Aftermarket Projector headlamp and HID DIY for MK5 Golf.

[benough]

Hey everyone.

This has been a 2 year journey for me (queue Australian Idol). Mainly due to being lazy but also learning the hard way. This guide is so that other people don't have to go through the same pain.

I will add a caveat though. Consider this one way of doing it. I will not be held responsible if following this guide breaks your car. I will also field questions if need be but please only if you are at a dead end or my grammar is terrible. :)

1. Parts

You will need a set of projector headlamps. You can debate projector vs reflector legality/looks till your blue in the face but this is the only way to do it properly. A HID kit and basic tools to remove the bumper/headlamps to install the kit.

The headlamps I have are HELLA Halogen projector lamps for the MKV Golf. Now they are designed for the non GT/GTI/R32 but it doesn't matter.

You can find the part on the HELLA website but these are the part numbers.

1LL 009476-011 for the Left Hand Side and 1LL 009476-021 for the Right Hand Side. This can be confirmed with the HELLA online catalogue.

You can buy these lamps from various online stores but I got this best price from this guy. I can't confirm if he is still operating.

Brian Hadlum
SEMAC Ltd
semacltd@aol.com

Now for a HID kit I have a "Phillips" one from eBay which has been reliable but I'm not convinced it's genuine. For the best result though I will recommend an MTEC kit. Another user I know has them and there is no delay in the bulbs getting to temperature plus the intensity is better. If that's out of your budget try eBay.

I've found if the kit is under $200-300 it's going to be crap/potentially damage your headlamps.

Finally a tool kit it "T" torx bits in it will be all you will need to remove the bumper and headlamps for installation.

2. Installation

Removing the bumper sounds daunting, but it's actually quite simple.

I won't write it up but you can follow the first 6 points in this document by Forge.

LINK (http://www.forgemotorsport.co.uk/media/GOLF%20GT%20TWINTERCOOLER.pdf)

To remove the headlamps, use your thumb to pull back the tab and slide off the power plug/connector. Now undo the 3 bolts holding it and and when you slide it out. See this picture from the HELLA install booklet.

https://lh6.googleusercontent.com/_Zy7IpJIf9Bs/TWnRvno-FuI/AAAAAAAABdE/Hr1I49NIlhA/headlamp.jpg

Installation is the reverse of removal.

3. Installing HID Kit

What I opted on doing was mounting the ballast underneath the headlamp. These headlamps are based on the OEM Xenon headlamps so there is already a mounting location plus it's cleaner, cops won't see it and it should pass rego :)

I used the bracket that came with the kit, some hard plastic (I used guitar scratch plate) and some malleable steel. All of these things should be available at Bunnings.

The screws you need to mount it are available from your VW dealer. Ask for the screws that mount the ballast into the headlamp. Was about $10.

This is the underside of the headlamp with the ballast mounting position.

https://lh5.googleusercontent.com/_Zy7IpJIf9Bs/TWnTcWBqXaI/AAAAAAAABeE/yhHJQ-zmADs/s1152/11022011028.jpg

This is how I cut up my plastic to sit the ballast on. Also I pre drilled the screw holes.

https://lh6.googleusercontent.com/_Zy7IpJIf9Bs/TWnTgK7Q6XI/AAAAAAAABek/a9gXMtCigKg/s640/11022011029.jpg

This is the ballast with it's mounting bracket screwed into the top hole.

https://lh3.googleusercontent.com/_Zy7IpJIf9Bs/TWnTd3X-4SI/AAAAAAAABeI/5h72IecBZX4/s1152/11022011030.jpg

Now you get your steel, measure up the dimensions of your ballast, bend it to fit and screw it on.

https://lh5.googleusercontent.com/_Zy7IpJIf9Bs/TWnTeT_a6DI/AAAAAAAABeM/nDXNsbPRgOk/s1152/11022011031.jpg

https://lh5.googleusercontent.com/_Zy7IpJIf9Bs/TWnTfX9mdaI/AAAAAAAABeg/BKEVceHGIjs/s1152/11022011032.jpg

https://lh4.googleusercontent.com/_Zy7IpJIf9Bs/TWnTcNuWrYI/AAAAAAAABeA/vMV9yNYA_Qk/s1152/11022011033.jpg

Now for connecting the kit to your actual headlamp, follow the instructions that were supplied with it.

