@mithril - thanks for the excellent DIY on this! Just swapped mine over this weekend and combined with a new high-pressure AC switch replacement, getting sorted today.

Adding to the photo library for the thread and my tips on what I encountered.

Comparision of old Hella E55 in background to new EvoX-R in foreground. The difference is stunning. You can see the wavy lines in the E55 lens, none in the EvoX-R—at all.







Removing the butyl in the housing channel, Heat gun and flathead screw driver.


Channel cleaned up best I could.


...ugh... All wires to H7 highbeam with cracked insulation. The more you move them, the more they crack (I'm at 163k mi). I've been here before, 11 quattros later, totally know the drill. The wires are fine, just the insulation is shot.


Unclip the connector, uncrimp the copper spade and install small heat shrink tubing on existing wires all the way down to the bottom. Then, I grouped the ground wires together and added larger heat shrink over. Re crimp spade, solder with flux, reinstall.



EvoX-R is direct bolt on fix!



All buttoned up, ready to go.



I even used German boxes to store the parts while rebuilding.


Cheers, Thompson