SLE
Beat me to it, and to think I took so many pictures of it yesterday... Hahaha.

Couple of things I would add. For the sockets, I would hit them with warm air from a blow drier to ease their removal.
You can use Steelstik and JB weld instead of using the screws to attach the projectors to the buckets. This is permanent of course, but is ultimately less work.
If you don't paint the low beams black, you'll get nasty reflections and random light. There is light escaping from the back of the projector, especially if you use the mini graphite shroud.
This is a dirty and dusty process. Make sure you wear safety goggles and something to cover your mouth and nose.
Do NOT buy Depo aftermarket replacements to retrofit. From the stand point of this process, they are Satan embodied into a small plastic lighting assembly. They are extremely hard to open, feature only vertical aim, and the sockets that attach the reflector buckets to the housing are notched and practically impossible to remove without breaking.
As mentioned, feel free to PM either of us with any questions you may have. I am taking long hiatus from retrofitting, which may or may not become a permanent one, but I will happily give advice to anyone who needs it.

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-Car Guy Carl
"Penelope" - 2003 SLE - 247k Miles
"Sydney" - 2000 Honda S2000 - 98k miles
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PostPosted: Sun Feb 22, 2015 9:49 pm 
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looking good!!!

:bwoohoo:

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2004 Bonneville GXP Crimson Tintcoat- Casual fuel gauge | Brake Performance drilled/slotted rotors front and rear| Retrofit Morimoto mini H1 | clear corners | disabled DRL | 3000K HID fogs | 5% tint | K&N | Yakima rack with fairing, bike rails and kayak rack | Intermittent radio display
1995 Bonneville SSE Deep Amethyst Pearl- SSEI tails | 5% tint | 3 12jlw3v2 in custom enclosure -Gone
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PostPosted: Sun Feb 22, 2015 10:03 pm 
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Year and Trim: 2006 Saab 9-3 SportCombi
Yes Carl I was waiting on your reply as with any write up you always forget something! The heating method for the sockets is a great idea, you really have to be careful removing them more than anything else in this project they are a very important part of the headlight! Yes it is a very dusty process, the reflector bowl is made of a material that is very messy when grinded. When dremeling in enclosed areas I took a break or two to let it air out as it is very easy to inhale this dust which can be damaging to your body I am sure, and goggles or glasses are reccomended when doing anything like this.

_________________
-Mike
2006 Saab 9-3 SportCombi
-17x8 OZ Racing Superleggera wheels- -GReddy Exhaust- -K&N Panel filter- Tinted Windows- -Blacked out side markers-
Tune coming soon
Image
2000 Bonneville SLE - Totalled


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PostPosted: Sun Feb 22, 2015 10:27 pm 
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Thanks to all for the great write-ups and comments. It is much appreciated. When/If I have the funds for a lighting up-date, it will be one of the two of you, that is if either of you are still doing the upgrade. - BC

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In Memory of Brad - 1/21/1977 .. 10/23/2013 ...... Aaron - 1977 .. 2017 .....
2017 Hyundai Santa Fe Sport ..... 1992 Bonneville SSE 1SB 170 HP L27 4T60E retired/sold to MattStrike ..... 2005 Bonneville SE 1SC 205 HP L36 4T65E - retired/salvage yard ..... PBCF user 2321


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PostPosted: Sun Feb 22, 2015 10:35 pm 
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The third set I ever did, I didn't wear anything over my mouth and nose. My lungs felt like death afterwards.. Don't do that to yourself!

Great write up though, on point. Patience is a virtue in this process.

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-Car Guy Carl
"Penelope" - 2003 SLE - 247k Miles
"Sydney" - 2000 Honda S2000 - 98k miles
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