Finally reinstall your headlamps, making sure they sit flush against the body work, re attach your bumper and drive to your nearest long dark road to enjoy the Xenon powah.

https://lh4.googleusercontent.com/_Zy7IpJIf9Bs/TWnTNVuBftI/AAAAAAAABd8/hZsqNaoWwvg/DSC00017.jpg

[10d]

Finally! Good stuff, Ben!
It's been a while.

[mikinoz]

Will this work if I have an RCD-510 or do I need to upgrade my CANBUS gateway?

[benough]

No it won't. You need the reverse light xenon kit. 7000K or it won't comply with ADRs.

[stephen8512]

great write up ben!

few questions though


whats a "reverse light xenon kit"?
and what does it have to do with the RCD-510? Why's it matter if you have an RCD-510 installed or not?

and i thought the legal Kelvin rating for HID's was 4300? wouldn't 7000K be more towards the blue?

[DeanCorp]

Nice job! If you don't mind me asking, how much did this cost?

[YouSnooze]

LMFAO!!!!!
http://dictionary.reference.com/browse/satire
http://dictionary.reference.com/browse/joke

[benough]

Nice job! If you don't mind me asking, how much did this cost?

Those headlamps were $350 each for me in September 2009 from memory and the current price for an MTEC kit is $440 although mine was $250.

[benough]

great write up ben!

few questions though

whats a "reverse light xenon kit"?
and what does it have to do with the RCD-510? Why's it matter if you have an RCD-510 installed or not?

and i thought the legal Kelvin rating for HID's was 4300? wouldn't 7000K be more towards the blue?

Tell me you are kidding right?

[DeanCorp]

Those headlamps were $350 each for me in September 2009 from memory and the current price for an MTEC kit is $440 although mine was $250.

Fark and suckers like me paid $1500 for the kit?? What's the difference (excuse my ignorance?)

[benough]

You paid $1500 for a HID kit?

[TRS]

I wouldn't trust this guy. His skills with a black texta are quite obviously rubbish, he can't even write an international number in the correct format, and WHO IS THE DOUCHE WEARING THREE QUARTER PANTS?! IT'S NOT 1999 YOU KNOW!

[benough]

I wouldn't trust this guy. His skills with a black texta are quite obviously rubbish, he can't even write an international number in the correct format, and WHO IS THE DOUCHE WEARING THREE QUARTER PANTS?! IT'S NOT 1999 YOU KNOW!

Don't feed the troll or hassle Doug about his pants!

Who works on your MK2 anyway?

[stephen8512]

Tell me you are kidding right?

i was actually serious....but after YouSnooze's post it seems like it was more of a pisstake than a genuine post.

If so, then my bad :) Initially, I couldn't tell. Its the internet so I guess I just misinterpreted it? lol

Still, nice job. Have you got any pics of the car without the HID's on? Just want to see how it looks during the daytime without them on?

[DeanCorp]

You paid $1500 for a HID kit?

I bought the full Xenon kit, something like this: https://shopping.boraparts.com/product_info.php?products_id=237&osCsid=1ded8veenakcito6ujqetircp1

[YouSnooze]

Ha ha. Sorry I wasn't wearing haute couture in my shed - my bad. My stage 2+ texta skills surely don't warrant such venom though :(
Thank you benough for a good DIY with pics. No thanks to the rude ALL CAPS troll however. Perhaps I could recommend some hormone replacement therapy for you :)

[YouSnooze]

Have you got any pics of the car without the HID's on? Just want to see how it looks during the daytime without them on?
They look identical to OEM xenons. This is the beauty of benough's work - inexpensive, effective and looks OEM.

[benough]

I bought the full Xenon kit, something like this: https://shopping.boraparts.com/product_info.php?products_id=237&osCsid=1ded8veenakcito6ujqetircp1

That's a very good price actually. The beam will be a bit nicer and no dicking around with the ballasts. Nice work.

[benough]

i was actually serious....but after YouSnooze's post it seems like it was more of a pisstake than a genuine post.

If so, then my bad :) Initially, I couldn't tell. Its the internet so I guess I just misinterpreted it? lol

Still, nice job. Have you got any pics of the car without the HID's on? Just want to see how it looks during the daytime without them on?

Just search for a Golf GT Sport. They are the GTI reflector headlamps.

[mikinoz]

I wouldn't trust this guy. His skills with a black texta are quite obviously rubbish, he can't even write an international number in the correct format, and WHO IS THE DOUGIE WEARING THREE QUARTER PANTS?! IT'S NOT 1999 YOU KNOW!

What you can't see his salmon polo with popped collar (before you mention his thongs, his boat shoes were off getting waterproofed).

