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D3S Headlight bulb/ballast upgrade Kit.

t8ups Mar 21, 2017

  1. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    D3S xenon Headlamp boost kit.


    Over the last few months i have been working on a few upgrades. Lots of my popular mods are plug and play, however some mods require the headlight to be opened. To do this mod would be an all-round better solution as no headlight needs to be split and you will get awesome results.


    A quick brief on a D3S system: it is a 42v input. Older cars that use a D1S system have a 85v input. So you will notice the difference in output. Doing the ballast boost you will gain extra output from your d3s bulb. For the ultimate output i will mod a D1S bulb to fit your D3S projectors along with the new Morimoto XB55 ballasts.


    A D3S ballast will NOT power a D1S bulb, not enough juice.


    Here are output pictures of the Bosch projector found in the A4 B8's and FL A5's:


    Oem bulb with oem ballast (D3S)

    [​IMG]


    Oem bulb (D3S) with the XB55 ballasts

    [​IMG]


    Morimoto 6500k D1S bulb with XB55 ballasts.

    [​IMG]


    All above pictures have been done on the same Projector (OEM Bosch found in the FL A5’s and All B8 A4’s that have xenons. This is on the OEM Projector lens, I do have a clear lens mod for these projectors if you would like to further enhance output, however this does require the headlight to be opened)



    Here are pictures of the kit i have put together: i have had ballast holders and grommets CNC'd so this is full plug and play. It will be sealed, a small trim in the headlight casing will be needed to allow the new high output bulb cable to be fed in, it will be very small and will still be sealed.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]


    The headlights in the above picture are from a 2016 Golf R which will use the same projectors as a pre Facelift A5 (Valeo projectors).

    Pictures of before and after on the Valeo projectors are also shown above. These are from a 2011 RS5 which came in for this mod also. I have turned exposure and contrasts down so you can see where the light is. (Ignore the black dots at the bottom of the shutter, they are exhaust splats from a 930hp RS6 which was sat idle for a few mins back in 2015 and cant be cleaned off).


    Before

    [​IMG]

    (Note that the RH headlight was poorly adjusted, I should of adjusted before taking but didn’t manage to)


    After – These are the Osram CBi bulbs with Morimoto XB55 ballasts

    [​IMG]


    Here are the test shots from a Valeo projector the same as the Bosch ones on the facelight A5’s and B8 A4’s.


    OEM Bulb and OEM ballast

    [​IMG]


    OEM Bulbs and Morimoto XB55 Ballasts

    [​IMG]


    Morimoto D1S 6500k and Morimoto XB55 ballasts

    [​IMG]


    The bulbs that will be supplied and modded will be the Osram CBi D1S bulbs. If you have recently bought D3S oem branded bulbs then the ballast kit can be sold separately to give them a boost. I do not recommend this ballast be used with cheap unbranded bulbs. The D1S needs modding to fit a D3S bulb holder, i will do this before the bulbs are sent out as part of the service, if I do not carry this out it will not fit.

    List of cars that can be done right now are:
    Audi A5 facelift and pre facelift
    Audi A4 B8 Facelift and pre facelift
    Audi Q5 Facelift
    Audi A7 With Xenons
    Audi A3 8V PRE FL with Xenons
    VW Golf MK7


    So headlights with the D3S system made by AL Bosch or Valeo. If you have Hella then there is no hope for you, its a fully rebuild with better projectors.


    The full kit will be £299 posted within the UK and you will get a full 2 year warranty.

    Postage in the UK is free and will be RM 2nd class signed for. Outside the UK will be £7.


    Any questions then please ask in this thread and I will try to answer as best I can.



    Thanks

    Trups

    EM Tuning
     
    Last edited: Mar 21, 2017
    martinivw, AU11 ALS, SteveMcB and 2 others like this.
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  3. SteveMcB

    SteveMcB Well-Known Member SQ5 owners group Team Sepang Audi Cabriolet Owner Group

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    Hi Trups, I've got an SQ5 plus with OME bulbs and lights, TBH I feel they could be a bit brighter with better penetration, are there any options you could recommend for that car? Cheers.
     
