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Discussion Starter · #1 · (Edited)
Changing Halogen Bulbs to Match Xenons

Thanks to everyone in this thread http://forums.vwvortex.com/zerothread?id=1183244 for the photos and instructions on how to change a halogen bulb in the headlight assembly. The reason for this project was to obtain a closer match of color between the xenon and halogen bulbs when high beams are on. Note: mine is VAGed for the Euro headlights so both the xenon and the halogens are on when high beams are activated.
You can also read about changing fog light bulbs here: http://forums.vwvortex.com/zerothread?id=1241457
I changed my 55w OEM halogen bulbs to H7 70w Hoen xenonmatch Titanium bulbs. They can be purchased here: http://www.hoen-usa.com/ti.htm. After some research, I have determined that the increased wattage from the OEM 55w bulbs to the Hoen 70w bulbs should not be an issue. The total wattage per headlight assembly 105w (35w xenon + 70w halogen) is still less than the standard headlights that have two 55w halogen bulbs (110w total per side).
The process can be a little tricky if you don't know what to look for and/or expect. This is particularly true for removal and installation of the headlight assembly. Hopefully these instructions and photos will help.
1. Remove the side engine cover panels (if you have them).
2. Get the headlight crank tool from the spare tire storage compartment.
3. Insert the headlight crank tool onto the hex bolt. With one hand, push lightly on the front the headlight assembly to release the tension and start to twist the crank tool toward the "open" arrow. (This is all about feel, so don't force anything.) Continue to twist until the headlight assembly partially pushes out of its socket.



Note: The following two photos are to illustrate what happens when the cranking tool is twisted. The chrome bar in the two photos below is what is being moved when you crank. Going too far will break the assembly.

This photo shows the position of the chrome bar when it is partially closed. It will continue backward until it locks into place when you reinstall the assembly.



This photo shows the position of the chrome bar when it is in it's open position allowing the headlight assembly to slide out.



4. With a long straight screw driver push down on the release clip. There is a small hole in the radiator bulkhead to access the clip. (The access hole is shown in the first photo at the upper left center.) While pressing down on the retaining clip, use your other hand and pull the headlight assembly out a little more. Once you're beyond the clip, you're all set to remove the assembly. Grab it on each side and just pull straight out. There are no cables attached.

5. Once out, remove the large rubber cap on top of the headlight assembly.



6. The inside will look like this. Remove the wire harness from the bulb, unfasten the retainer clip, and pull the bulb out. The inside looks like this.



7. Reinstall the new bulb making sure not to touch the glass portion of the bulb, refasten the retainer clip, reattach the wire harness and replace the rubber cap. Make sure you have the rubber cap on tightly all the way around.

8. Replace the headlight assembly back into its cavity. Make sure that all the tracks line up so it slides in smoothly. Look underneath the assembly for the two rails on the bottom side.

9. Slide the assembly back into place until you hear a small click. Once you hear the click (retainer clip), with one hand continue to apply light pressure on the front of the headlight assembly and start twisting the crank tool to the close position. The crank tool will pull the headlight assembly back into the cavity easily. With some force, continue to twist the crank tool until you hear a rather loud snap. The snap means the headlight assembly is locked into place.

Here are the results.

Xenon & 55w OEM Halogen




Xenon & 70w Hoen xenonmatch Titanium




Driver's Side Modified / Passenger Side OEM Comparison




Both Sides Modified / Project Complete



Now that night has fallen, I had my first chance to really see the difference and let me tell you, the difference is awesome. You can not tell the difference in light color between the xenon and the halogen bulb. I highly recommend the Hoens. Here are some night photos. (Note: the spotlights off on the right side of the photos illuminating the barn are 100w halogens.)

Xenons Only




Fogs Only (yellow bulbs)




Xenons & Halogens (note: no color difference)

 

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Re: Changing Halogen Bulbs (bravocharlie)

That was a fantastic post. (btw, That silver acura was the right color, wrong license plate). and nobody passes me, no matter what I'm drivng or pedaling.
Now, when I go to visit my son i Plymouth, can I stop by for you to do that mod for me? that is, if spock can't?
thanks, BC,
mark
me.
ps: The lakes region is beautiful.
 

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Discussion Starter · #4 ·
Re: Changing Halogen Bulbs (mdjak)

Quote, originally posted by mdjak »
That was a fantastic post. (btw, That silver acura was the right color, wrong license plate). and nobody passes me, no matter what I'm drivng or pedaling.
Now, when I go to visit my son i Plymouth, can I stop by for you to do that mod for me? that is, if spock can't?