[stephen8512]

Just search for a Golf GT Sport. They are the GTI reflector headlamps.

what about the projectors? Which car did they come off?

[benough]

what about the projectors? Which car did they come off?

They are a spare part from HELLA. Hence the part numbers.

[Justified]

Awesome writeup!

Would you happen to have any photos showing the HELLA Halogen projector lamps mounted in the headlamp? How do they bolt in?

Thanks!

[benough]

Awesome writeup!

Would you happen to have any photos showing the HELLA Halogen projector lamps mounted in the headlamp? How do they bolt in?

Thanks!

Nope. With bolts I guess...

[d2_dang]

Hey all,

I found myself a pair of R32 headlamps and am tempted to put them on my mk5 GTI. By installing these along with HID's will I need to do anything else? I.e. Will I need to do anything with the can bus or programming? Cheers!

[stephen8512]

i believe its a straight bolt on with some coding needed via VAGCOM. Paolo did it to his Pirelli when he got a hand of some xenons himself

[d2_dang]

Thanks Steve,

Yea suspected that some coding would need to be done.

[Pharkus]

Thanks Steve,

Yea suspected that some coding would need to be done.

And also the headlight washer kit and autolevelling if you want to take it that far.

[d2_dang]

Thanks guys for your advice, I think im gonna focus on putting the RNS510 in first then hid's.

[iluvbrownale]

Okay, for what it's worth, I just did the mod last weekend so have some additional blurb

Hella projectors RHD from Tuning Fanatics in Germany. Bought thru eBay for $550 delivered
Lights were Philips 4200k Hid kit off eBay, aussie seller, $239 for the slimline kit.

Time:
remove bumper - 20 mins
remove headlights - 5 mins
make up some sort of plate and bracket to hold the ballast in place - 1hr the first one, 10 mins on the second one
reinstall lights - 10 mins and a bit of swearing (the addition on the ballasts makes it a bit trickier slotting them back in but in the end you get it)
reinstall bumper and grille (and wonder why you have two screws left over) - 15 mins
Stick the free 'R' badge that was a surprise gift from seller of the Xenon kit on the boot - 10 mins

A few additional points: at each stage I checked the lights were wired correctly - I didn't want to reinstall only to find I'd not done it correctly. Once i'd put back together the MFD was saying indicator and sidelight on one headlamp wasn't working and the high beam on the other wasn't even tho they were when i tested them. I started to kick things before having a "haaaaaang ooooon" moment and realised that the main connector to the headlights (like the old VCR Scart leads) weren't pushed all the way in. Push *Click* Done. Whew.

I'm going to swap the sidelights over to the two bluey phillips bulbs that came included with the Kit (the hella projectors actually come with all the bulbs installed) as I didn't realise that these stay on when on dipped/high so being yellowy at the moment spoils the look. They seemed a bastad to get out when I did the main install and I didn't want to poison an otherwise successful day!

I should add that I am the ballsup king. If it can be ballsed up DIY style, I'm your man so anyone who thinks they can't do it is being far too cautious and should just crack on. I made my bracket by going to the local hardware store and asking for some sort of maleable thin steel. No idea what i bought (was like a vee shaped 12 inch bit of metal) for a few bucks. Flattened it, cut it with scissors and did same as benough but not nearly as neat. Was easy to work with - the screws included with the kit could just be pushed and screwed thru the metal (no drilling). I deviated from the DIY in that I actually just used the included screws rather than buy torx ones and they fit perfectly into the holes of the headlamp to fix the plate/bracket/ballast on with.

I'd also add, don't forget to add the earth wire to the ballast (all you do is hook it on when you screw the ballast to the plate you made) and there's heaps of spots to earth when you have the headlamps in place.

Since enjoying some super bright night runs, I have two questions that perhaps benough can answer: I appear to have a difference in the colouration of my two bulbs that seems more apparent a week later than at first. When they first turn on, one goes straight to the correct colour (whitey blue), while the other is a slightly reddish white before ending up less blue than the other (4200k kit). Faulty bulb? it's not noticeable in the beam, more head on looking at the lights themselves. Any ideas?

Also, the actual headlamps have adjustment for up/down left/right. How do i know I've set them correctly? They seem ok but I want to make sure i'm not selling myself short. My F-in-law has an S3 so I was thinking we'd line up both on a wall and I'd match mine to his pattern. Any other ideas?

happy to answer questions from anyone who's thinking of doing the mod themselves.

Cheers

Mike

[benough]

Hey Mike

Good job on the DIY.

