Fitting twin headlights

[nesty]

Hi

I got a set of twin headlights to fit. Anybody know a garage that could fit these around the Watford, Hertfordshire area?

I haven't got a garage (and doubt the T25 would fit in anyway). Just need the job doing, as they cluttering up my shed now & just want them on!

[Cruz]

Twin round or twin square?

Twin square are pretty straight forward. I did mine the other week in about 2 hours and I'm an electrical numpty. However I am a military aircraft fitter by trade and have a cheap Lidl soldering iron

I bought the correct lower mounting brackets (seen below) from VW 255-853-647 (now available again from http://www.brickwerks.co.uk/shop?page=s ... gory_id=57" onclick="window.open(this.href);return false;)





Then to fit you need to gently bend back the two outer mountings on the Van with a hide mallet or something. not quite 90 degrees back should do it (that way you can bend them back if you ever go back to round headlights). They are the outer 2 of the 3 tabs that the grill is secured to, as they get in the way of the square light assemblies and you don't need them for the square grill.

Screw the VW mounting tabs onto the lower inner corners of each lamp assembly so that the are orientated as in the picture above

The two outer upper and lower screw holes on each side are used to attach the square lights. So screw the light fittings to these two holes then mark where to drill the upper inner hole and the two lower holes for the mounting tabs.

Remove light assemblies and drill holes approx 3 to 3.2mm (I used 4mm tamper proof self tappers). Be carefull not to damage your paintwork or any wiring looms as you break through.

Rivet the mounting tabs to the body. Again watch the paintwork.

I am assuming you got the wiring looms with the headlights?

Leave your existing side light wires alone you can use these

Snip off your existing headlight connectors about 3 inches back from the plastic connector block

Now solder and heat-shrink the wiring looms you got with the square headlights to your existing loom matching up the wire colours on each side. Ignore the side light block on the loom. Tie wrap this up neatly out of the way and maybe tape up the socket to prevent any water getting in.

Fit headlights to body remembering to plug them in first.

Fit square grill

Ring local MOT place to get the lights re-aligned

Stand back and admire.

Plan the next job which is the headlight relay upgrade (did mine a few years ago)

[nesty]

Twin Square headliught, sorry should of said.

Many thanks for this. I have a VW Dealer in the town so will enquire about the part. My van is a 1984 version so not sure if that makes any difference in the mounting. The MOT is is almost expired, so will get MOT centre to adjust them as part of the MOT!

[Cruz]

Doesn't matter what year your van is. If it came with round headlights you'll need the mounting tab brackets. Did the lights come with the looms?

I've got the number for the pop rivets for fitting them N90576301

You will need to borrow a pop rivet gun though

[nesty]

I'll check the lights on Monday, (not home at moment) for the looms, though yes I think were there.

I was thinking of getting a pop rivet gun anyway.

On the 2 outer tabs, the ones I have to bend back. Will they be apprent to see?

[Cruz]

Do you mean apparent, as to which ones you bend back?

If so then yes. Just remove the round headlights and try put the square headlight unit in their place and you will see that what gets in the way.

[nesty]

OK cheers, I'll give this a go.

Is the mounting like exactly where the mounting plates go straight forward enough? Do you need the grill to help to align where to mount?

[Cruz]

Is the mounting like exactly where the mounting plates go straight forward enough? Do you need the grill to help to align where to mount?

The mounting isn't for the grill. It's for fixing the headlight brackets to the body. The 2 inner clip positions are different on the square headlight grill to the round headlight grill. That's why you no longer need the tabs you have to bend back (vans with factory square lights don't have them)

When you address up the headlight assembly to the van you will see that the inner lower screw hole fixing points on each headlight are nowhere near the bodywork and are floating in thin air. That's what the mounting bracket is for. You align it for drilling the rivet holes by following what I said above

Screw the VW mounting tabs onto the lower inner corners of each lamp assembly so that the are orientated as in the picture above

The two outer upper and lower screw holes on each side are used to attach the square lights. So screw the light fittings to these two holes then mark where to drill the upper inner hole and the two lower holes for the mounting tabs.

What I will do for you is take some pics of my lights so you can see what I mean. It won't be until Wednesday though

[nesty]

OK many thanks pics are appreciative.

My lights have the looms on them. I Order the mounting plates and rivets from VW. Come to about £9. They will be here on Tuesday. Then about 2 hours later I found 2 used mounting plates right in the bottom of the box, the lights came with! Anyway gonna attempt to fit them later in the week.

One other thing. The main biger light haven't got any headlight bulbs. Looking to purchase Osram nightbreakers, I take it they will fit. Also what is the code for these lights. Is it H4?

Thanks for the help.

[Cruz]

H4

I got some Philips Extreme Power +80% off ebay. Top rated bulbs in most comparisons

http://cgi.ebay.co.uk/PHILIPS-EXTREME-P ... 3ca6e788eb" onclick="window.open(this.href);return false;

[Gandalf]

Bit of a thick question Cruz but do I need to removed the headlights to replace the lamps or??

[Cruz]

I take it you mean changing the bulb? As far as I know yes. You need to remove the whole square headlight assembly from the van to change the bulbs as as far as I can tell the headlight unit is attached to the mounting plate via the adjusting screws unlike the round headlights which can be unscrewed from the mounting plates

[nesty]

Actully you answered a question there for me. I was looking at the light units and I couldn't really see a way of separating the lights from the mounting plate. All I could see was adjusting screws!

[Gandalf]

I take it you mean changing the bulb? As far as I know yes. You need to remove the whole square headlight assembly from the van to change the bulbs as as far as I can tell the headlight unit is attached to the mounting plate via the adjusting screws unlike the round headlights which can be unscrewed from the mounting plates

Hmmm - does that mean I will need to get them re adjusted once I've fitted new bulbs (the questions just get thicker and thicker!)?

[Cruz]

No. because you will refit them in the same place