JETTA MKIV FK PROJECTORS + HID DIY DETAIL INSTALL INSTRUCTIONS (lots of pictures)

[hidusa]

I've always loved the look of a projector headlight on any car and this is the first thing I had to change on my Jetta. Here is a DIY for anybody that wants the same thing and needs a little help...

Disclaimer: I do not take responsibility for anybody's actions. Be responsible with what you do. If one follows the instructions, this installation will be professional and flawless.

Tools and parts list needed:
- FK projector housing headlight kit including: headlamp units - 2pcs., harness - 2pcs., rubber covers 4pcs., plastic cover - 1 pcs.
- HID kit including: 2 ballasts with igniters, 2 H7-based HID bulbs (5000K recommended), cable ties, 2 rubber gromets.
- 2xPY21W orange bulbs or 2x1156 orange bulbs
- 2 regular halogen H7 bulbs for the highbeams
- Flathead screwdriver
- cross screwdriver
- torx screwdriver or equivalent size allen wrench
- pliers
- mini wrench tool
- silicone
- exacto knife
- insulating tape

1. First open the hood and locate the cover (the one with a light bulb symbol on top) behind the driver's side headlight. Use a cross head screwdriver to unscrew the two screws holding the cover.

Remove the cover and place it on the side.

2. Removing the grille: using a flathead screwdriver pop the top side of the grille next to the hood latch. DO NOT use exesive force.

Lift the lower part of the grille next to the headlight where the clips are. Now do the other side also.

Same on the opposite side.
Locate and unscrew the circled screws located behind the vents.

It is a good idea to place all the remover screws in a container so nothing gets lost.

Next rotate the steering wheel a full rotation clockwise. Go to the left wheelwell to locate the 4 screws securing the wheelwell cover to the bumper (the 4th is behind my hand in the picture).

Next remove the 4 screw holding the undercover by the oil pan.

http://forums.vwvortex.com/zerothrea...ostid=29855529

[hidusa]

Next remove the 5 screw holding the top part of the bumper cover located behind the front grille, one is hiding just under the front VW badge.

Now the bumper cover can be pulled out. Be careful though since the bumper side markers are still connected with wires. You don't need to take the bumper completely off, just pull it out a little so there is access to the bolts holding the bottom part of the headlights.

Locate the two screws at the bottom part of the headlamp and two more at the top and remove them.

You should remove 4 screws per headlight total and the assembly can be pulled out.

Unplug the harness at the back of the headlight.

Now lets prepare the new headlight. This will include installing all the bulbs, passing the wires throug the back cover to the ballasts and connecting the HID bulbs, putting the light assembly together ready to be installed in place of the old one.
First start off with the small rubber cover which came in the kit looking like this.

The hole should look like that when ready:

No lets install a H7 halogen bulb in the headlights for the high beams.

Next is the signal bulb. You can use a PY21W orange light bulb from a VW Passat (get it from the dealership for around $5/ea) or you can use a 1156 orange bulb, but have to modify a little.
The 1156 bulb has two points of contact one across another. File down one of them so it'll fit the socket.

[hidusa]

Install the socket into it's house just above the fog light bulb socket by twisting it clockwise.

Next we'll install the H7 HID bulb in it's socket. I recommend 5000K for color temperature. It's pure white and really bright.

Remember to hold the bulb by it's base and not touch the glass.

http://img297.imageshack.us/my.php?i...sc003285lt.jpg

Secure it in te socket with the spring, by running the plugs through and locking it in place.

Now the cables for the HID ballast.
Insert the rubber gromet with the cables coming from the HID bulb through the prep'd rubber cover and pierce two small holes at the indicated places for the cable coming from the ballast to go into the headlight housing:

run the two cables through (black and red)

Now if you got a proper H7 HID kit the cables should come with proper connectors. However I was using my old kit from my old car and it was designed for 9006 bulb. Therefore the connectors were a bit thinner than I needed the so I had to solder an H7 size pins at the ends of the cables.

Connect the other end of the harness to the one in the engine compartment of the car to test if the LED are working properly. If some of them don't light up - pull them out and turn the 180 degrees. Now they will light up.

Install the back cover and make sure it is sealed around the edges:

Connect the ballast to the HID bulb cable plugs:

Install the headlight assembly in its place and tighten the 4 screws securing it to the car:

Done!!