As for the bulbs I'd have to see them. I do know the ballasts take a bit to get to temp and one of mine is a touch slower than the other but once at temp it's apples.

Yeah it's best to compare them to another car. I had trial an error with mine but I have them spot on now. I CBF making measurements on a wall in a carpark. ;-)

Otherwise, ask if a euro maechanic has one of those headlight aiming trolleys. That's the only proper way to do it.

http://img340.imageshack.us/img340/7465/xenonadjust1.jpg

[technopato]

Bumping this thread for info!!!

Ben... You fountain of information and infinite wisdom!!! I need some info... Have done some research but generally most of it is for US based vehicles.

I got my hands on a set of OEM Xenon headlights for my Golf. I already purchased the adapters required, like the ones below.

http://i895.photobucket.com/albums/ac152/technopato/300202.jpg

However the adapters have the extra yellow wire coming out of each adapter which is supposed to be used to plug back into the CEC bus under the steering column. Now my questions:

- Is this yellow wire required for our cars here? As far as i read it had something to do with ensuring both beams didnt come on at once.
- Do the Auto Levelling mechanisms/motors come with cars factory fitted with Xenons in Australia? If so should i bother with it?

Planning to do the install myself this weekend so I would like to be as ready as possible.

I read that Dean did the Retrofit of the OEM Xenons, did you have to run this yellow wire at all?

Cheers Peeps!

[benough]

Hey Pat.

Nice find. Are they LHD or RHD Xenons?

AFAIK you do need the yellow wire. Jarred (Jazd) did this himself recently. It's so the CECM will move the cut off down for high beam.

Yes they do but no, not really. As long as you aim them right you'll be fine. I don't have it and I NEVER get flashed. Also it's over a grand to retro fit.

No he didn't b/c he used the halogen projects AKAIK where these are the factory ones.

Whered you get them?

[M4RK0]

Pato, you don't need the Yellow cable, I did a custom HID install on mine for the Dynabeams, I'll post you my DIY... with Ben's you will be ready to go!

Where are you located?

[benough]

Marko

If they are a set from a car that came with Xenons from the factory then yes he will. Jarred got a set from Germany and had to do so. If it's the HELLA sort we bought then yeah, you're correct.

Considering he has the adaptor, I'd say they are an OEM set.

[technopato]

Hey Pat.

Nice find. Are they LHD or RHD Xenons?

AFAIK you do need the yellow wire. Jarred (Jazd) did this himself recently. It's so the CECM will move the cut off down for high beam.

Yes they do but no, not really. As long as you aim them right you'll be fine. I don't have it and I NEVER get flashed. Also it's over a grand to retro fit.

No he didn't b/c he used the halogen projects AKAIK where these are the factory ones.

Whered you get them?

Thanks for the quick reply.

I got them from a friend of mine who runs a wrecking yard, He gave them to me at a steal! So I couldnt refuse espescially after having that chat with you about the differences between Halogens and Xenons! They are literally brand spanking NEW!!!!!

Anyway going back this arvo to get the Auto levelling kit... May as well grab it and if i do decide to put it in I have it good to go!
Just want to make sure I do it right the first time, so I dont have to go back and F&@k around with it again.

If anyone is interested, he has another set of OE Xenons off a Mk5 GTI, the right hand headlight is broken, but the internals are still intact, the passenger side is practically new. I know for a fact he would do a good deal on them!! PM me and ill pass on details!

[M4RK0]

In addition to Ben's DIY after-market Xenon kit, both bought sparely; I must say that the biggest problem that I found was fitting a second ballast on my car for the first HID kit installed on my fog lights,

Tools:

1 Torx screwdriver set
1 Drill Circle adaptor of 1/4 (Used to do the circle holes on the headlights covers).
Insulator Tape.
Cable Ties.
Floor Mat

1.- First is fit the Xenon bulbs into the H7 original sockets, this if the headlight doesn't have HID system already,

http://i574.photobucket.com/albums/ss182/Marco-Contreras/BulbSocket1.jpg

2.- Drill the holes in the Headlights covers,

http://i574.photobucket.com/albums/ss182/Marco-Contreras/CoversHoles.jpg

3.- Prepare and disassemble the connector of power cables in the Headlights that will be connected to the ballast later,

http://i574.photobucket.com/albums/ss182/Marco-Contreras/PowerConnectors2.jpg

With the HID bulb installed,

http://i574.photobucket.com/albums/ss182/Marco-Contreras/PowerConnectors3.jpg

4.- Put the cover on the headlight and pass through the cables by the holes,

http://i574.photobucket.com/albums/ss182/Marco-Contreras/CablesnCovers.jpg

5.- Remove the front bumper from the car, and one of the original Headlights, find a place to install the Ballast, but remember that the length of the cables, a bit different from Ben's I think his idea is heaps better, in any case you can't avoid having to remove the bumper,

http://i574.photobucket.com/albums/ss182/Marco-Contreras/Ballast1.jpg

On my case I'll install it next to the Fog lights Ballast, for that I'll use the cable ties,