  4. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    Hi.

    This is the Kit for you :D.

    your headlights are the Valeo ones so you would go with the ones along the bottom, you can see the improvement it gave, fitted some last week to a 2016 Golf R and the feedback email came in last night and its said " its like a fuc*king lighthouse, its unreal, I'm over the moon".

    Its a plug and play kit, only snipet you need to do is in the back case with a Stanley blade to let the high voltage cable pass into the headlight.

    Trups
     
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  5. SteveMcB

    SteveMcB Well-Known Member SQ5 owners group Team Sepang Audi Cabriolet Owner Group

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    Thanks for this, it's got the adaptive lights and must admit I'm a bit reluctant to try taking them out and modding them myself - it's also under warranty! Can you maybe point me to an installation guide?
     
  6. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    HI.

    The headlights don't need to be opened to carry out this Mod. They will need to be taken off the car, on a Q5 I am unsure how they come out but once off you remove the old bulb and old ballasts, you plug in the new kit, mount the ballasts in place of the existing ballast and plug it all together, this will not mess with any of the adaptive systems, it will all still work as it did before.

    If you look at the pictures, you can see where I removed the old ballasts, plugged in the new wiring and put it all back together, I have plenty of spare headlights of other models so It wont be hard for me to help but from the pics in this thread will be more than enough for you to fit them, it really is just a case of swapping the parts over then driving down a dark road thinking why the hell Audi didn't put a higher voltage system in.

    Trups
     
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  7. SteveMcB

    SteveMcB Well-Known Member SQ5 owners group Team Sepang Audi Cabriolet Owner Group

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    Thanks mate, I'll do a bit more research and hopefully find out how easy/difficult it is to get them out. Sorry if this sounds a bit thick, but do I use my existing bulbs or the modded D1s?
     
  8. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    You will use the new ones I send out which are D1S, they have a higher input voltage which make them perform better than D3S. We can go D3S bulbs or you can use the 50W ballasts with your existing bulbs but they will go warmer in colour.

    The good thing about this kit is that it can be Fully reversed so when you sell the car you can put the old items back on and no one will ever know they where ever fitted.

    Trups
     
  9. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    The Q5 headlights come out without bumper removal making this whole task easier.
     
  10. Gavin0478

    Gavin0478 Active Member Team Daytona Team V8 VCDS Map User TDi Audi Q7 quattro S-line owners group

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    Will you be making a kit for the facelifted Q7?
     
  11. SteveMcB

    SteveMcB Well-Known Member SQ5 owners group Team Sepang Audi Cabriolet Owner Group

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    That's good news, I've been doing a bit digging but can't find any guides on how to get the lights right out. It looks easy enough to loosen them off but all the threads I've read say that they only slide out a few cm.
     
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  13. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    Where are you based? when you slide forward you turn them out slightly then they come off the slider, like the B8 A4 and A5's.

    Trups
     
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  14. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    let me come back to you later, I know the headlights are Valeo in the Q7 which is what the kit is for, I just need to see what ballast you have fitted so my bracket kit and wiring can work with your headlight.

    Trups
     
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  15. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    Just checked it all on etka, my kit WILL work on your Car all the same as the others, yours are Valeo headlights so your referance pics are the bottom shots of the opening post.
     
  16. SteveMcB

    SteveMcB Well-Known Member SQ5 owners group Team Sepang Audi Cabriolet Owner Group

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    In Edinburgh mate otherwise I would have asked you to do it. Thanks for the tip on removal I'll give that a look.
     
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  17. JulianW

    JulianW Active Member

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    So, t8ups, (or should I say Dr Evil?), sharks with frickin' laser beams in their heads, huh?! Nice work, really nice.
    And timely - I've just recently returned from a road trip through the wilds of south-eastern Australia, that included a deal of night driving on unlit country roads. I've come away from the experience somewhat underwhelmed by the quality of light cast by the xenons on my FL A5, particularly on high beam. How can anything that looks so impressive in an urban setting be so disappointing in the big dark? So, any data on "throw" range for dipped and high beam?
     
