How to fit Golf HID headlights

Hardware Used:

S/H Hella HID Ballast Units - Ebay

New 8500K (colour temp) HID bulbs & Adaptor leads - www.globalpremier.com

S/H Golf Mk4 Headlamp Units

Aluminium strip & bolts to make mounting brackets - B&Q

Introduction

The Hella HID system is commonly used in OEM headlamp applications, consequently there is now a steady supply of parts available from crashed vehicles.

As standard, the Hella system is fitted with bulb type known as D2S/R (below), onto which a large square bayonet connector on the HT lead locates. Unfortunately this bulb is not a direct replacement for the H7 halogen bulb used in the Golf mk4 lights dipped beam lamp, and the large connector makes it awkward to fit into a Golf light unit.

A neater solution is to use a new H7 fitment bulb such as that supplied by Global Premier in the USA (www.globalpremier.com). The new bulbs are guaranteed to fit firmly into the existing bulb holders and retain the existing bulb clamps. These bulbs also are fitted with flying leads that allow the connection to the ballast box to be made outside the confines of the Golf mk4 lights. Also available is an adaptor lead kit that allows effortless connection to the Hella ballast box and the existing bulb connector to be removed.

The new xenon bulbs are ready fitted with a large grommet to seal the new hole that must be made through the rear cover of the golf lights, and a low voltage cable loom to connect onto the existing 2 way bulb connector inside the headlights.

Procedure for fitting golf mk4 hid conversion.

• Remove front bumper to gain access to the lower headlight fixings

• Remove both headlights and place them on a secure working surface

• Remove the rear covers from the headlight unit and unplug the existing dipped beam bulb connector

• Remove the H7 dipped beam bulb

• Insert the new H7 HID bulb, taking care not to touch the bulb surface with bare hands

• Replace the bulb clip, taking care to fit the bulb cables through the middle of the wire clip

• Insert the new low voltage spade connectors into the old dipped bulb connector. Insulate and tie back the connector inside the light if necessary to ensure that it cannot foul the adjustment mechanism or contact the other electrical connections.

• Drill a 20mm diameter hole through the rear cover in a suitable position to allow free passage of the HID conversion cables past the adjustment motor.

• Refit the rear cover to the headlamp and pass the cables and grommet through the new hole.

• Refit the headlights

• Prepare the ballast boxes by chopping off the old bulb connectors and connecting the supplied single connectors to each of the two wires.

• Plug the ballasts into the HID bulb wires underneath the headlamps and decide on suitable mounting positions for each box

• Fabricate brackets as necessary to mount the ballasts securely behind the bumper, ensuring clearance to adjacent components such as the intercooler (if fitted) and the inside of the bumper cover. Try to use existing fixing bolts/screws if possible to save on drilling any new holes through the bodywork.

• Test the operation of the Xenon bulbs before refitting the bumper and grille.

• Ensure that the headlamps are correctly adjusted to avoid dazzling oncoming traffic before using the lights on the road.

• Prepare to be amazed by the difference!

Legal Notice about the use of HID conversion.

The UK regulations for motor vehicles stipulate that a Xenon/HID headlamp system should only be fitted to vehicles in conjunction with an automatic headlamp level adjustment system and headlamp washers, to avoid dazzling oncoming traffic. As the conversion detailed above will not utilise an automatic levelling system (unlike the OEM VW HID lamps) you are advised to carry out this modification at your own risk - this author accepts no responsibility for the legality of your vehicle.

This article was provided courtesy of
www.golfmk4.co.uk
Please visit them for more Audi A4 articles