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valeo 2 to 1 pc headlight conversion by sandman

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valeo 2 to 1 pc headlight conversion by sandman

Old 10-11-2005, 12:47 PM
6th Gear
Thread Starter
Join Date: Nov 2003
Location: Columbs, Ohio
Posts: 10,684
Default valeo 2 to 1 pc headlight conversion by sandman

DISCLAMER: i do not advise doing this to your car because you will most likley screw up and make your car look even worse

this wasnt a hard project but it was time consuming. there is some fender trimming involved and some re wiring
so on a scale from 1-10 i give this a 4.5...

tolls i used
-angle grinder
-t-30 torx socket
-10mm allen socket
-some sort of volt finder (i used a craftsman digital voltmeter)
-other common tools

start off by removing your front bumper, you will need to do this to get to the lower mounting bolt for the stock headlights. the bumper is held on by two hex screws in the fenders and two long bolts under the grill around where foglights would be. once these bolts are removed firmly push down on the bumper by the fenders and pull up and out. this is tricky and dont be afraid to be forcefull the bumpers are made of a strong flexible material. if you are having problems with this step look here for more info http://www.audiworld.com/tech/eng.html under timing belt replacement.

now that the bumper is off remove the three torx bolts surrounding the headlight and they should slide right out.

now that the headlights are out the harness needs to be cut to accomidate for the new upgraded harness

the new harness comes pre labeled, but the audi wires dont and they arent color matched so i used my volt meter to figure this out
audi wire colors are
-yellow with black stripe=regular driving beam
-white with black stripe=high beams
-white with yellow stripe was for the stock fog lights. if you bought aftermarket fogs like me this would be where the + wire would be connected
-the orange wire on the left is for the city lights, i wanted to utalize this function so i tapped in to the corner blinker and used that wire. the wire that needs to be used is the smallest of the three.

this is the blinker harness, the slot on the bottom is the ground and the one on the top right is for the blink and top left is city lights, like i said before the wire coming out of this slot is going to be smaller than all the others. tap in to this and connect it to the city light labeled wire from the new harness.

time to cut the fenders,

mask the fender liberly to avoid any damage to the paint. draw a lins somewhat like this and cut it out with a sawzall. from this point see if the lights fit properly, most likely they wont. so whip out the grinder and do some more trimming, try for fit again. do this untill the lights fit perfect.
now paint the area where metal is exposed.
connect the blinker to the housing before installing. it is way harder to do afterwards. connect the harness and make sure everything works.

aim them and waa laaa your done

all the parts needed can be found at ECS Tuning, they even sent me all new lightbulbs.
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