 Last additions - Passat HID install |
The install342 viewsLiquid electrical tape used to fill in and insulate crimps. High-quality ratcheting crimpers make the difference!Feb 06, 2010
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282 viewsThe cover back in place with room to spare. Keeps the engine bay looking tidy.Feb 06, 2010
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279 viewsI used the supplied double-sided tape to mount the electronics under the cosmetic cover. If you do this make sure you clean the mounting surfaces with rubbing (isopropyl) alcohol.Feb 06, 2010
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278 viewsThe hard cover in place with the gasket. I can't tell you how many hours I spent trying to get this all to work with such limited space...grrr...Feb 06, 2010
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284 viewsCable passed through hole, ready for the gasket.Feb 06, 2010
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276 viewsClose-up of the connectors tucked away, ready for the rubber boot to cover them.Feb 06, 2010
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274 viewsDrill a small pilot hole first then...Feb 06, 2010
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Through the hard cover299 viewsJust an FYI: I do NOT recommend this method! PITA if you have any issues. Go through the rubber cover.
Make a template that is 7/8" in diameter and trace with a permanent marker. Or put a nail or screw into the center of the circle and tap it so it leaves a dimple -- that's where you will drill. I used this location because it gave me the most slack in the wiring. The shop that does this recommended not putting the gasket in the center of the hard cover because there wouldn't be enough wiring slack.Feb 06, 2010
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Right side286 viewsThis is the side I started on and passed the harness through the hard cover as recommended by a shop that does the procedure. What a MAJOR pain in the butt! Ideally, it would be best to REMOVE the airbox in order to get enough space to maneuver around; a much bigger task than I cared to do after 3 hours of work involved already! I have long thin fingers and trying to get the bulb in the socket, as well as the gasket into the hard cover, was quite difficult. Anyone with thicker and/or shorter fingers would likely have an even more difficult time as the space is just too cramped around that area.Feb 06, 2010
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285 viewsHow it looks with the plug in place and the gasket ready for the hard cover.Feb 06, 2010
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270 views...use a hole saw or reamer to enlarge to 7/8" diameter. This is where the gasket will mount and allow the wires to pass through.Feb 06, 2010
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279 viewsThe decorative cover fits nicely over the unit, hiding it from view.Feb 06, 2010
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270 viewsFeb 06, 2010
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298 viewsThe bulb I originally had for the left side was bad so I got a replacement. This had the wires through it but no connector. Overall, it is better as there was no need for me to cut the wires, push them through the gasket, and butt-crimp them. For the connection, I pushed the spade connectors into the stock connector, dabbed liquid electrical "tape" around it to electrically insulate it as well as help hold the connectors, then wrapped the connector in electrical tape to further hold the connectors in. Not ideal at all but it works.Feb 06, 2010
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288 viewsFeb 06, 2010
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307 viewsLocation where I placed the left side electronics. Attached by using the supplied double-sided tape (strong stuff!).Feb 06, 2010
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290 viewsGently pull on the brown and yellow wires to help keep the connector in its place when putting the rubber boot back on.Feb 06, 2010
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287 viewsWhatever plug you may have, simply push the connectors into the gap on the inward side of the light housing as this has a good gap to hold it out of the way.Feb 06, 2010
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299 viewsThe original bulbs came with a plastic ring to help hold them in their shipping case. I split it and put it behind the bulb, then carefully pushed the bulb retaining tangs onto the plastic ring. This kept the tangs more even. Without them you'll need to push the tangs down a little bit as well as bend them inward in order to retain the bulb. I oriented the bulb just like the halogen it replaced, tab pointing up. No shadows were cast, full light is output.Feb 06, 2010
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313 viewsThe plug wouldn't lock into the stock connector so I used a supplied zip-tie to bind it and electrical tape to keep it together. Notice that the RED wire mates with the YELLOW (+12 volts) bulb connector wire and the BLACK wire mates with the BROWN (ground) bulb connector wire.Feb 06, 2010
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