I just spent an hour writing this up and doing the photos so others could follow the directions and do it themselves!!!!!!!!!!!!!!!!

Sure, I'll do it for you.
 

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Re: Changing Halogen Bulbs (bravocharlie)

On a serious note for a moment, did the writeup take longer than the actual job itself? Now that you've done it once, will it be easier next time? I'm going to that site to order the bulbs now. Hey, Spock, how bout it? I'll get the bulbs for you too.
me.
PS: Which model number bulb do I order?


Modified by mdjak at 9:32 PM 2-20-2004
 

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Discussion Starter · #6 ·
Re: Changing Halogen Bulbs (mdjak)

Quote, originally posted by mdjak »
On a serious note for a moment, did the writeup take longer than the actual job itself? Now that you've done it once, will it be easier next time? I'm going to that site to order the bulbs now. Hey, Spock, how bout it? I'll get the bulbs for you too.
me.
PS: Which model number bulb do I order?

The job took about 40 minutes total. The first took longer than the second because I was paranoid about breaking something. DenverBill broke something and it cost him $350 for a new headlight assembly. I didn't want that to happen.
It does take a while to write this stuff up, but I'm happy to do it. Others have contributed and I figured this is my way of contributing. Until you compress the photos, write it up, proof read, ftp the photos up, etc. it took almost an hour to write it.
The bulbs are H7.
Swing by the big lake, I'll do it for you. Then we can go race.



Modified by bravocharlie at 10:03 PM 2-20-2004
 

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Re: Changing Halogen Bulbs to Match Xenons (bravocharlie)

Thanks for the thorough write-up and photos. Your new headlights look great and must give terrific visibility at night. I just hope you're right about 70 watts not being too much for the wires, relays, fuses, etc. I've heard of people burning out wiring harnesses with high wattage bulbs, but it was probably with higher wattage than yours.
 

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Discussion Starter · #10 ·
Re: Changing Halogen Bulbs to Match Xenons (Outrageous)

Quote, originally posted by Outrageous »
Thanks for the thorough write-up and photos. Your new headlights look great and must give terrific visibility at night. I just hope you're right about 70 watts not being too much for the wires, relays, fuses, etc. I've heard of people burning out wiring harnesses with high wattage bulbs, but it was probably with higher wattage than yours.

Based on my research, I was told that anything up to 80w is safe without having to upgrade the wire harness.
 

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Re: Changing Halogen Bulbs to Match Xenons (bravocharlie)

Great post BC. It is not clear how slick these headlight mechanism is without your picture post.
As I mentioned before I have been running 100 watt H7s in my low beams for ~60 days with great results.
 

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Re: Changing Halogen Bulbs to Match Xenons (bravocharlie)

You keep this thread up top long enough and I might even have to do this mod.
 

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Re: Changing Halogen Bulbs to Match Xenons (bravocharlie)

Hi Bravo,
After looking at your pictures I got my H7s changed to IPF Super Low Beam x H7 65W. The color Temperature is 5000K. The bulbs costed $80. Got it replaced at the VW dealer another $100. The lights are phenominal!
 

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Discussion Starter · #18 ·
Re: Changing Halogen Bulbs to Match Xenons (ssarma)

Quote, originally posted by ssarma »
Hi Bravo,
After looking at your pictures I got my H7s changed to IPF Super Low Beam x H7 65W. The color Temperature is 5000K. The bulbs costed $80. Got it replaced at the VW dealer another $100. The lights are phenominal!

Quite a few people on the forum have gone with the Hoens and seem to be pleased with them. This is also a bump http://****************.com/smile/emthup.gif for the newbies.
 

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Re: Changing Halogen Bulbs to Match Xenons (bravocharlie)

Quote, originally posted by bravocharlie »

Quite a few people on the forum have gone with the Hoens and seem to be pleased with them. This is also a bump http://****************.com/smile/emthup.gif for the newbies.

Chit, thanks for reminding me. I've had the bulbs for weeks now and forgot about them


Meat
 

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Re: Changing Halogen Bulbs to Match Xenons (ssarma)

They ripped you off for a hundred bucks. When spock came to my house, we literally did the swap in ten minutes. At that rate, your dealer must get a grand an hour.
 
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