Right Side

http://i574.photobucket.com/albums/ss182/Marco-Contreras/Ballast.jpg

Left Side

http://i574.photobucket.com/albums/ss182/Marco-Contreras/Ballast2.jpg

6.- Once that the Ballast are fitted connect the first Dynabeam to main socket and the power cables from the headlight to the ballast (the last one it's a bit ticky because both cables are BLACK!!!, so, try outs it's the way to go) if you don't get the right connection of the power cables at the first time don't stress the only thing that will happen will be that the light won't go ON and the alert on the dash will show, just inverse the cable and that's it!!!

Note: It's very important use the insulator tape to separate the power cable terminals, once that you turn On the main switch they become alive!!

Test the Headlights!!

http://i574.photobucket.com/albums/ss182/Marco-Contreras/Test23.jpg

http://i574.photobucket.com/albums/ss182/Marco-Contreras/Cellis-1.jpg

7.- Now install the fogs HID's

http://i574.photobucket.com/albums/ss182/Marco-Contreras/FogTest.jpg

8.- Mounted on the bumper,

http://i574.photobucket.com/albums/ss182/Marco-Contreras/FogMounted2.jpg

If everything it's ok, fit and screw the headlights, and mount the front bumper!!!!
My result!!!

http://i574.photobucket.com/albums/ss182/Marco-Contreras/P1010640.jpg

http://i574.photobucket.com/albums/ss182/Marco-Contreras/DSC_0076.jpg

Hope this helps!

[benough]

You've had no issues with the heat from those two ballasts being so close together?

[M4RK0]

You've had no issues with the heat from those two ballasts being so close together?

No Bro, they are directly on the vents, I have them for 2 and half years now, no problem at all,

But your option of fix them on the top of the headlight it's heaps better :)

[technopato]

Hey Fellas...
Ben is correct, I have the OEM Xenon off another Mk5 that came fitted with them from factory. So according to all the reading i have done, it looks like i will need to run those yellow wires through the firewall and connect them to the CEC under the steering column, Damn.. not looking forward to that espescially with the fat fingers and big head i have!!!! LOL..

I have the week off work so I am going to attempt it either tomorrow or thursday, will post pics once done!

Ben..... ive just replied to your email! Youre good to go!!

[M4RK0]

Hey Fellas...
Ben is correct, I have the OEM Xenon off another Mk5 that came fitted with them from factory. So according to all the reading i have done, it looks like i will need to run those yellow wires through the firewall and connect them to the CEC under the steering column, Damn.. not looking forward to that espescially with the fat fingers and big head i have!!!! LOL..

I have the week off work so I am going to attempt it either tomorrow or thursday, will post pics once done!

Ben..... ive just replied to your email! Youre good to go!!

Oh man!, uff! it's a bit messy, not a big deal, a couple of steps more, I can give you a hand this weekend if you like, two heads think better than one....they say,

PM if you want, I'm up!

Good luck!

[dsiew]

Kinda resurrecting this thread...

I wonder if this (http://www.golfmkv.com/forums/showthread.php?t=41203) location is best for running the two pin 11 (shutter) wires through the firewall? I believe the CECM module is underneath the steering column (no matter if it's LHD/RHD) and the poster mentions that those firewall holes exist on both sides which should make things easier. It would mean that the common method of removing the battery + tray is now unnecessary. Run the wires in some weatherproof tubing along the sides and under the plastic upper tray below the wipers (for the LHS). It would certainly make things A LOT easier, require less tools and also minimise complexity ...

For those who have done the halogen > OEM xenon conversion, where did you run your shutter wires through the firewall?

[M4RK0]

Hi Danny,

From my point of view is not the HID convertion what annoys me, is the bumper removal and all the million of crews, but after said that, I've tried this method, to be honest, I remove the bumper+Remove Halogens+Install the ballast (at your best preference)+Connect HID's+Install new Headlights+Mount the bumper and that's it!!!

But! I will do a HID retrofit on my car sometime next year and I'll try this one if I' not able to get the OEM xenon headlights on a decent price,

cheers!