{"id":3854,"date":"2025-12-02T17:47:06","date_gmt":"2025-12-02T16:47:06","guid":{"rendered":"https:\/\/www.retrofitguru.com\/?p=3854"},"modified":"2026-10-24T20:25:24","modified_gmt":"2026-10-24T19:25:24","slug":"xenon-projector-replacement-ford-s-max-mk1","status":"publish","type":"post","link":"https:\/\/retrofitguru.com\/en\/blog\/vymena-xenonovych-projektoru-ford-s-max-mk1\/","title":{"rendered":"Replacement of Xenon Projectors \u2013 Ford S-Max Mk1"},"content":{"rendered":"

We have prepared detailed instructions for upgrading the xenon headlights on\u00a0Ford S-Max mk1<\/strong>\u00a0at\u00a0more powerful bi-xenon projectors<\/strong> with our repair Plug & Play kit<\/strong><\/a>. The whole process is designed to be\u00a0as simple as possible and did not require any modifications<\/strong>\u00a0headlights.<\/p>\n

Opening the Headlight<\/strong><\/h2>\n

Separating the lens from the housing may sound intimidating, but if you follow the correct procedure, it\u2019s a safe and controlled process. On the S-Max, the headlights are sealed only with butyl<\/strong> (not hard permaseal)<\/p>\n

The Most Reliable Method: Oven or Heat Box<\/strong><\/h3>\n

Temperature<\/strong>\u00a090 \u00b0C
Time:<\/strong> 7\u201312 minutes
Why:<\/strong> Butyl softens around 60 \u00b0C but releases best at 80\u201390 \u00b0C.
Tip:<\/strong> Place the headlight on a wooden board or cardboard so it doesn\u2019t touch metal.<\/p>\n

Note: Make sure the oven is truly at the correct temperature. Use an external thermometer rather than relying solely on the oven\u2019s built-in thermostat. At temperatures above 120 \u00b0C, you risk deforming the plastic.<\/em><\/p>\n

Opening Procedure<\/h3>\n
    \n
  1. Preheat the oven to 85\u201390 \u00b0C.<\/li>\n
  2. Remove all rear covers and bulbs.<\/li>\n
  3. Heat the headlight for 8\u201310 minutes.<\/li>\n
  4. After removing it, start prying from the corners or the longest straight edge<\/strong> \u2013 there are no hidden locks.<\/li>\n
  5. Use a plastic trim tool<\/strong>, not a screwdriver. Spreader pliers work well too.<\/li>\n
  6. If the butyl hardens, return the headlight to the oven for another 3\u20135 minutes.<\/li>\n
  7. Separate the cover gradually around the entire perimeter<\/strong>, not with one strong pull.<\/li>\n
  8. Ideally, clean the remaining butyl from the channel, but if some is left, it will merge with the new one once heated.<\/li>\n<\/ol>\n

    \u00a0<\/h3>\n

    Alternative: Heat Gun<\/strong><\/h3>\n

    If you don\u2019t have an oven, you can heat the headlight with a heat gun:<\/p>\n