VW Electrics Standard Headlights
Round headlights
Budget Lucas-style headlights by Covkid
Currently stocked by Euro Car Parts and described as @lucas' headlights, these can be made to fit existing round headlight holders. My thanks to Oldie but goodie for guiding me on the fitment, which requires only very minor modifications.
With headlight existing assembly removed whole, first undo the three small philips screws that hold in original light unit. Ignore plastic fittings - these are for light adjustment only.
The three lugs on back of the new light unit should drop nicely into the three recesses in existing light frame (see photo below). Do NOT cut them off. You need them to help locate the headlight and to avoid major headlight realignment. In practice I found I had to bend them very slightly (careful) towards the outer edge so that they drop in really snugly into these recesses to stop the light moving side to side. Spend a few minutes getting this right. With headlight pressed into frame with your fingers, it shouldn't move side to side or up and down.
Photo below shows lug and recess. At bottom left you can see screwhole for the clips you need to fit:
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Once they're right, all you need is three metal clips similar to those used to fasten brake or gas pipe to bodywork, bent slightly so it grips outer metal edge of front lens. Below are actually what I used. Not sure what they are called but not too difficult to fashion.
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Then just screw to where light was originally fitted. Works well. Nice to have bright lights again.
Bear in mind they ARE curved rather than flat like stock ones but you don't really notice to be honest.
I have concluded that these units are almost certainly the same as those fitted to the Ambassador car, common on India's streets. Certainly thats where they're made. They are Autopal HL-101 units and they make fancier versions with fluted reflectors but these are bog standard reflectors. For under a tenner, they're a bargain but remember you'll need P-clips or something similar to hold them in place.
If you can't get hold of suitable clips, stiff coathanger wire, bent round on itself to take the screw, with the tails cut to length and bent to grab outer rim of headlight would also work. You can swap existing screws for similarly sized but longer self-tapping screws if it makes fitting easier.
The alternative is to pay £45+ for complete headlight assemblies from JK and others but for the sake of three clips, they're worth a shot. I think I paid £8.80 for each one. :D
I'd marked a wall prior to removing headlights and they lined up perfectly but you may wish to mark a wall like this so you can readjust if required.
Square Headlights
Inner main beam lights are The same as a MKII Scrirocco They are becoming hard to source and are no longer available from dealers. The Hella part numbers for RHD are LEFT 301-127 761-01 RIGHT 301-127 760-01 This is etched into the glass. The Adjusters are hard plastic and are very difficult to remove without snapping I have found it is best to remove the entire headlight unit to get to the rear plastic retaining lugs and rotate them by 90 degrees to remove all at the same time. The two upper ones are adjustable and the lower one is fixed (The Scrirocco screws are shorter and probably not suitable but some of the plastic clips are interchangeable). If you have condensation in your lamp I managed to remove it by removing all the plastic parts and oven baking for 10-20 minutes at 100degrees, take it out and shake it to disperse the droplets and aid evaporation. There is a fix which involves using a bag of silica gel attached to a piece of fishing line or dental floss popping it in then refitting the bulb and leaving it in till the moisture is absorbed. The string is used tea bag style to retrieve the bag when done. It would save you having to remove the plastic clips which are likely to snap. When refitting clean up the threads of the adjusters as best you can with scribe or small wire brush and coat with copper grease so adjustments can be made easily without the rust on the screws binding and ending up with chewed screw heads, it sees a lot of weather in its position and any rust prevention you spend time on will pay dividends in the future when bulb replacement or adjustment comes around.
Square Headlight inner adjusters
Cruz
Adjusters needed for each square inner light 1x 255-941-133A 2x 255-941-141B
You may or my not be aware but the headlight adjusters for the square inner main beam headlights are obsolete and the only source is to buy expensive reproductions from America which at my last reckoning was about £36 (gowesty) for adjusters for both inner lights not including any taxes or customs charges at this end which may apply
Having recently found a source of the obsolete 191-941-297 headlamp adjuster at eurocarparts I thought I'd have a look to see if an adjuster from another VW vehicle of that era would suffice and I came across adjusters from a Mk2 Golf (picture below)
Adjuster 191-941-133 is a perfect replacement for 255-941-141B
Adjuster 191-941-141 is just about 5mm shorter than 255-941-133A so the inner light will just sit that little bit lower than the dipped headlight unit in the grill but once you have had them aligned it shouldn't affect the functionality of the high beam.
The 141 adjuster has a slotted head and not a pozi drive head. But that is a small price to pay I say.
Tonight I tried the adjusters in my headlight frame and they fit the holes fine.
So onto the two sources for these parts.
Both adjusters are available from eurocarparts and eurowagens with free shipping. One is cheaper than the other.
For each inner light you need 2 x 191-941-141 and 1 x 191-941-133
Eurocarparts 191-941-133 @ £2.39 Eurocarparts number 470440331 191-941-144 @ £3.48 Eurocarparts number 470440341
Eurowagens 191-941-133 @ £1.49 191-941-141 @ £1.49
Eurowagens regularly do a set of 3 adjusters on ebay (a kit for each inner light) for £5.49 http://myworld.ebay.co.uk/eurowagensltd
So basically instead of £36+ you can get a set for the inner lights for less than a tenner
Hopefully people can follow this
Current availability of Adjuster as at March 2011
Below is a post I made on the brick-yard regarding availablity of adjusters for square headlights
Some available still from VW, some not
2 x Number 10 - 255-941-141C adjusting screw for horizontal adjustment available (24/2/11)
2 x Number 11 - 191-941-297 adaptor with adjusting screw for vertical adjustment - obsolete from VW in the UK but available from classic parts in germany and eurocarparts.com (eurocarparts part number 470440351 and available from eurocarparts as of 24/2/11)
2 x Number 8 - 255-941-133 adjusting piece available (24/2/11)
10 x Number 8A - 7L0945299 - Little plastic clips for the screw heads available
adjusters for square main beam light
2 x Number 9 - 255-941-141B obsolete not available from classic either
2 x Number 12 - 255-941-133A obsolete not available from classic either
update Feb 2013
Just an update as eurocarparts don't stock the alternatives any more and the eurowagens links have changed
(original part 255-941-141B top) Alternative top adjusters (two needed) http://www.eurowagens.com/en/headlamp-adjusting-screw-vw-golf-mk2.html
(original part 255-941-133A bottom) Alternative to bottom adjuster http://www.eurowagens.com/en/vw/golf-2-jetta-2/headlights/headlamp-adjusting-screw-long-vw-golf-mk2.html
So to replace all adjusters on both mainbeams you need to order two sets of the first link but only one set of the second link