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  18. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    HI.

    yes they are poor, I do a clear lens mod also which on the FL A5 headlights aint too bad to do but you do need to split the headlights to do that, mated with this mod you will never ever struggle on light but just doing the clear lens mod has had good results without the need for uprated ballasts but that mod is not for everyone.

    The Range of the Dipped beam does not change, (this is down to the reflector bowl/design of the projector) if you look at the pictures, any light under the cutoff is whats projected onto the Road, so see on the pictures where the hot spot is larger and wider this means ALOT more light projected onto the roads in front and also at the sides. In High beam the light will travel further as the light output is more intense, where on a D3S bulb it will Dye out the D1S system will throw that light a good distance.

    if you wanted your lights to have a longer range in dipped and high then its a full on projector swap which I can do but I need the lights here with me or there are a few companies in OZ that work on lights but none that mainly work on Audi lights like I do.

    Trups
     
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  19. JulianW

    JulianW Active Member

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    The local authorities are already slightly weird on xenons as it is. I suspect that clear lenses would push them right over the edge. So, maybe not that option. However, given your kit is pushing out MUCH more light, that would probably be sufficient, especially side scatter.
    Right, well, I'd better start saving my Oz pesos, then!
     
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  20. Chris90

    Chris90 Active Member VCDS Map User

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    Any pics of them in the dark vs the stock ones? There is clearly more light on the garage door, but what about the real world.

    How is beam pattern and light scatter for oncoming cars on the kits?

    Would love a touch brighter light, but not sure I can justify £300 unless they are ****** epic.
     
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  21. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    Hi Chris.

    I can arrange a local B8.5 to quickly fit the kit for me and take some shots in the Dark so you can see on the Road.

    To your Answer for the Beam pattern and light scatter the answers are in the Pictures in the OP. Beam PATTERN is unaffected, the light still travels to the left for the UK Beam Pattern.

    Light Scatter is also unharmed, any light about the cut off is what causes glare to oncoming traffic, if you look in all pics there is no visible difference in Glare/scatter, when doing the fitting you need to mark where the beam is and when putting the lights back in you need to make sure they are back in exactly the same place, fitting new bulbs and ballasts wont change this, removal of the headlamp and refitting can so that's important.

    All light that is BELOW the cut off is what projectors onto the road where you need the light, the characteristics of the distance don't change on low beam but the intensity does meaning a lot more light, on high beam you will get more distants as the light will travel further as there is more power to push it.

    These wont be a touch brighter Chris, these will be ****** Epic in your words :), if it wasn't worth it then I wouldn't bother but it really is a night and day transformation and its where the D3S system struggles.

    Thanks
     
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  22. Chris90

    Chris90 Active Member VCDS Map User

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    Cheers for the reply Trups.

    Some dark shots would be good, preferably over the distance the light covers. We have a lot of country roads round here which are often unlit and my work pattern usually means leaving home around 6am and can return in the early hours of the morning depending what shift pattern im on. (1-2am) So having the bit extra light is good; especially in the winter months.

    Look forward with interest on this. I guess the full kit includes the ballasts and the D1S modified bulb to fit the D3S headlight fittings. I guess the bulbs are good quality parts as seen the prices of some D3S bulbs and can top the £100 mark!!! :eek:
     
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  23. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    The bulbs in this kit are Osram CBi D1S's, not cheap bulbs at all, I have selected them to come with the kit as they give a good colour and they are known in the lighting world as best of the best.
     
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  24. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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    These pictures have been taken by a customer for me, car is a 64reg A4 B8.5, this uses the Bosch projectors.

    OEM bulbs where Philips xenstart OEM 4300k.
    New bulbs are Osram CBi.

    Pictures of afters are with around 1 hour of use, they will get a lot whiter as they bed in.

