Headlight Question

[Atomic Avant]

Ok, So I am having a hard time tracking down replacement rear dust covers for my headlights.

My 2005 B6 S4 Avant has PN? 8E0941003R/8E0941004L. This is the Bi-Xenon model as far as I can tell. It has the motor for auto leveling and the 2 sensors on the front and rear suspension.

Everywhere I look The b6 S4 seems to come with just regular xenon headlights.

The biggest differences I can see are:

1. The ballast location, underside for the headlight for xenon and integrated into the rear dust cover for bi-xenon.
2. The projector lens is larger on the bi-xenon
3. The bi-xenon have auto leveling vs none on the xenon.

I only care because I had to finally replace my old D1S bulbs and noticed that my back dust covers must be from 2004 as they feel like they are made of rice paper. (they are already full of cracks an missing some parts.

Any help with what I have and what a reasonable replacement is. I do have a set of xenon headlights off another B6 S4 that are in ok condition but the plastic still isn't great.

[djzerog]

Found this .

https://www.printables.com/model/125...light-dust-cap

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[djzerog]

And this..

https://www.ecstuning.com/b-genuine-...caAhkqEALw_wcB

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[Atomic Avant]

Found this .

https://www.printables.com/model/125...light-dust-cap

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I am currently looking at a failed set I printed and tried to install.

and the ECS tuning site only has one side it. it ships March 6th 2023. so I doubt it would ever show up.

[djzerog]

Used so the condition is questionable..

https://wolfautoparts.com/high-beam-...a-ps10889.html

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[djzerog]

https://www.audipartsstore.com/oem-p...RzJms9MQ%3D%3D

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[djzerog]

Disregard last one.. not Xenon.

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[Dondbg]

In the same situation. Mine are beyond repair and can’t find them anywhere.
Stupid French they made out of toys plastic.

[Dondbg]

I am currently looking at a failed set I printed and tried to install.

and the ECS tuning site only has one side it. it ships March 6th 2023. so I doubt it would ever show up.

Did you print the model above ? It fits and mirroring worked for the other side?

[Atomic Avant]

Did you print the model above ? It fits and mirroring worked for the other side?

Yeah I printed it. I imagine I would have to mess around with the file and re-try the print. I might just move to the other set of headlights I have but I don't like that the projector housing is smaller.

[ak-s4]

You could try different filament materials and/or have a company print them for you professionally.

Complete assemblies land on ebay every so often, there is a pair on there now that you could swipe parts from, assuming it matches what you have now:
https://www.ebay.com/itm/275355912910
https://www.ebay.com/itm/275355922844

If you don't want to pay that price, then set up an ebay search using various terms and be prepared to wait a bit, or hit up a junkyard and have them check their parts network...

[Dondbg]

Yeah I printed it. I imagine I would have to mess around with the file and re-try the print. I might just move to the other set of headlights I have but I don't like that the projector housing is smaller.

It doesn’t fit ? What is the issue with it.

[Atomic Avant]

It doesn’t fit ? What is the issue with it.

The print was a little too big. The two upper tabs were snug and the bottom locking spring wouldn't fit over the bottom retention tab. Once I added any material for a gasket in the channel it was impossible to line yup the bottom holes for the two T25's. I was worried about stripping out the housing.

It looks like a good file, I am by no means an expert on printing but I don't know if I want to waste half a roll to try again.

I do have a spare set of headlights, the ones that have the ballast on the bottom side of the housing. I am still unsure what there is two different styles/models of headlights.

ECS advertises my headlights as Euro spec.

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[Dondbg]

The print was a little too big. The two upper tabs were snug and the bottom locking spring wouldn't fit over the bottom retention tab. Once I added any material for a gasket in the channel it was impossible to line yup the bottom holes for the two T25's. I was worried about stripping out the housing.

It looks like a good file, I am by no means an expert on printing but I don't know if I want to waste half a roll to try again.

I do have a spare set of headlights, the ones that have the ballast on the bottom side of the housing. I am still unsure what there is two different styles/models of headlights.

ECS advertises my headlights as Euro spec.

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The ones with the ballast at the bottom are not bi xenon, they got smaller lenses even.

[ak-s4]

My understanding is that for the US spec S4, 2004 had the smaller diameter projectors with two rear access doors, 2005 had the slightly larger projectors and only one access door and 2005.5 was a completely different assembly. So they are somewhat rare...

[Atomic Avant]

The ones with the ballast at the bottom are not bi xenon, they got smaller lenses even.

Ok, so I am learning something here.

What makes the headlights Bi-xenon vs just xenon? I was under the impression that it was the motor for the auto leveling system.

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[Atomic Avant]

My understanding is that for the US spec S4, 2004 had the smaller diameter projectors with two rear access doors, 2005 had the slightly larger projectors and only one access door and 2005.5 was a completely different assembly. So they are somewhat rare...

That would explain why these headlights don't exist.

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[ak-s4]

Sure, they are somewhat more rare now and more expensive, but still can be found easily enough if you want them. The two links I previously posted are still available. Here are some more:
https://www.ebay.com/itm/144692881591
https://www.ebay.com/itm/115299355020

[Dondbg]

Ok, so I am learning something here.

What makes the headlights Bi-xenon vs just xenon? I was under the impression that it was the motor for the auto leveling system.

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It’s the motor that is attached to the lens not the auto levelling one.