I recently bought myself brand new OEM EVO 9 headlamps.
Fitted them to the car and as you can see from the images bellow, the RH light is out of focus and not as strong as it should be.
I changed the H1 bulb inside, hoping it would fix the problem. Well, it didn't.
Then I unplugged both lamps and exchanged them, just to see if RH lamp connected to LH connector, makes any difference. Well, no difference.
I also connected the H1 bulb directly to 12V and as soon as I put it in the housing so it sits where it should, and I face the lamp towards a wall, still the same, out of focus and very very bad beam.
The height adjustment motors are working fine, the lamps are both going up and down as I turn the knob from inside the car. But it doesn't make a difference to the beam spread and strength.
I also manually turned the two bolts that adjust the height and the right/left of the lamp but no matter what way I turn, the beam is still bad.
So, please help as I am literally out of ideas what else to test before I return it under warranty.
Is it possible that the lamp is bad from factory? Should I just try to get a replacement? Anyone else had a problem like this?
Nothing in the lamp seems loose...


left beam is OK, right beam is out of focus and not strong enough

seen from the front

H1 bulb and housing

H1 bulb housing

Inside the housing of the projector

 

OK so just as I finished posting this thread, I went down to the garage to take another closer look what is going on inside the lamp... Well... Looks like I found out what the problem is. The inside of the lens housing is melted/burnt. So the chrome part that is round and round.
I guess from the bulb?
But this looks like a faulty interior of the lamp from the factory to me, as the bulb was factory fitted and I never opened it until now. How could this happen? Woooot! I'm completely shocked by this. See attached images. Photos taken through the hole where the H1 bulb goes.
So yeah, problem solved. Well, not yet, I hope Mitsubishi will not complicate about this.

 

If I were you, I would swap in some different projectors and fix the problem that way. Why did you have a heat gun on the floor in your first photo?

 

Yeah, if Mitsubishi won't want to replace it I will have to open it and replace just the projector inside. But it's a pain in the *** job, because you have to open in from the front. Which means heating up the whole lamp etc. I don't think it can be done from the back?
Heat gun was for the double-sided tape on the licence plate. As one of the two bolts for the bumper is behind the plate, I have to remove it every time.
I'll find out tomorrow and hope for the best.

 

damn, this is why I went with all LED's even the headlights.

 

was the led for headlight direct plug or you had to modify plug?
you like the led?

 

what are your plans with the bad lamp?

 

Thankfully got it replaced under warranty and therefore had to return the defect lamp back to the factory.