    Low beam OEM
    [​IMG]

    Low Beam Modded
    [​IMG]

    High beam OEM
    [​IMG]
    High beam Modded
    [​IMG]

    Low beam OEM
    [​IMG]

    Low Beam Modded
    [​IMG]

    High Beam OEM
    [​IMG]

    High beam Modded
    [​IMG]
     
    Last edited: Mar 28, 2017
  25. AU11 ALS

    AU11 ALS Well-Known Member Audi RS4 Audi A4 Audi Avant Owner Group Black Edition

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    Looking forward to this next stage upgrade to our B8 lamps :)
     
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  26. DeanoC

    DeanoC Well-Known Member VCDS Map User

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    So I have the Hella lights on my C7 where splitting is a pain. Spoke to Trups and i got myself some morimoto ballasts and Osram CBI bulbs. No internal changes at all but quite a difference on the road!

    Next day delivery, he walked me through the swap on the phone and i was done in under an hour.

    Great as always. Thanks mate[​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG][​IMG]

    Sent from my SM-G935F using Tapatalk
     
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  27. And

    And Member Team Lava Grey Audi A4 Audi Avant Owner Group quattro

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    Trups Hi

    all your pics seem to have been taken offline - are you able to reconnect them or perhaps send me a PM or link to them so I can see the original pics as well as the follow ups you sent out?

    A
     
  28. t8ups

    t8ups Site Sponsor Site Sponsor VCDS Map User

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  29. PenttisHSR

    PenttisHSR Active Member Audi S4 Audi Avant Owner Group Manual

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    Dark wet winter nights have got me searching for an upgrade for my headlights.
    These supercharged cars are fast and the lights are just not good enough.
    Back in the day, we simply bolted on a big pair of Hella or Cibie Spotlights.

    Eureka! I found this post - D3S to D1S conversion, appears to be the best/most sensible/worthwhile option.
    Brilliant idea - Kit ordered
     
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  30. PenttisHSR

    PenttisHSR Active Member Audi S4 Audi Avant Owner Group Manual

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    Here's my results, converted passenger side to compare.............
    Dipped.JPG Main.JPG Main (2).JPG
     
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  31. Chris90

    Chris90 Active Member VCDS Map User

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    sooo tempted by these kits. Any discount for previous customers :p
     
  32. Chris90

    Chris90 Active Member VCDS Map User

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    Eventually bit the bullet and ordered a kit off Trups for my A4 B8.5. Rocked up saturday morning and fitted before lunch. Fitting was a doddle, although pretty tight behind the B8.5 headlights especially airbox side, but nothing that cant be solved if you have small hands.

    Quality of the kit is very impressive. Ballasts had plenty weight in them which is good, finished in strong metal casing. Wiring for both parts very good quality made by reputable brand....tyco I think it was.

    Got installed and went out for test drive that night, and difference was immense, tonnes more light output over the factory D3s bulbs. Only managed to get the 1 comparison pic in the same location at present, but also took a pic on dark road home tonight comparing dipped and main beams. Fairly big image so be hard viewing on a phone....sorry.

    [​IMG]

    And this pic below doesnt have a before unfortunately.

    [​IMG]


    Hopefully upload doesnt take away too much photo quality.

    Other comparisons to come when I get chance to travel the same route in the dark.
     
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  34. JohninMK

    JohninMK Member

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    Fed up with the pitiful output, especially in the rain on tarmac when it was basically dangerous, of the standard HIDs on my 65 S3 8V, I have also taken the plunge and this week went up and bought a kit off Thrups. Brilliant guy by the way, certainly knows his stuff.

    Using Osram bulbs but rather than go for his standard 5000k Cool Blue I went for the same as standard 4300k bulbs but in uprated Nightbreaker form. I prefer the less white light. As it was the first he had used Thrups said that he checked the bulb in a fitting with a lumens meter and its output was at least the 70% over standard, and much more than the Cool Blue. So that was a positive sign for good things to come.

