After putting in OEM Bora HIDs a month ago and wanting the factory setup with High and Low Beams together (like the Golf/GTI) I searched high and low
for a DIY or FAQ on the web without success so I decided to tackle this with the help of the Bentley and create a quick how to.
Tools and Parts Needed
Steering Wheel Removal Apparatus (Torx T55 or Star Tool and Torque Wrench)
VW 1.5mm Wire Repair Kit with Single Wide Connector (Part #???)
Barrel Wire Splice
Phillips #1 (at least 7")
Torx T25 Driver
Wire Cutters/Strippers
The Factory Setup is with a 1.5mm (16ga?) green/yellow wire running to terminal 58b on the turn signal stalk. The Factory setup for Golf has this same wire running to Terminal 56* (yes star/asterisk) on the headlight switch.
1) Remove the Steering Wheel & Airbag (Bentley / or Look for Posts on MFA Stalk or R32 Wheel install) - Be Sure to Disconnect the Battery before starting the Airbag
2) Remove the upper and lower covers of the steering column (2 Screws front, 2 Screws Bottom Plus a Torx screw with washer and the two torx screws holding the column adjuster handle)
3) At this point if you look at the turn signal stalk you should see 2 connectors one with wires coming out the back towards the instruments and another coming out the top with some smaller gauge wires (these are for the cruise control).
4) Locate the Yellow/Green Wire coming out of pin 8 on the turn signal stalk and cut it (yellow circle) I left some extra from the back of the connector in case I want to go back to the Factory Single Bulb 9007 lights later
5) Cutoff one of the ends of the 1.5mm VW Wire Repair Kit and strip back the wire on this cut end and the wire harness side leading into the dash (not the Turn Signal Switch Side) 1/4" as appropriate and connect and crimp with the wire splice. (White Circle)
6) Since this wire must move with the adjustable steering column make sure to follow the existing wire harness back under the dash board. I did this by tracing the existing harness path by placing zip ties every couple of inches (red circles) and wrapping electrical tape at the top (green circle)
7) Pop Out the Headlight Switch and turn it over to locate pin #7 (white arrow). Feed the wire from the turn signal harness behind the dash and into the light switch hole. I was able to do this by feeding a stiff wire in through the light switch hole and out the steering column then taping the wire to it and pulling it back through.
8) Push the wire repair kit end into the hole at #7 on the headlight switch connector until it snaps into place and cannot be removed. (orange circle)
9) Assembly is the reverse of removal. The Steering wheel and column should have marks to align them and the steering wheel bolt torque is 37 ft/lbs. The steering wheel bolt should have a punch mark added to it to show it's been removed. (It should be replaced after 5 removals). See posts in step one for more detailed steps.
Enjoy your OEM Hids as the VAG Engineers intended. Since this is the factory setup everything works as expected including Flash to Pass, Dash Highbeam Icon, Fogs Off with High Beams on, DRL's etc.
Notes
* - The Pictures show more disassembly than is actually required due to testing while implementing
* - Sorry I don't have the 1.5mm (16ga) Wire Repair Kit part number (I walked into the dealer at 10min before closing, paid cash for the $2 part and didn't keep the receipt (ooops)
* - This goes without saying but don't try this with the Jetta single bulb lights (9007/H4). You will likely melt your headlight housing from the heat and cause your bulb to fail very prematurely - it just wasn't designed for this.
Modified by drowningman at 12:09 PM 12-27-2003
Tools and Parts Needed
Steering Wheel Removal Apparatus (Torx T55 or Star Tool and Torque Wrench)
VW 1.5mm Wire Repair Kit with Single Wide Connector (Part #???)
Barrel Wire Splice
Phillips #1 (at least 7")
Torx T25 Driver
Wire Cutters/Strippers
The Factory Setup is with a 1.5mm (16ga?) green/yellow wire running to terminal 58b on the turn signal stalk. The Factory setup for Golf has this same wire running to Terminal 56* (yes star/asterisk) on the headlight switch.
1) Remove the Steering Wheel & Airbag (Bentley / or Look for Posts on MFA Stalk or R32 Wheel install) - Be Sure to Disconnect the Battery before starting the Airbag
2) Remove the upper and lower covers of the steering column (2 Screws front, 2 Screws Bottom Plus a Torx screw with washer and the two torx screws holding the column adjuster handle)
3) At this point if you look at the turn signal stalk you should see 2 connectors one with wires coming out the back towards the instruments and another coming out the top with some smaller gauge wires (these are for the cruise control).
4) Locate the Yellow/Green Wire coming out of pin 8 on the turn signal stalk and cut it (yellow circle) I left some extra from the back of the connector in case I want to go back to the Factory Single Bulb 9007 lights later
5) Cutoff one of the ends of the 1.5mm VW Wire Repair Kit and strip back the wire on this cut end and the wire harness side leading into the dash (not the Turn Signal Switch Side) 1/4" as appropriate and connect and crimp with the wire splice. (White Circle)
6) Since this wire must move with the adjustable steering column make sure to follow the existing wire harness back under the dash board. I did this by tracing the existing harness path by placing zip ties every couple of inches (red circles) and wrapping electrical tape at the top (green circle)
7) Pop Out the Headlight Switch and turn it over to locate pin #7 (white arrow). Feed the wire from the turn signal harness behind the dash and into the light switch hole. I was able to do this by feeding a stiff wire in through the light switch hole and out the steering column then taping the wire to it and pulling it back through.
8) Push the wire repair kit end into the hole at #7 on the headlight switch connector until it snaps into place and cannot be removed. (orange circle)
9) Assembly is the reverse of removal. The Steering wheel and column should have marks to align them and the steering wheel bolt torque is 37 ft/lbs. The steering wheel bolt should have a punch mark added to it to show it's been removed. (It should be replaced after 5 removals). See posts in step one for more detailed steps.
Enjoy your OEM Hids as the VAG Engineers intended. Since this is the factory setup everything works as expected including Flash to Pass, Dash Highbeam Icon, Fogs Off with High Beams on, DRL's etc.
Notes
* - The Pictures show more disassembly than is actually required due to testing while implementing
* - Sorry I don't have the 1.5mm (16ga) Wire Repair Kit part number (I walked into the dealer at 10min before closing, paid cash for the $2 part and didn't keep the receipt (ooops)
* - This goes without saying but don't try this with the Jetta single bulb lights (9007/H4). You will likely melt your headlight housing from the heat and cause your bulb to fail very prematurely - it just wasn't designed for this.
Modified by drowningman at 12:09 PM 12-27-2003