    So back home me and my mate, now retired after a working life in bodyshops, set to work in the sunshine yesterday. We set aside a couple of hours to do the job. Although I am an amateur, I have spent much of the last 10 years stripping and reassembling cars, he is not and knows what he is doing but neither of us had tackled an S3 or A3 before but he has worked on other Audis. We also have a good collection of tools including battery wrench, screwdrivers etc.

    Due to his past experience with shitshields we decided to leave them in place and just release back to the struts with the front wheels off. Probably a mistake. From inserting the jacks, due to the difficulty of easy access to the bumper bolts, it was 75 minutes until the bumper was free. Now we had a headlight to work on. It took us 15 mins to work out how to release the bulb and much the same to work out the best wiring route, the S3 needs a longer ballast to bulb wire than the EM standard, then similar to modify the housing, silicone seal the cable access hole under the ballast, then trial fit it and test OK, which it was. So that was another hour gone and we wern't halfway. Now we were up to speed the second light unit was a doddle, 20 mins or so. Fitting them took another 10 mins or so. Then it was onto bumper replacement. This was when we really regretted have the shields still in place. Even though we both have skinny arms it was a nightmare not getting a straight push onto some of the bolts. If we hadn't had a magnetic bit screwdriver for the T30 bit I shudder to think how long it would have taken, we really needed the long reach version which my mate had at home, of course. Jacks in to jacks out/bolts tight was the best part of 5 hours!

    Talk about a steep learning curve. I would think we could do it again, with that screwdriver, in half that time. Faster with the shields off but I don't know how long it would take to refit them. Think I should have perhaps have asked if Thrups would fit them!

    The good thing about it taking so long was that by then it was dark and I could test them. I had previously had the aiming checked to be spot on and marked the garage doors for simple beam alignment. The good news was that the new bulb combination was spot on. Initially the light output seemed to be much as the old was but once they had been on for 20 minutes or so output was rising fast. Now, after an hour or so they are just as I had hoped them to b, same spread but much more light in the centre. There is so much that I adjusted the offside down abit to reduce any possible ahgst from oncoming traffic.

    Having recently had a 67 A4 courtesy car with LEDs, which were only marginally better than the S3, I am now a really happy bunny, £300 very well spent.

    Clearly, based on my experience, these new light systems are not a patch on the old D1S ones but no doubt a lot cheaper for Audi.
     
  35. Darjanator

    Darjanator New Member

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    Is this still a thing? I'm looking for something to upgrade my B8 A5 pre FL and have looked all over the internet with this being the most appealing option.

    I haven't found any guide on how to disassemble the lights anywhere, does the kit come with one? It seems rather daunting as it's all glued together.
     
  36. JohninMK

    JohninMK Member

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    With my S3 there is no dismantling of the light unit. The old ballast is unscrewed and swapped, a small notch is cut in one of the access holes for the new cable and the bulb replaced as normal. All the work, in terms of time, is getting the headlight units out of the car.
     
  37. Darjanator

    Darjanator New Member

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    The way I see it, the A5 has horrible projector lenses that need to be swapped out. If it's possible through just keyhole surgery, as it were, all the better.
     
  38. JohninMK

    JohninMK Member

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    So you don't have Xenon light units?
     
  39. Darjanator

    Darjanator New Member

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    I do, but the lenses are **** and fogged up and are the main reason for the dimness. If they can be cleaned, no need to buy new ones.
     
  40. JohninMK

    JohninMK Member

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    Fair enough but your original question didn't belong in this thread.

    You might get better answers if you start a thread of your own asking for suggestions on the best way forward.
     
  41. Darjanator

    Darjanator New Member

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    I suppose, I was just following the topic as the original post did mention the A5, among other models. Didn't want to spam the forums with yet another thread if it could possibly be answered by the OP in here (if he's still around).
     
  42. Sandra

    Sandra Administrator Staff Member Administrator TeamMisano TFSI Owners Group Audi S3 quattro Platinum Supporter S tronic Audi Main Dealer

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